JC18003373 Weighfeeder Complete Manual

O & M Manual
900mm Weigh Feeder

60-241-5010P
MT 9105F Integrator
PRECISION PERU S.A.

ORDER NUMBER: 00030000007556
THERMO JOB NUMBER: JC18003373
APPROVED BY POSITION DATE SIGNATURE
THERMO P Mkosana PROJECT ENGINEER
O & M Manual
INDEX
1/ EQUIPMENT
• SEW MOTOR MANUAL

• SEW GEARBOX MANUAL
• THERMO FISHER RUN OFF SWITCHES DATA SHEET
• THERMO FISHER SAFETY PULL SWITCHES DATA SHEET
• BRELKO BELT SCRAPER MANUAL (E905-900)
• AB POWERFLEX 525 VARIABLE SPEED DRIVE MANUAL
• BEARINGS DATA SHEETS
• BELT RIP DETECTOR DATASHEET
• THERMO FISHER INTEGRATOR MANUAL (MT 9105F)
• IDEA MODULE MANUAL
• SPEED SENSOR MANUAL 60-241-500P
2/ SPARE LIST
SECTION 1
EQUIPMENT
• SEW MOTOR MANUAL

• SEW GEARBOX MANUAL
• THERMO FISHER RUN OFF SWITCHES DATA SHEET
• THERMO FISHER SAFETY PULL SWITCHES DATA SHEET
• BRELKO BELT SCRAPER MANUAL (E905-900)
• AB POWERFLEX 525 VARIABLE SPEED DRIVE MANUAL
• BEARINGS DATA SHEETS
• BELT RIP DETECTOR DATASHEET
• THERMO FISHER INTEGRATOR MANUAL (MT 9105F)
• IDEA MODULE MANUAL
• SPEED SENSOR MANUAL 60-241-500P
Drive Technology \ Drive Automation \ System Integration \ Services *22760253_0816*
Operating Instructions
AC Motors
DR..71 – 315, DRN80 – 315
Edition 08/2016 22760253/EN

SEW-EURODRIVE—Driving the world
Contents
Contents
1 General information.................................................................................................................. 6
1.1 About this documentation ............................................................................................... 6
1.2 Structure of the safety notes ........................................................................................... 6
1.3 Rights to claim under limited warranty ............................................................................ 8
1.4 Exclusion of liability......................................................................................................... 8
1.5 Product names and trademarks...................................................................................... 8
1.6 Copyright notice .............................................................................................................. 8
1.7 Other applicable documentation ..................................................................................... 8
1.8 Designation convention................................................................................................... 9
2 Safety notes ............................................................................................................................ 10

2.1 Preliminary information ................................................................................................. 10
2.2 General information ...................................................................................................... 10
2.3 Operator's duties........................................................................................................... 11
2.4 Target group ................................................................................................................. 12
2.5 Designated use ............................................................................................................. 12
2.6 Functional safety (FS)................................................................................................... 13
2.7 Transport/storage.......................................................................................................... 14
2.8 Installation..................................................................................................................... 15
2.9 Electrical connection ..................................................................................................... 15
2.10 Startup/operation .......................................................................................................... 16
3 Motor structure ....................................................................................................................... 17

3.1 Basic structure DR..71 – 132/DRN80 – 132S motors................................................... 17
3.2 Basic structure DR..160 – 180, DRN132M – 180 motors ............................................. 18
3.3 Basic structure DR..200 – 225, DRN200 – 225 motors ................................................ 19
3.4 Basic structure DR..250 – 280, DRN250 – 280 motors ................................................ 20
3.5 Basic structure DR..315, DRN315 motors .................................................................... 21
3.6 Nameplate..................................................................................................................... 22
3.7 Type designation........................................................................................................... 25
3.8 Designs and options ..................................................................................................... 26
4 Mechanical installation .......................................................................................................... 29

4.1 Before you start............................................................................................................. 29
4.2 Extended storage of motors.......................................................................................... 30
4.3 Motor installation notes ................................................................................................. 32
4.4 Installation tolerances ................................................................................................... 33
4.5 Assembling the input elements ..................................................................................... 33
4.6 Mounting of third-party encoders .................................................................................. 34
4.7 Terminal box ................................................................................................................. 38
22760253/EN – 08/2016
4.8 Retrofitting (option /F.A) or modifying (option /F.B) motor feet ..................................... 40
4.9 Options.......................................................................................................................... 43
5 Electrical installation.............................................................................................................. 49

5.1 Additional regulations.................................................................................................... 49
5.2 Wiring diagrams and terminal assignment diagrams .................................................... 50
5.3 Wiring notes .................................................................................................................. 50
Operating Instructions – AC Motors 3

Contents
5.4 Special aspects for operation with a frequency inverter ............................................... 51

5.5 Exterior grounding at the terminal box, LF grounding................................................... 53
5.6 Improving the grounding (EMC), HF grounding ............................................................ 54
5.7 Special aspects in switching operation ......................................................................... 58
5.8 Special aspects of torque motors and low-speed motors ............................................. 58
5.9 Special aspects of DRK.. single-phase motors............................................................. 59
5.10 Ambient conditions during operation............................................................................. 61
5.11 Notes regarding the connection of the motor................................................................ 62
5.12 Connecting the motor via terminal block....................................................................... 63
5.13 Connecting the motor plug connector ........................................................................... 72
5.14 Connecting the motor via terminal strip ........................................................................ 78
5.15 Connecting the brake.................................................................................................... 80
5.16 Options.......................................................................................................................... 87
6 Startup ..................................................................................................................................... 99

6.1 Before startup ............................................................................................................. 100
6.2 Motors with reinforced bearing.................................................................................... 100
6.3 Motors with backstop /RS ........................................................................................... 101
7 Inspection/maintenance....................................................................................................... 102
7.1 Inspection and maintenance intervals......................................................................... 104
7.2 Bearing lubrication ...................................................................................................... 105
7.3 Reinforced bearings.................................................................................................... 106
7.4 Motor and brake maintenance – preliminary work ...................................................... 107
7.5 Inspection/maintenance work for DR..71 – 315, DRN80 – 315 motors ...................... 119
7.6 Inspection/maintenance work for DR..71 – 315, DRN80 – 315 brakemotors ............. 126
7.7 Inspection/maintenance work diagnostic unit /DUB.................................................... 148
7.8 Inspection/maintenance work diagnostic unit /DUE.................................................... 151
7.9 Altering the blocking direction on motors with a backstop .......................................... 161
8 Technical data....................................................................................................................... 164

8.1 Braking torques........................................................................................................... 164
8.2 Work done, working air gap, brake disk thickness...................................................... 166
8.3 Operating currents ...................................................................................................... 167
8.4 Resistors ..................................................................................................................... 170
8.5 Brake control............................................................................................................... 174
8.6 Permitted rolling bearings ........................................................................................... 178
8.7 Lubricant tables........................................................................................................... 180
8.8 Encoders..................................................................................................................... 182
8.9 Diagnostic unit /DUE................................................................................................... 190
8.10 Characteristic values of functional safety.................................................................... 191
22760253/EN – 08/2016
8.11 S1 duty cycle DRK.. single-phase motor .................................................................... 192
9 Malfunctions.......................................................................................................................... 193
9.1 Motor malfunctions...................................................................................................... 194
9.2 Brake malfunctions ..................................................................................................... 196
9.3 Malfunctions when operated with a frequency inverter............................................... 197
9.4 Customer service ........................................................................................................ 198
4 Operating Instructions – AC Motors

Contents
9.5 Disposal ...................................................................................................................... 198
10 Appendix ............................................................................................................................... 199

10.1 Wiring diagrams .......................................................................................................... 199
10.2 Auxiliary terminals 1 and 2.......................................................................................... 214
11 Address list ........................................................................................................................... 215
Index ...................................................................................................................................... 226

22760253/EN – 08/2016

General information
1 About this documentation
1 General information
1.1 About this documentation
This documentation is an integral part of the product. The documentation is written for
all employees who assemble, install, start up, and service this product.
Make sure this documentation is accessible and legible. Ensure that persons respons-
ible for the machinery and its operation as well as persons who work on the product
independently have read through the documentation carefully and understood it. If you
are unclear about any of the information in this documentation or require further in-
formation, contact SEW‑EURODRIVE.
1.2 Structure of the safety notes

1.2.1 Meaning of signal words
The following table shows the grading and meaning of the signal words for safety
notes.
Signal word Meaning Consequences if disregarded

DANGER Imminent hazard Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the product or its envir-
onment
INFORMATION Useful information or tip: Simplifies
handling of the product.
1.2.2 Structure of section-related safety notes

Section-related safety notes do not apply to a specific action but to several actions
pertaining to one subject. The hazard symbols used either indicate a general hazard
or a specific hazard.
This is the formal structure of a safety note for a specific section:
SIGNAL WORD
Type and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the hazard.
22760253/EN – 08/2016

General information
Structure of the safety notes 1
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning

General hazard
Warning of dangerous electrical voltage
Warning of hot surfaces
Warning of risk of crushing
Warning of suspended load
Warning of automatic restart
1.2.3 Structure of embedded safety notes

Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous action.
This is the formal structure of an embedded safety note:
SIGNAL WORD Type and source of hazard. Possible consequence(s) if disreg-
arded. Measure(s) to prevent the hazard.
22760253/EN – 08/2016

General information
1 Rights to claim under limited warranty
1.3 Rights to claim under limited warranty

Read the information in this documentation. This is essential for fault-free operation
and fulfillment of any rights to claim under limited warranty. Read the documentation
before you start working with the product.
1.4 Exclusion of liability

Read the information in this documentation, otherwise safe operation is impossible.
You must comply with the information contained in this documentation to achieve the
specified product characteristics and performance features. SEW‑EURODRIVE as-
sumes no liability for injury to persons or damage to equipment or property resulting
from non-observance of these operating instructions. In such cases,
SEW‑EURODRIVE assumes no liability for defects.
1.5 Product names and trademarks

The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.6 Copyright notice

© 2016 SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-
tion, distribution or any other use of the whole or any part of this documentation is
strictly prohibited.
1.7 Other applicable documentation
1.7.1 DR..71 – 315, DRN80 – 315 AC motors

The following publications and documents should also be observed:
• Wiring diagrams provided with the motor
• "Gear Unit Series R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W" operating instruc-
tions for gearmotors
• "DR.. AC Motors" catalog and/or
• "DRN.. AC Motors" catalog
• "DR.. Gearmotors" catalogs
• Addendum to the operating instructions "Safety-Rated Brakes – DR..71 – 225,
DRN80 – 225 AC Motors – Functional Safety"
22760253/EN – 08/2016
• Addendum to the operating instructions "Safety-Rated Encoders – DR..71 – 315,

DRN80 315 AC Motors – Functional Safety", if necessary
• "MOVIMOT® MM..D Functional Safety" manual, if necessary

General information
Designation convention 1
1.8 Designation convention
DR.. Applies to all motors of the DRS.., DRE.., DRP.., DRL.., DRK..,
DRM.., DRU.. series
DRN.. Applies to motors of the DRN.. series
.. Equals the nominal size or size
22760253/EN – 08/2016

Safety notes
2 Preliminary information
2 Safety notes
2.1 Preliminary information
The following general safety notes have the purpose to avoid injury and damage to
property. They primarily apply to the use of products described in this documentation.
If you use additional components also observe the relevant warning and safety notes.
2.2 General information
WARNING
During operation, the motors or gearmotors can have live, bare (in the event of open
connectors/terminal boxes) and movable or rotating parts as well as hot surfaces,
depending on their degree of protection.
Severe or fatal injuries.
• All work related to transportation, storage, installation, assembly, connection,
startup, maintenance and repair may only be carried out by qualified personnel,
in strict observance of the following points:
– Applicable detailed documentation(s)
– Warning and safety signs on the motor/gearmotor
– All the project planning documents, startup instructions and wiring diagrams
related to the drive
– System-specific regulations and requirements
– National/regional safety and accident prevention regulations.
• Never install damaged drives.
• Report any damage to the shipping company immediately.
Removing required covers without authorization, improper use or incorrect installation

and operation may result in severe injury to persons, or damage to machinery.
Refer to the following chapters for more information.
22760253/EN – 08/2016

Safety notes
Operator's duties 2
2.3 Operator's duties
Make sure that the basic safety notes are read and observed. Make sure that persons
responsible for the machinery and its operation as well as persons who work on the
device independently have read through the documentation carefully and understood
it. If you are unclear about any of the information in this documentation, or if you re-
quire further information, contact SEW‑EURODRIVE.
The operator must ensure that the following works are only performed by qualified per-
sonnel:
• Transport
• Storage
• Setup and assembly
• Installation and connection
• Startup
• Maintenance and repair
• Shutdown
• Disassembly
• Waste disposal
Make sure persons working on the product adhere to the following regulations, re-
quirements, documents and information:
• National and regional safety and accident prevention regulations
• Warning and safety signs on the product
• All other relevant project planning documents, installation and startup instructions,
wiring diagrams and schematics
• Do not assemble, install or operate damaged products
• All specific specifications and requirements for the system
Make sure that systems with the product installed are equipped with additional monit-
oring and protection devices. Observe the applicable safety regulations and legislation
governing technical equipment and accident prevention regulations.
22760253/EN – 08/2016

Safety notes
2 Target group
2.4 Target group

Specialist for Any mechanical work may only be performed by adequately qualified personnel. Qual-
mechanical work ified personnel in the context of this documentation are persons familiar with the
design, mechanical installation, troubleshooting and maintenance of the product, who
possess the following qualifications:
• Qualification in the field of mechanics according to applicable national regulation.
• They are familiar with this documentation
Specialist for elec- Any electronic work may only be performed by adequately skilled persons (electric-
trotechnical work ally). Qualified electricians in the context of this documentation are persons familiar
with electrical installation, startup, troubleshooting and servicing of the product who
possess the following qualifications:
• Qualification in the field of electrical engineering according to applicable national
regulation.
• They are familiar with this documentation
In addition to that, these persons must be familiar with the valid safety regulations and
laws, as well as with the requirements of the standards, directives and laws specified
in this documentation. The above mentioned persons must have the authorization ex-
pressly issued by the company to operate, program, configure, label and ground
devices, systems and circuits in accordance with the standards of safety technology.
Instructed persons All work in the areas of transportation, storage, operation and waste disposal must be
carried out by persons who are trained appropriately. The purpose of the instruction is
that the persons are capable of performing the required tasks and work steps in a safe
and correct manner.
2.5 Designated use

The product is intended for installation in electrical plants or machines.
When installed in machines, startup (i.e. start of designated operation) is prohibited
until it is determined that the machine complies with the local laws and directives. In
the individual area of application, you must especially observe the Machinery Directive
2006/42/EC as well as the EMC Directive 2004/108/EU. The EMC test specifications
EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-6 and EN 61000-6-2 must
be taken into account during startup.
The standards given in the declaration of conformity apply to the product.
Using these products in potentially explosive atmospheres is prohibited, unless spe-
cifically designated otherwise.
Air-cooled motors/gearmotors are dimensioned for ambient temperatures of -20 °C to
+40 °C and installation altitudes ≤ 1000 m above sea level. Any differing specifications
on the nameplate must be observed. The ambient conditions must comply with all the
specifications on the nameplate.
22760253/EN – 08/2016

Safety notes
Functional safety (FS) 2
2.6 Functional safety (FS)
Drives from SEW‑EURODRIVE can be equipped with optional motor options for func-
tional safety.
Frequency inverters, encoders or brakes, or other accessories, can be integrated in
the AC motor as safety-related components either individually or in combination.
SEW‑EURODRIVE indicates the integration of functional safety by the following FS
logo and a 2-digit number on the "Nameplate" (→ 2 22) of the motor.
02
The number is a code that indicates which components in the drive are safety-related.
Observe the following excerpt from the valid code table for all products.
Functional Brake Encoder

safety
02 x
04 x
11 x x
If the FS logo on the nameplate contains the code "FS 11," for example, the motor is
equipped with a combination of a safety-rated brake and safety-rated encoder.
If the drive bears the FS mark on the nameplate, you must adhere to the information in
the following documents:
• Addendum to the operating instructions "Safety-Rated Brakes – DR..71 – 225,
DRN80 – 225 AC Motors – Functional Safety"
• Addendum to the operating instructions "Safety-Rated Encoders – DR..71 – 315,
DRN80 315 AC Motors – Functional Safety", if necessary
• "DR..71 – 315 AC motors" catalog
• "AC Motors DRN80 – 315" addendum to the catalog
You find the characteristic safety values of the following components in the chapter
"Technical data" (→ 2 191) so you can determine the security level for systems and
machines yourself:
• Characteristic safety values for brakes: B10d values
• Characteristic safety values for encoders: MTTFd values
The characteristic safety values of SEW‑EURODRIVE components are also available
on the homepage at www.sew‑eurodrive.de and in the SEW‑EURODRIVE library for
the BGIA Sistema software.
22760253/EN – 08/2016

Safety notes
2 Transport/storage
2.7 Transport/storage
Inspect the shipment for damage as soon as you receive the delivery. Report any
transport damage to the shipping company immediately. If necessary, suspend start-
up.
Tighten the eyebolts securely. They are designed to only carry the weight of the gear
unit/motor/gearmotor; do not attach any additional loads.
The installed lifting eyebolts are in accordance with DIN 580. The loads and regula-
tions specified in that document must always be observed. If two or four lifting eyes or
eyebolts are attached to the gear unit/motor/gearmotor, all lifting eyes or eyebolts
must be used during transport. In this case, the tension force vector of the slings must
not exceed a 45° angle in accordance with DIN 580.
Use suitable, sufficiently rated handling equipment if necessary. Reattach these in the
case of further transportation.
If the gear unit/motor/gearmotor is not installed immediately, it must be stored in a dry
and dust-free storage location. You must not store the gear unit/motor/gearmotor out-
doors or on the fan guard. The gear unit/motor/gearmotor can be stored for up to 9
months without requiring any special measures before startup.
22760253/EN – 08/2016

Safety notes
Installation 2
2.8 Installation
Make sure that the supports are even, the foot and flange mounting is correct and if
there is direct coupling, align with precision. Resonances between the rotational fre-
quency and the double line frequency caused by the structure are to be avoided. Re-
lease the brake (if installed), turn rotor manually, check for unusual grinding noise.
Check the direction of rotation in decoupled state.
Only install or remove belt pulleys and couplings using suitable devices (heat up) and
cover with a touch guard. Avoid improper belt tension.
Make the pipe connections that may eventually be required. Mounting positions with
shaft ends pointing upwards should be equipped with a cover to prevent foreign ob-
jects from falling into the fan. Ensure that ventilation openings are not obstructed and
that exhaust air, including air from adjacent units, cannot be drawn in again straight
away.
Observe the notes in the "Mechanical installation" chapter.
2.9 Electrical connection

All work may only be carried out by qualified personnel. During work, the low-voltage
machine must be at standstill, de-energized, and safeguarded against accidental re-
start. This also applies to auxiliary circuits (e.g. anti-condensation heating or forced
cooling fan).
Check whether the unit is de-energized.
Exceeding the stated tolerances in EN 60034-1 (VDE 0530, part 1) – voltage ± 5 %,
frequency ± 2 %, curve shape, symmetry – increases the heating and influences elec-
tromagnetic compatibility. Also observe EN 50110 (and, if applicable, other national
regulations, such as DIN VDE 0105 for Germany).
Observe the wiring information and differing data on the nameplate as well as the wir-
ing diagram in the terminal box.
The connection must be a permanently secure electrical connection (no protruding
wire ends); use the cable end equipment intended for this purpose. Establish a secure
protective earth connection. When the motor is connected, the distances to non-insu-
lated and live parts must not be shorter than the minimum values according to IEC
60664 and national regulations. With low voltage, the distances should be no shorter
than the following values, in compliance with IEC 60664:
Nominal voltage VN Distance

≤ 500 V 3 mm
≤ 690 V 5.5 mm
The connection box must be free from foreign objects, dirt and humidity. Unused cable
entry openings and the box itself must be closed so that they are dust- and water-
proof. Secure the key(s) for test mode without output elements. When operating low-
voltage machines with brakes, check that the brake is functioning correctly before
22760253/EN – 08/2016
startup.
Observe the notes in chapter "Electrical installation".

Safety notes
2 Startup/operation
2.10 Startup/operation
Whenever changes to normal operation occur in the gear unit/motor/gearmotor, such
as increased temperatures, noise, vibrations, determine the cause. Consult the manu-
facturer if required. Never deactivate protection devices, even in test mode. Switch off
the motor if you are not sure.
Regularly clean air ducts in dusty or dirty environments.
2.10.1 Surface temperature during operation
CAUTION
The surfaces of the drive can be very hot during operation.
Risk of burns.
• Make sure that hot surfaces cannot be touched unintentionally or during normal
operation. Install covers or warning signs according to regulations.
• Let the motor cool down sufficiently before you start working on it.
22760253/EN – 08/2016

Motor structure
Basic structure DR..71 – 132/DRN80 – 132S motors 3
3 Motor structure
INFORMATION
The following figures are block diagrams. They are to facilitate the assignment of
components to the spare parts list. Motor size and design may cause deviations.
3.1 Basic structure DR..71 – 132/DRN80 – 132S motors
[132]
[123]
[131]
[156]
[119]
[117]
[113]
[118] [115]
[116] [262]
[112]
[111] [134]
[129]
[707]
[9] [103] [100] [705]
[706]
[35]
[30]
[42]
[22]
[106] [41]
[392] [32]
[107] [13]
[24] [36]
[108] [3] [44]
[109] [11]
[16] [1480] [10]
[12]
[7]
[2] [1]
[91]
[93] [93]
[90]
[90]
9007212623958923
[1] Rotor [30] Oil seal [106] Oil seal [123] Hex head screw
[2] Retaining ring [32] Retaining ring [107] Oil flinger [129] Screw plug with O-ring
[3] Key [35] Fan guard [108] Nameplate [131] Gasket for cover
[7] Flanged endshield [36] Fan [109] Grooved pin [132] Terminal box cover
[9] Screw plug [41] Shim [111] Gasket for lower part [134] Screw plug with O-ring
[10] Retaining ring [42] B-side endshield [112] Terminal box lower part [156] Information sign
22760253/EN – 08/2016
[11] Deep groove ball bear- [44] Deep groove ball bear- [113] Pan head screw [262] Connection terminal,
ing ing complete
[12] Retaining ring [90] Base plate [115] Terminal board [392] Seal
[13] Cap screw [91] Hex nut [116] Terminal clip [705] Canopy
[16] Stator [93] Pan head screws [117] Hex head screw [706] Spacer
[22] Hex head screw [100] Hex nut [118] Lock washer [707] Pan head screw
[24] Lifting eyebolt [103] Stud [119] Pan head screw [1480] O-ring

Motor structure
3 Basic structure DR..160 – 180, DRN132M – 180 motors
3.2 Basic structure DR..160 – 180, DRN132M – 180 motors

[117] [137]
[219] [262]
[616]
[123] [118]
[132] [116]
[131]
[119] [128]
[140]
[156]
[139]
[112]
[111] [134]
[115] [113] [129]
[390]
[109]
[108]
[24]
[12]
[9]
[7]
[106] [707]
[705]
[107] [706]
[35]
[715]
[30]
[19]
[41] [42] [22]
[17]
[91]
[90] [32]
[100]
[103] [94] [93]
[15] [16] [44]
[36]
[14] [31]
[3] [1]
[11] [2]
[104]
[10]
18014399036804619
[1] Rotor [31] Key [108] Nameplate [132] Terminal box cover
[2] Retaining ring [32] Retaining ring [109] Grooved pin [134] Screw plug with O-ring
[3] Key [35] Fan guard [111] Gasket for lower part [137] Screw
[7] Flange [36] Fan [112] Terminal box lower part [139] Hex head screw
[9] Screw plug [41] Cup spring [113] Screw [140] Washer
[10] Retaining ring [42] Rear endshield [115] Terminal board [156] Information label
[11] Deep groove ball bearing [44] Deep groove ball [116] Serrated lock washer [219] Hex nut
bearing
[12] Retaining ring [90] Foot [117] Stud [262] Connection terminal
[14] Washer [91] Hex nut [118] Washer [390] O-ring
[15] Hex head screw [93] Washer [119] Cap screw [616] Retaining plate
[16] Stator [94] Cap screw [123] Hex head screw [705] Canopy
[17] Hex nut [100] Hex nut [128] Serrated lock washer [706] Spacer
22760253/EN – 08/2016
[19] Cap screw [103] Stud [129] Screw plug with O-ring [707] Hex head screw
[22] Hex head screw [104] Supporting ring [131] Gasket for cover [715] Hex head screw
[24] Eyebolt [106] Oil seal
[30] Sealing ring [107] Oil flinger

Motor structure
Basic structure DR..200 – 225, DRN200 – 225 motors 3
3.3 Basic structure DR..200 – 225, DRN200 – 225 motors
[117] [137]
[219] [262]
[123] [118] [616]
[116]
[132]
[131]
[156]
[119] [129]
[134]
[112]
[128]
[111] [140]
[113] [139]
[109] [390]
[108] [115]
[24]
[15]
[105]
[9]
[106]
[107]
[707]
[705]
[706]
[715]
[35]
[30]
[25]
[19] [26]
[22] [32]
[42] [36]
[40]
[93]
[90] [44] [43]
[21]
[94] [31]
[103] [7]
[100] [16] [1]
[3]
[11]
[2]
9007200332597387
[1] Rotor [31] Key [107] Oil flinger [132] Terminal box cover
[2] Retaining ring [32] Retaining ring [108] Nameplate [134] Screw plug
[3] Key [35] Fan guard [109] Grooved pin [137] Screw
[7] Flange [36] Fan [111] Gasket for lower part [139] Hex head screw
[9] Screw plug [40] Retaining ring [112] Terminal box lower part [140] Washer
[11] Deep groove ball bearing [42] Rear endshield [113] Cap screw [156] Information label
[15] Hex head screw [43] Supporting ring [115] Terminal board [219] Hex nut
[16] Stator [44] Deep groove ball [116] Serrated lock washer [262] Connection terminal
bearing
[19] Cap screw [90] Foot [117] Stud [390] O-ring
[21] Oil seal flange [93] Washer [118] Washer [616] Retaining plate
[22] Hex head screw [94] Cap screw [119] Cap screw [705] Canopy
[24] Eyebolt [100] Hex nut [123] Hex head screw [706] Spacer bolt
[25] Cap screw [103] Stud [128] Serrated lock washer [707] Hex head screw
[26] Shield ring [105] Cup spring [129] Screw plug [715] Hex head screw
[30] Oil seal [106] Oil seal [131] Gasket for cover
22760253/EN – 08/2016

Motor structure
3 Basic structure DR..250 – 280, DRN250 – 280 motors
3.4 Basic structure DR..250 – 280, DRN250 – 280 motors

[137] [262] [616] [156]
[219]
[118]
[123]
[116]
[132]
[117]
[131]
[119]
[112]
[139]
[140]
[111] [128]
[159]
[160]
[161] [19]
[115]
[113] [129] [134] [22]
[24] [1453]
[105]
[9]
[7]
[106]
[107]
[707]
[705]
[706]
[715]
[35] [32]
[26] [25] [40]
[36]
[30]
[42] [43]
[109] [44]
[108] [21]
[94] [31]
[93]
[90] [1]
[15]
[16] [3]
[100]
[103] [11]
[2]
9007206690410123
[1] Rotor [32] Retaining ring [108] Nameplate [134] Screw plug
[2] Retaining ring [35] Fan guard [109] Grooved pin [137] Screw
[3] Key [36] Fan [111] Gasket for lower part [139] Hex head screw
[7] Flange [40] Retaining ring [112] Terminal box lower part [140] Washer
[9] Screw plug [42] B-side endshield [113] Cap screw [156] Information sign
[11] Deep groove ball [43] Supporting ring [115] Terminal board [159] Connection piece
bearing
[15] Cap screw [44] Deep groove ball [116] Serrated lock washer [160] Connection piece seal
bearing
[16] Stator [90] Foot [117] Stud [161] Hex head screw
22760253/EN – 08/2016
[19] Cap screw [93] Washer [118] Washer [219] Hex nut
[21] Oil seal flange [94] Cap screw [119] Hex head screw [262] Connection terminal
[22] Hex head screw [100] Hex nut [123] Hex head screw [616] Retaining plate
[24] Lifting eyebolt [103] Stud [128] Serrated lock washer [705] Canopy
[25] Cap screw [105] Compression spring [129] Screw plug [706] Spacer bolt
[26] Shield ring [106] Oil seal [131] Gasket for cover [707] Hex head screw
[30] Oil seal [107] Oil flinger [132] Terminal box cover [715] Hex head screw
[31] Key [1453] Screw plug

Motor structure
Basic structure DR..315, DRN315 motors 3
3.5 Basic structure DR..315, DRN315 motors
[452] [634]
[123] [633]
[132] [151]
[131] [117] [454]
[219]
[119] [128]
[156] [118]
[116] [140]
[112]
[111] [139]
[134] [113] [607]
[129] [115]
[109]
[108]
[707]
[24] [706]
[716]
[705] [715]
[30]
[35]
[26] [25]
[22] [40] [36]
[43]
[17] [42] [32]
[16] [94] [19] [21] [44]
[93] [1] [31]
[15] [90]
[609]
[608] [3]
[11]
[9] [606] [604]
[90] [7] [105]
[93] [94] [250]
[106]
[107]
[2]
[100]
[103]
45035996625703563
[1] Rotor [32] Retaining ring [111] Gasket for lower part [156] Information sign
[2] Retaining ring [35] Fan guard [112] Terminal box lower part [219] Hex nut
[3] Key [36] Fan [113] Cap screw [250] Oil seal
[7] Flange [40] Retaining ring [115] Terminal board [452] Terminal strip
[9] Screw plug [42] B-side endshield [116] Serrated lock washer [454] Mounting rail
[11] Rolling bearing [43] Supporting ring [117] Stud [604] Lubrication ring
[15] Cap screw [44] Rolling bearing [118] Washer [606] Grease nipple
[16] Stator [90] Foot [119] Hex head screw [607] Grease nipple
[17] Hex nut [93] Washer [123] Hex head screw [608] Oil seal flange
[19] Cap screw [94] Cap screw [128] Serrated lock washer [609] Hex head screw
[21] Oil seal flange [100] Hex nut [129] Screw plug [633] End bracket
[22] Hex head screw [103] Stud [131] Gasket for cover [634] End plate
[24] Eyebolt [105] Cup spring [132] Terminal box cover [705] Canopy
22760253/EN – 08/2016
[25] Cap screw [106] Oil seal [134] Screw plug [706] Spacer bolt
[26] Shield ring [107] Oil flinger [139] Hex head screw [707] Hex head screw
[30] Oil seal [108] Nameplate [140] Washer [715] Hex nut
[31] Key [109] Grooved pin [151] Cap screw [716] Washer

Motor structure
3 Nameplate
3.6 Nameplate
The marks on the upper edge of the nameplate are only present when the motor has
been certified accordingly or when it includes the relevant components.
3.6.1 DRN.. motor nameplate

The following figure shows an example of a nameplate:
[1] [1]
[2] DRN90L4/FF [2]

[3] 01.41027997602.0001.16 Inverter duty VPWM 3~IEC60034 [3]
[4] Hz 50 r/min 1461 V 230/400 Δ/Y [4]
[5] kW 1.5 S1 A 5.9/3.4 eff% 85.6 IE3 [5]
[6] Cosφ 0.74 IP 54 [6]
[7] Th.Kl 130(B) [7]
[8] [8]
[9] [9]
[10] FF FF165 D200 WE 24X50 [10]
[11] IM B5 [11]
[12] kg 23.555 188 684 3 Made in Germany [12]
17443243147
Line Information
[1] • Manufacturer, address
• CE marking
[2] • Type designation
[3] • Serial number
• Suitability for inverter operation
• Number of phases and underlying rating and performance standards
(IEC 60034-X and/or equivalent national standard)
[4] • Rated frequency
• Rated speed
• Nominal voltage
[5] • Rated power/duty type
• Rated current
• IE class and rated efficiency for motors included in the scope of the
IEC 60034-30-1 standard
[6] • Power factor for AC motors
• Degree of protection according to IEC 60034-5
[7] • Thermal class
22760253/EN – 08/2016
[10] • Flange
• Shaft end
[11] • Mounting position

Motor structure
Nameplate 3
Line Information
[12] • Weight
• Part number nameplate
• Country of manufacture
3.6.2 DRN.. global motor nameplate
DRN90L4/FF
01.1808089014.0001.16 3~IEC60034
50 Hz r/min 1461 V 220-230Δ/380-420Y IP54 TEFC
kW 1.5 S1 A 6.0/3.45 P.F.0.74 Nom.Eff% 85.6 IE3
kW 1.5 S1 A 5.2/3.0 P.F.0.7 Nom.Eff% 86.5 IE3
60 Hz r/min 1767 254-266Δ/440-460Y K.V.A.-Code M
Th.Kl. 130(B) S.F.1.0 ML 02 Design NEMA A CT 300-1800rpm
FF FF165 D200 WE 24X50
IM B
kg 23.555 AMB C° -20...40 1885723 Made in Germany
17443240715
3.6.3 Markings
The following table lists all markings that can be given on a nameplate or attached to
the motor and an explanation of what they mean.
Mark Meaning
CE mark to state compliance with European guidelines, such as the Low
Voltage Directive.
ATEX mark to state compliance with the European Directive 94/9/EC
UR logo to confirm that UL (Underwriters Laboratory) is informed about the

registered components; register number by UL: E189357
DoE mark to confirm compliance with US-American efficiency limit values
for AC motors
UL logo to confirm that a component is UL (Underwriters Laboratory)

tested, also valid for CSA in conjunction with the register number
CSA mark to confirm the Canadian Standard Association (CSA) and the
22760253/EN – 08/2016
market conformity of AC motors
CSAe mark to confirm compliance with the Canadian efficiency limit values
for AC motors

Motor structure
3 Nameplate
Mark Meaning
CCC logo to confirm the adherence to the Chinese regulation for small ap-
s
pliances
VIK mark to confirm the compliance with the directive of the German Asso-
ciation of Energy and Power Industry (V.I.K.)
FS mark with code number to identify functional safety relevant compon-
ents.
02
EAC mark (EurAsian Conformity)

Confirms compliance with the technical regulations of the economic and
customs union of Russia, Belarus, Kazakhstan, Armenia.
UkrSEPRO mark (Ukrainian Certification of Products)
013
Confirms compliance with the technical regulations of the country Ukraine.
EU REGULATION 640/2009 Motors with this mark may only be operated with frequency inverter (VSD =
IE2 USE WITH VARIABLE
SPEED DRIVE ONLY! Variable Speed Drive) according to regulation 640/2009.
3.6.4 Serial number

The following table lists the structure of a serial number:
Example: 01. 12212343 01. 0001. 16

01. Sales organization
12212343 Order number (8 digits)
01. Order item (2 digits)
0001 Quantity (4 digits)
16 End digits of the year of manufacture (2 digits)
22760253/EN – 08/2016

Motor structure
Type designation 3
3.7 Type designation
The following diagram shows the structure of the motor type designation:
DRN132M4/BE11/HR/FI/TF
DR Product family
N Code for product line identification
132M Size
4 Number of poles
/BE11 Brake
/HR Manual brake release
/FI Output option
/TF Thermal motor protection
3.7.1 Designation of the motors
Designation
DRS.. Standard motor, Standard efficiency IE1
DRE.. Energy-efficient motor, High Efficiency IE2
DRP.. Energy-efficient motor, Premium Efficiency IE3
DRN.. Energy-efficient motor, Premium Efficiency IE3
DRU.. Energy-efficient motor, Super Premium Efficiency IE4
DRL.. Asynchronous servomotor
DRK.. Single-phase operation with running capacitor
DRM.. Torque motor: AC motor for operation at speed n = 0
DR..J Line start permanent magnet motor
71 – 315 Nominal sizes:
71, 80, 90, 100, 112, 132, 160, 180, 200, 225, 250, 280,
315
K, S, M, L, Lengths
MC, LC,
ME, MS, H, LS, LM
2, 4, 6, 8/2, 8/4, 4/2, 12 Number of poles
22760253/EN – 08/2016

Motor structure
3 Designs and options
3.8 Designs and options
3.8.1 Output variants
Designation Description
/FI IEC foot-mounted motor
/F.A /F.B Universal foot-mounted motor
/FG 7series integral motor, as stand-alone motor
/FF IEC flange-mounted motor with bore
/FT IEC flange-mounted motor with threads
/FL General flange-mounted motor (other than IEC)
/FM 7-series integral motor with IEC feet
/FE IEC flange-mounted motor with bore and IEC feet
/FY IEC flange-mounted motor with threads and IEC feet
/FK General flange-mounted motor (deviating from IEC) with feet
/FC C-face flange-mounted motor, dimensions in inch
3.8.2 Mechanical attachments
/BE.. Spring-loaded brake with specification of size
/HR Manual brake release of the brake, automatic re-engaging
function
/HF Manual brake release, lockable
/RS Backstop
/MSW MOVI‑SWITCH®
/MM03 – MM40 MOVIMOT®
/MO MOVIMOT® option(s)
/MI Motor identification module for MOVIMOT®
3.8.3 Temperature sensor / temperature detection
/TF Temperature sensor (PTC thermistor or PTC resistor)
/TH Thermostat (bimetallic switch)
/KY 1 KTY84 – 130 sensor
22760253/EN – 08/2016
/PT 1 or 3 PT100 sensor(s)

/PK PT1000 temperature sensor

Motor structure
Designs and options 3
3.8.4 Encoder
/ES7S /EG7S Add-on speed sensor with Sin/Cos interface
/EH7S /EV7S
/ES7R /EG7R Add-on speed sensor with TTL (RS-422) interface,
/EH7R V = 9 – 26 V
/EI7C1) /EI76 /EI72 Built-in incremental encoder with HTL interface and 6 / 2 / 1
/EI71 period(s)
/AS7W /AG7W Add-on absolute encoder, RS485 interface (multi-turn)
/AS7Y /AG7Y / Add-on absolute encoder, SSI interface (multi-turn)
AH7Y
/ES7A /EG7A Mounting adapter for speed sensors
/EV2T /EV2R Add-on incremental encoder with solid shaft
/EV2S /EV2C
/XV.A Mounting adapter for third-party speed sensors
/XV.. Mounted third-party speed sensor
/XH.A Mounting adapter for third-party hollow-shaft encoders
1) Also available as safety-rated incremental encoder (identification with FS logo on the nameplate.)
3.8.5 Connection alternatives
/IS Integrated plug connector
/ISU Integrated plug connector – Design with only the lower part of
the plug connector
/ASE. HAN 10ES plug connector on terminal box with single locking
latch (cage clamp contacts on the motor side)
/ASB. HAN 10ES plug connector on terminal box with double locking
latch (cage clamp contacts on the motor side)
/ACE. HAN 10E plug connector on terminal box with single locking
latch (crimp contacts on the motor side)
/ACB. HAN 10E plug connector on terminal box with double locking
latch (crimp contacts on the motor side)
/AME. /ABE. HAN Modular 10B plug connector on terminal box with single
/ADE. /AKE. locking latch (crimp contacts on the motor side)
/AMB. /ABB. HAN Modular 10B plug connector on terminal box with double
/ADB. /AKB. locking latch (crimp contacts on the motor side)
/KCC 6 or 10-pole terminal strip with cage clamp contacts
22760253/EN – 08/2016
/KC1 C1-profile-compliant connection of the electrified monorail drive

(VDI guideline 3643), for more compact connection areas.
/IV Other industrial plug connectors according to customer spe-
cifications

Motor structure
3 Designs and options
3.8.6 Ventilation
/V Forced cooling fan
/Z Additional inertia (flywheel fan)
/AL Metal fan
/U Non-ventilated (without fan)
/OL Non-ventilated (closed B-side)
/C Canopy for the fan guard
/LF Air filter
/LN Low-noise fan guard
3.8.7 Bearing
/NS Relubrication device
/ERF Reinforced bearings on A-side with rolling bearing
/NIB Insulated bearing B-side
3.8.8 Condition monitoring
/DUB Mount-on microswitch for monitoring function and wear of the
brake (Diagnostic Unit Brake)
/DUE Eddy-current sensor for function and wear monitoring of the
brake (Diagnostic Unit Eddy Current)
3.8.9 Other additional features
/DH Condensation drain hole
/RI Reinforced winding insulation
/RI2 Reinforced winding insulation with increased resistance
against partial discharge
/2W 2nd shaft end on the motor/brakemotor
22760253/EN – 08/2016

Mechanical installation
Before you start 4
4 Mechanical installation
INFORMATION
Observe the safety notes in chapter 2 of these operating instructions for the mechan-
ical installation.
If the nameplate of the drive bears the FS icon, also comply with the information on
mechanical installation in the associated addenda to the operating instructions , or in
the associated manual.
4.1 Before you start
INFORMATION
The mounting position for installation must correspond with the specifications on the
nameplate.
Install the drive only if the following conditions are met:

• The specifications on the nameplate of the drive correspond to the supply system
or the output voltage of the frequency inverter
• The drive is undamaged (no damage caused by transport or storage)
• All transport protection has been removed
• You are certain that the following requirements have been met:
– Ambient temperature between -20 °C and +40°C
Note that the temperature range of the gear unit may also be restricted (see
gear unit operating instructions).
Any differing specifications on the nameplate must be observed. The ambient
conditions must comply with all the specifications on the nameplate.
– No oils, acids, gases, vapors, dusts, radiations, etc.
– Installation altitude max. 1000 m above sea level
Observe chapter Designated use.
– Note the restrictions for encoders
– Special design: The drive is designed in accordance with the ambient condi-
tions
The above mentioned information refers to standard orders. The conditions might be
different when you order drives other than the standard. Refer to the order confirma-
tion for differing conditions.
22760253/EN – 08/2016

4 Extended storage of motors
4.2 Extended storage of motors

• Note that the service life of the lubricant in the ball bearings is reduced by 10% per
year after the first year of storage.
• You should re-lubricate the lubrication devices on motors that have been in stor-
age for longer than 5 years before startup. Observe the information on the motor
lubricant plate.
• Check whether the motor has absorbed moisture as a result of being stored for a
long time. Measure the insulation resistance for this purpose (measuring voltage
500 V).
The insulation resistance (see the following figure) varies greatly depending on
the temperature. The motor must be dried if the insulation resistance is insuffi-
cient.
[M ]
100
10
0,1
0 20 40 60 80
[ ˚C ]
173323019
If the measured resistance, depending on the ambient temperature, is in a range

above the limit characteristic curve, the insulation resistance is sufficient. If the value
is below the limit characteristic curve, the motor must be dried.
4.2.1 Drying the motor

Proceed as follows to dry the motor:
Heat up the motor, either using warm air or using an isolation transformer:
• With warm air
DR.. motors with rotor designation "J" may be dried with warm air only.
WARNING
Risk of crushing due to torque at the motor shaft.
• Only use warm air for drying DR.. motors with rotor designation "J".
• Do not use an isolation transformer for drying DR.. motors with rotor designation
"J".
22760253/EN – 08/2016
End the drying process when the minimum insulation resistance is exceeded.
Check the terminal box for the following points:
• The inside is clean and dry.
• The connections and fastening parts are free from corrosion.

Extended storage of motors 4
• Seals and sealing surfaces are intact.
• The cable glands are tight, otherwise clean or replace them.
• Using an isolation transformer
– Connect the windings in series (see following figures)
– Auxiliary AC voltage supply max. 10% of the nominal voltage with max. 20% of
the rated current
Connection with wiring diagram R13
[1]
2336250251
[1] Transformer

[1]
V3 W3 U3
T8 T9 T7
V2 W2 U2
T5 T6 T4
V4 W4 U4
T11 T12 T10
U1 V1 W1
T1 T2 T3
[2]
2343045259
[1] Motor terminal boards [2] Transformer
W2 W3 U2 U3 V2 V3 [1]
T6 T9 T4 T7 T5 T8
U1 V1 W1
T1 T2 T3
[2]
22760253/EN – 08/2016
2343047179
[1] Motor terminal boards [2] Transformer

4 Motor installation notes
4.3 Motor installation notes
CAUTION
Sharp edges due to open keyway.
Cuts.
• Insert the key into the keyway.
• Pull a protective tubing over the shaft.
NOTICE
Improper assembly may damage the drive and corresponding components.
The drive system might be damaged.
• Note the following information.
• Motor shaft ends must be thoroughly cleaned of anti-corrosion agents, contamina-

tion or similar (use a commercially available solvent). Do not allow the solvent to
penetrate the bearings or sealing rings – this could damage the material.
• Only install the gearmotor in the specified mounting position on a level, vibration-
free and torsionally rigid support structure.
• Align the motor and the driven machine carefully in order to prevent the output
shaft from being exposed to unacceptable strain. Observe the permitted overhung
and axial forces.
• Do not jolt or hammer the shaft end.
• Use an appropriate cover, e.g. option /C "Canopy", to prevent objects or fluids en-
tering motors in vertical mounting positions (M4/V1).
• Make sure that there is sufficient clearance around the motor to provide for ad-
equate cooling air supply, and that the motor does not draw in warm exhaust air
from other units.
• Balance components for subsequent mounting on the shaft with a half key (motor
shafts are balanced with a half key).
• Existing condensation drain holes are sealed with closing plugs. If contaminated,
the condensation drain holes must be checked for proper functioning on a regular
basis and cleaned if required.
• Protect shaft again against corrosion, if necessary.
INFORMATION
DR.. motors: To mount motors with a foot made of aluminum, you have to use wash-
ers with at least twice the bolt diameter. Use bolts of strength class 8.8. Do not ex-
ceed the tightening torque according to VDI 2230-1.
DRN.. motors: To mount motors with a foot made of aluminum, you have to use
washers with an outer diameter that is at least twice the bolt diameter (e.g.
22760253/EN – 08/2016
DIN EN ISO 7090). Use bolts of strength class 8.8 up to max. 10.9. Tightening torque
according to VDI 2230-1. The maximum bolt length for DRN80 – 90 motors = M8×20,
for DRN100 – 132S motors = M10×25.
4.3.1 Installation in damp locations or outdoors

• Use suitable cable glands for the incoming cable (use reducing adapters if neces-
sary) according to the installation instructions.

Installation tolerances 4
• If possible, arrange the terminal box in such a way that the cable entries are point-
ing downwards.
• Seal the cable entry properly.
• Clean the sealing surfaces of the terminal box and the terminal box cover carefully
before re-assembly; replace embrittled gaskets.
• If required, touch up the corrosion protection (especially at the eyebolts).
• Check the degree of protection.
• Protect the shaft against corrosion using a suitable anti-corrosion agent.
4.4 Installation tolerances
Shaft end Flanges

Diameter tolerance according to Centering shoulder tolerance according
EN 50347 to EN 50347
• ISO j6 with Ø ≤ 28 mm • ISO j6 with Ø ≤ 250 mm
• ISO k6 with Ø ≥ 38 mm up to ≤ • ISO h6 with Ø ≥ 300 mm
48 mm
• ISO m6 at Ø ≥ 55 mm
• Centering bore according to DIN 332,
shape DR
4.5 Assembling the input elements

Drive components that are installed on the motor shaft end, e.g. pinions, must be
warmed up prior to assembly in order to prevent damage, e.g. to the encoder of stand-
alone motors.
WARNING
Unsecured key skidding out of the keyway.
Severe or fatal injuries due to flying parts.
• Only operate the motor with attached customer output element (e.g. gear unit), or
with a suitably secured key.
22760253/EN – 08/2016

4 Mounting of third-party encoders
4.6 Mounting of third-party encoders

If a drive was ordered with third-party encoder, SEW‑EURODRIVE will deliver the
drive with enclosed coupling. You must not connect the coupling for operation without
third-party encoder.
4.6.1 XV.A encoder mounting adapter

If you have ordered the XV.A encoder mounting adapter, the adapter and the coupling
are enclosed with the motor and are to be assembled by the customer.
The following figure shows how to assemble the coupling and the adapter:
[212]
[225]
[E] [D] [C] [B] [A]
[220] [269] [22] [361] / [170]
[F] [E] [D] [C] [B] [A]
[251] [232]
3633163787
[22] Screw [361] Safety cover

[170] Forced cooling fan guard [269] Grommet
[212] Fan guard with encoder mount [A] Adapter
[220] Encoder [B] Retaining screw
[225] Intermediate flange (not with XV1A) [C] Central retaining screw
[232] Screws (only with XV1A and XV2A) [D] Coupling (spread- or solid shaft coupling)
[251] Conical spring washers (only with XV1A [E] Retaining screw
and XV2A) [F] Screw
22760253/EN – 08/2016

Mounting of third-party encoders 4
Mounting the XV.A encoder mounting adapter to DR..71 – 225, DRN80 – 225 motors
1. If available, remove safety cover [361] or forced cooling fan guard [170].
2. For XV2A and XV4A: Remove intermediate flange [225].
3. Screw in the coupling [D] into the encoder bore of the motor shaft with the screw
[C].
DR..71 – 132, DRN80 – 132S motors: Tighten the screw [C] with a tightening
torque of 3 Nm.
DR..160 – 225, DRN132M – 225 motors: Tighten the screw [C] with a tightening
torque of 8 Nm.
4. Push the adapter [A] on the encoder [220] and tighten it with the retaining screw
[B] with a tightening torque of 3 Nm.
5. For XV2A and XV4A: Mount the intermediate flange [225] with the screw [F] with
a tightening torque of 3 Nm.
6. Push the encoder and the adapter on the coupling [D] and tighten the retaining
screw [E] with a tightening torque of 3 Nm.
7. With XV1A and XV2A: Arrange conical spring washers [251] with retaining screws
[232] and place in annular groove of the encoder [220] and tighten with a tighten-
ing torque of 3 Nm.
8. For XV3A and XV4A: Installation by the customer via the bores in the encoder
plate.
22760253/EN – 08/2016

4 Mounting of third-party encoders
4.6.2 Encoders with EV../AV.. mounting adapter

If you have ordered the EV../AV.. encoder mounting adapter, the coupling is enclosed
with the motor and must be installed by the customer.
The following figure shows an example of how the coupling is installed:
[35]
[A]
[1458]
[233]
[225]
[226]
[220]
[251]
[232]
[269]
[361]
[22] [1496]
[1497]
[1498]
[1459] [1489]
[1460] [1461] [1462] [33]

[34]
9007206970704907
[22] Screw [361] Safety cover (normal/long)

[33] Washer [1458] Screw
[34] Screw [1459] Cage nut
[35] Fan guard [1460] Serrated lock washer
[220] Encoder [1461] Washer
[225] Intermediate flange (optional) [1462] Screw
[226] Screw [1489] Ground strap
[232] Screws (enclosed with .V1A and .V2A) [1496] Serrated lock washer
[233] Coupling [1497] Washer
[251] Conical spring washers (enclosed with .V1A [1498] Screw
and .V2A)
[269] Grommet [A] Encoder mounting adapter
22760253/EN – 08/2016

Mounting of third-party encoders 4
Mounting the encoder to the EV../AV encoder mounting adapter of DR..250 – 280, DRN250 – 280
motors
1. Remove safety cover [361], if installed. Loosen screws [34].
• With /V forced cooling fan option: Remove forced cooling fan guard [170].
Loosen screws [22].
2. Push the coupling [233] with diameter 14 mm onto the pin of the encoder mounting
adapter [A]. Tighten the screw of the coupling clamping hub [233] with 3 Nm
through the slots in the encoder mounting adapter [A].
3. With option EV2/3/4/5/7A, AV2/3/4/5/7A: Mount the intermediate flange [225] to
the encoder mounting adapter [A] with screws [226]. The tightening torque must be
3 Nm.
4. Mount the conical spring washers [251] to the encoder mounting adapter [A] with
screws [232]. Do not tighten the screws [232] yet.
5. Mount the encoder [220] to the encoder mounting adapter [A] or intermediate
flange [225]. Insert the encoder shaft [220] into the coupling [233]. Turn the conical
spring washers in the encoder [220] fixture. Tighten screws [232] with 3 Nm.
Tighten the screw of the coupling clamping hub [233] on the encoder end with
3 Nm.
6. Pull the cable of the encoder [220] through the cable grommet [269]. Insert the
cable grommet [269] into the safety cover [361].
• With /V forced cooling fan option: Insert the cable grommet into the forced
cooling fan guard [170].
7. Mount the safety cover to the fan guard with screws [34] and washers [33].
• With /V forced cooling fan option: Mount the forced cooling fan guard [170]
with screws [22].
4.6.3 XH.A encoder mounting adapter

The XH1A, XH7A and XH8A encoder mounting adapters for hollow shaft encoders are
premounted on delivery.
To mount the encoder, proceed as described in chapter "Motor and brake
maintenance – preliminary work" (→ 2 107).
22760253/EN – 08/2016

4 Terminal box
4.7 Terminal box

4.7.1 Turning the terminal box
The following figure shows the structure of the terminal box design with terminal
board:
[123]
[131]
[a]
[b]
[c]
[119]
[111]
7362206987
[111]Seal [a] Terminal

[119]Terminal box [b] Auxiliary terminal retaining
retaining screws (4 x) screws (2 x)
[123]Terminal box cover [c] Retaining plate
retaining screws (4 x)
[131]Seal
Proceed as follows to turn the terminal box:

1. Loosen the screws [123] from the terminal box cover and remove the cover.
2. Remove the terminals [a], if available.
3. Loosen the retaining screws [119] of the terminal box.
4. Clean the sealing surfaces at the stator shoulder as well as at the lower part and
the cover of the terminal box.
5. Check the gaskets [111 and 131] for damage and replace them if necessary.
6. Position the terminal box as desired. Refer to the appendix for the arrangement of
the auxiliary terminals.
22760253/EN – 08/2016
7. Tighten the screws of the lower part of the terminal box with the following tighten-
ing torques:
• DR..71 – 132, DRN80 – 132S motors: 5 Nm
• DR..160 – 225, DRN132M – 225 motors: 25.5 Nm
Do not forget the retaining plate [c] if available.

Terminal box 4
8. Tighten the screws of the terminal box cover with the following tightening torques:
• DR..71 – 132, DRN80 – 132S motors: 4 Nm
• DR..160, DRN132M/L motors: 10.3 Nm
• DR..180 – 225, DRN160 – 225 motors (aluminum design): 10.3 Nm
• DR..180 – 225, DRN160 – 225 motors (gray cast iron design): 25.5 Nm
Make sure the gasket is seated properly.
4.7.2 Terminal box with NPT thread

In terminal boxes with NPT thread, cable glands cannot always be screwed in all the
way (up to the O-ring).
NPT
14949925387
SEW‑EURODRIVE recommends to seal the screw fitting with Teflon tape or Loctite®.
22760253/EN – 08/2016

4 Retrofitting (option /F.A) or modifying (option /F.B) motor feet
4.8 Retrofitting (option /F.A) or modifying (option /F.B) motor feet

The following figure shows a DR..280 motor with option /F.A (retrofit feet).
[16]
[90]
[1457]
18014406536422539
[16] Stator [1457] Set screw

[90] Foot Remove the paint from the marked sur-
faces.
The tapped holes of the foot mounting surfaces are closed with set screws [1457]. The
contact surfaces at the feet [90] and stator [16] are painted.
1. Remove the set screws [1457]. Only remove the set screws from those threads
into which you will screw the foot screws [94]. For DR..250/280, DRN250/280 mo-
tors, 4 set screws. For DRN315 motors, 6 set screws.
2. Remove the paint from the contact surfaces of the stator [16] (see marking in the
"Example illustration DR..280" above). For DR..250/280. DRN250/280 motors,
there are 8 surfaces, for DRN315, motors there are 12. SEW‑EURODRIVE recom-
mends to use a chisel or flat scraper for this purpose. Remove the paint only from
those surfaces to which the feet will be mounted. Refer to the illustration "Terminal
box positions" below for selecting the contact surfaces. A thin layer of corrosion
22760253/EN – 08/2016

Retrofitting (option /F.A) or modifying (option /F.B) motor feet 4
protection agent can be applied to the contact surfaces once the paint has been
removed.The possible terminal box positions are shown below:
0° 270° 180°
9007211165643403
3. Remove the paint from the contact surfaces of the feet [90] (see marking in the
"Example illustration DR..280" above). SEW‑EURODRIVE recommends to use a
chisel or flat scraper for this purpose. A thin layer of corrosion protection agent can
be applied to the contact surfaces once the paint has been removed.
4. Attach the feet [90] to the motor using the screws [94] and washers [93]. The tight-
ening torque for the screws [94] must be 410 Nm. The screws are microencapsu-
lated. This is why you have to screw in and tighten the screws quickly.
5. If necessary, you can apply paint or corrosion protection at the joint after attaching
the feet [90].
22760253/EN – 08/2016

4 Retrofitting (option /F.A) or modifying (option /F.B) motor feet
4.8.1 Changing the position of the motor feet
[16]
[90]
[93]
[94]
7741968395
[16] Stator [93] Washer

[90] Foot [94] Screw
When re-installing the motor feet in another position, observe the following:
• After removing the screws [94], check them for damage, e.g. to the thread.
• Remove the used microencapsulation.
• Clean the thread of the screws [94].
• Apply a high-strength thread locker to the screw threads [94] before inserting the
screws again.
• The set screws removed from the new mounting position can be reused for the
bores of the old mounting position. After inserting the set screw [1457] into the
open tapped holes in the stator [16], paint or corrosion protection can be applied
on the bare joining surfaces.
22760253/EN – 08/2016

Options 4
4.9 Options
4.9.1 /HR, /HF Manual brake release
INFORMATION
In case of brakemotors ordered with the option manual brake release /HR or /HF, the
manual brake release is preinstalled and set at the factory.
If your drive was not delivered with manual brake release and you wish to retrofit it,
observe the instructions in chapter "Retrofitting the /HR, /HF manual brake
release" (→ 2 146).
/HF Manual brake release

You can use the optional lockable /HF manual brake release to continuously mechan-
ically release the BE.. brake with a set screw and a releasing lever.
On delivery, the set screw is inserted far enough to not fall out and to not affect the
brake performance. The set screw is designed as self-locking with nylon coat. This
prevents it from unintended turning in or from falling out.
Proceed as follows to activate the lockable /HF manual brake release:
1. Screw in the set screw until there is no more clearance at the releasing lever.
2. Screw in the set screw by 1/4 or 1/2 revolution in order to manually release the
brake.
Proceed as follows to loosen the lockable /HF manual brake release:
3. Loosen the set screw at least until the floating clearance of the manual brake re-
lease has completely returned, see chapter "Retrofitting the /HR, /HF manual
brake release" (→ 2 146).
WARNING
No brake function due to incorrect brake installation.
• Only qualified staff may perform work on the brake.
• Before startup, make sure that the set screw is not turned in too far.
22760253/EN – 08/2016

4 Options
/HR manual brake release

You can use the option /HF manual brake release to mechanically release the BE..
brake for a short time via a combination of releasing lever and hand lever. It is de-
signed with a spring mechanism, so that it reengages automatically.
During the assembly the mechanics inside the fan guard is preset at the factory. A
hand lever is included in the delivery that is attached to the stator housing via clamps.
Proceed as follows to activate the /HR manual brake release:
1. Remove the hand lever from the stator housing.
2. Screw the thread of the hand lever completely into the thread of the releasing
lever.
3. To release the brake, pull the hand lever in the direction away from the terminal
box. The correct direction to pull the lever is specified by the arrow on the fan
guard.
INFORMATION
The releasing procedure can be performed with usual force application, do not apply
too much force to the lever to avoid damage to the drive.
Proceed as follows to loosen the /HR manual brake release:

1. Let go of the lever in actuated state. The lever reengages to the initial position and
the brake is applied.
2. Screw out the hand lever and attach it to the stator housing using the clamps.
WARNING
No brake function due to incorrect brake installation.
• Only qualified staff may perform work on the brake.
• Before startup, make sure that the hand lever has been removed to prevent unin-
tentional brake release during operation.
22760253/EN – 08/2016

Options 4
4.9.2 Air filter /LF
The air filter, a filter fleece, is installed in front of the fan grille. It can be easily re-
moved and installed for cleaning purposes.
The attached air filter avoids that dust and other particles drawn in by the air flow are
distributed. It also prevents that the ducts between the cooling fins become clogged
with dust.
In very dusty environments, the air filter protects the cooling fins from dirt or from be-
coming clogged.
The air filter must be cleaned or replaced depending on the amount of dust in the en-
vironment. No maintenance intervals can be specified due to the individuality of each
drive and the environment where it is installed.
Technical data Air filter

Approvals All certifications
Ambient temperature -40 °C to +100 °C
Suitable for the following motors: DR..71 – 132
Filter material Viledon PSB290SG4
22760253/EN – 08/2016

4 Options
4.9.3 Mounting adapter for measuring nipple

Depending on the respective order specifications, SEW‑EURODRIVE delivers the
drives as follows:
• with bore
• with bore and enclosed measuring nipples
The following figure shows a motor with bores and inserted measuring nipples [1]:
[1]
[1]
9007201960947467
[1] Bore with inserted measuring nipples
Proceed as follows to connect the customer measuring device:

• Remove the protective plugs from the bores.
• Insert the measuring nipple in the bores of the motor and screw in the measuring
nipple with a tightening torque of 15 Nm.
• Plug the mounting adapter of the measuring unit into the measuring nipple.
22760253/EN – 08/2016

Options 4
4.9.4 Second shaft end with optional cover
SEW‑EURODRIVE delivers motors with the /2W option second shaft end with the key
inserted and secured by transport protection.
WARNING
Unsecured key skidding out of the keyway.
Severe or fatal injuries due to flying parts.
• Only operate the motor with a suitably secured key.
A cover for the second shaft end is not included in the delivery as standard. It can be
ordered optionally for DR..71 – 280, DRN80 – 280 motors.
WARNING
Rotating shaft end or attachements.
• Only start the motor with installed protective cover at the second shaft end.
The following figure shows the dimensions of the optional cover.

[361]
L1
EA
DA
[4]
[34]
LB/LBS 1) X
18014402029073931
[4] Keyway [361] Safety cover

[34] Tapping screw LB/LBS Length of the motor/brakemotor
1) Refer to the "AC Motors" catalog for dimen-
sions
22760253/EN – 08/2016

4 Options
Dimensions
Motors DA EA L1 X
DR.. DRN.. mm mm mm mm
DR..71 – 11 23 2 91.5
DR..71 /BE – 88
DR..80 DRN80 14 30 2 95.5
DR..80 /BE DRN80 /BE 94.5
DR..90 DRN90 14 30 2 88.5
DR..90 /BE DRN90 /BE 81
DR..100 DRN100 14 30 2 87.5
DR..100 /BE DRN100 /BE 81
DR..112 – 132 DRN112 – 132S 19 40 3.5 125
DR..112 – 132 /BE DRN112 – 132S /BE 120.5
DR..160 DRN132M/L 28 60 4 193
DR..160 /BE DRN132M/L /BE 187
DR..180 DRN160 – 180 38 80 4 233
DR..180 /BE DRN160 – 180 /BE 236
DR..200 – 225 DRN200 – 225 48 110 5 230
DR..200 – 225 /BE DRN200 – 225 /BE 246
DR..250 – 280 DRN250 – 280 55 110 3 243.5
DR..250– 280 /BE DRN250 – 280 /BE
22760253/EN – 08/2016

Electrical installation
Additional regulations 5
5 Electrical installation
If the motor includes safety-relevant components, observe the following safety note:
WARNING
Disabling functional safety devices.
• Only qualified personnel is allowed to carry out work on functional safety com-
ponents.
• Any work on functional safety components must be carried out by strictly ob-
serving the specifications in the operating instructions at hand and the respective
addendum to the operating instructions. Otherwise, the warranty will become
void.
WARNING
Electric shock due to incorrect installation.
• Use switch contacts in utilization category AC-3 according to EN 60947-4-1 for
switching the motor.
• Use switch contacts to switch the brake. Depending on brake type and type
design, the switch contacts meet the specifications in the following utilization cat-
egories:
– Switch contacts for the supply voltage at AC voltage operation: AC-3 accord-
ing to EN 60947-4-1, or AC-15 according to EN 60947-5-1.
– Switch contact for the supply voltage at DC voltage operation: Preferably
AC-3 or DC-3 according to EN 60947-4-1. As an alternative, contacts in utiliz-
ation category DC-13 according to EN 60947-5-1 are also permitted.
– Switch contacts for optional separation on DC side: AC-3 according to
EN 60947-4-1.
• When motors are powered by inverters, you must adhere to the wiring instruc-
tions in the frequency inverter operating instructions.
5.1 Additional regulations

The generally applicable installation regulations for low-voltage electric equipment
(such as DIN IEC 60364, DIN EN 50110) must be complied with when setting up elec-
trical machinery.
22760253/EN – 08/2016

5 Wiring diagrams and terminal assignment diagrams
5.2 Wiring diagrams and terminal assignment diagrams

Connect the motor as shown in the wiring connection diagrams provided with the mo-
tor. You can obtain the valid wiring diagrams free of charge from SEW‑EURODRIVE.
INFORMATION
Do not connect or start up the motor if the wiring diagram is missing.
5.3 Wiring notes

During installation observe the safety notes in chapter 2 and 5.
5.3.1 Protecting the brake control system against interference

Brake cables must always be routed separately from other unshielded power cables
with phased currents to prevent interference with brake control. In particular, power
cables with phased currents include:
• Output cables from frequency inverters and servo inverters, soft-start units and
brake units
• Incoming cables for braking resistors and similar options
For line-operated motors and when using AC and DC circuit cut-off, the connection
between the brake rectifier and the external switch contact must be in a different
power cable that is separate from the motor power supply.
5.3.2 Protecting the motor protection devices against interference

Adhere to the following points to protect motor protection devices by
SEW‑EURODRIVE against interference:
• You may route separately shielded supply cables together with switched-mode
power cables in one cable.
• Do not route unshielded supply cables together with switched-mode power lines in
one cable.
22760253/EN – 08/2016

Special aspects for operation with a frequency inverter 5
5.4 Special aspects for operation with a frequency inverter
When motors are powered from inverters, you must observe the wiring instructions is-
sued by the inverter manufacturer. You must also observe the operating instructions
for the frequency inverter.
5.4.1 Motors with SEW‑EURODRIVE frequency inverter

Operation of the motor on SEW‑EURODRIVE frequency inverters has been tested.
The required dielectric strength values of the motors were confirmed and the startup
routines adjusted to the motor data. You can operate the motor with any frequency in-
verter from SEW‑EURODRIVE. To do this, start up the motor as described in the op-
erating instructions for the frequency inverter.
5.4.2 Motor with non-SEW inverter

Operating SEW‑EURODRIVE motors on third-party frequency inverters is permitted if
the pulse voltages at the motor terminals indicated in the following figure are not ex-
ceeded.
2.2
U LL [kV]
[1]
2.0 [2]
[8] 1.8
[3]
1.6
[4]
1.4
[5]
1.2 [6]
1.0
0.8
0.6
0 0.2 0.4 0.6 0.8 1 1.2 1.4
[7] [µs]
9007203235332235
[1] Permitted pulse voltage for DR.., DRN.. motors with reinforced insulation and in-
creased resistance against partial discharge (/RI2)
[2] Permitted pulse voltage for DR.., DRN.. motors with reinforced insulation (/RI)
[3] Permitted pulse voltage according to NEMA MG1 part 31, VN ≤ 500 V
[4] Permitted pulse voltage according to IEC 60034-25, limit value curve A for nom-
inal voltage VN ≤ 500 V, star connection
[5] Permitted pulse voltage according to IEC 60034-25, limit value curve A for nom-
22760253/EN – 08/2016
inal voltage VN ≤ 500 V, delta connection

[6] Permitted pulse voltage according to IEC 60034-17
[7] Voltage rise time
[8] Permitted pulse voltage

5 Special aspects for operation with a frequency inverter
The insulation class depends on the voltage.

• ≤ 500 V = standard insulation
• ≤ 600 V = /RI
• > 600 V – 690 V = /RI2
INFORMATION
Compliance with the following limit values must be checked and considered:
• The supply voltage level at the third-party inverter
• The threshold of the brake chopper voltage
• The operating mode of the motor (motoring/regenerative operation)
→ If the permitted pulse voltage is exceeded, you must install limiting measures,
such as filters, chokes or special motor cables. Consult the manufacturer of the
frequency inverter.
22760253/EN – 08/2016

Exterior grounding at the terminal box, LF grounding 5
5.5 Exterior grounding at the terminal box, LF grounding
In addition to the interior PE connection, a LF grounding cable can be attached to the
outside of the terminal box. It is not installed as standard.
LF grounding can be ordered as completely pre-installed at the factory. For this an
aluminum or gray cast iron terminal box designed for brake connections is required for
DR..71 – 132, DRN80 – 132S motors. For DR..160 – 225 motors, DRN132M – 225,
this option can be combined with all terminal box types.
The option can be combined with "HF grounding" (→ 2 54).
INFORMATION
All parts of the LF grounding kit are made from stainless steel.
DR..71 – 132, DRN80 – 132S motors
[1]
9007207279069579
[1] LF grounding at the terminal box
DR..160 – 225, DRN132M – 225 motors
[1]
22760253/EN – 08/2016
8026938379
[1] LF grounding at the terminal box

5 Improving the grounding (EMC), HF grounding
5.6 Improving the grounding (EMC), HF grounding

For improved, low-impedance grounding at high frequencies, we recommend using
the following connections. SEW‑EURODRIVE recommends to use corrosion-resistant
connecting elements.
HF grounding is not installed as standard.
The HF grounding option can be combined with LF grounding at the terminal box.
If you require LF grounding in addition to HF grounding, you can connect the con-
ductor to the same point.
The HF grounding option can be ordered as follows:
• Completely pre-installed at the factory, or as
• "Grounding terminal" kit for customer installation; part numbers listed in the follow-
ing table.
Motors Part number of "Grounding ter-

minal" kit
DR..71, DR../DRN80 13633953
DR../DRN90
DR..100M, DRN100LS
DR..100L – 132, DRN100L – 132S 13633945
DR..160 – 225, DRN132M – 225
with aluminum terminal box
INFORMATION
All parts of the kit are made from stainless steel.
INFORMATION
For further information regarding the grounding, refer to the SEW‑EURODRIVE pub-
lication "Drive Engineering – Practical Implementation, EMC in Drive Engineering".
INFORMATION
If 2 or more ground straps are used, you have to attach them with a longer screw.
The specified tightening torques refer to a strap thickness of t ≤ 3 mm.
22760253/EN – 08/2016

Improving the grounding (EMC), HF grounding 5
5.6.1 DR..71 – 80, DRN80 motors with HF(+LF) grounding
[1]
[2]
[3]
[4]
[3]
[5]
8026768011
[1] Use of the pre-cast bore at the [4] Ground strap (not included in the deliv-
stator housing ery)
[2] Serrated lock washer [5] Self-tapping screw DIN 7500 M6 × 16,
tightening torque 10 Nm
[3] Disk ISO 7093
5.6.2 DR../DRN90 motors with HF(+LF) grounding
[1]
[2]
[3]
[4]
[3]
[5]
8026773131
22760253/EN – 08/2016
stator housing ery)
[3] Disk ISO 7093

5 Improving the grounding (EMC), HF grounding
5.6.3 DR..100M, DRN100LS motors with HF(+LF) grounding
[1]
[2]
[3]
[4]
[3]
[5]
18014402064551947
stator housing ery)
[3] Disk ISO 7093 tightening torque 10 Nm
5.6.4 DR..100L – 132, DRN100L – 132S motors with HF(+LF) grounding
[1]
[2]
[3]
[4]
[3]
[5]
18014402064551947
[1] Use of tapped hole for lifting eyes [4] Ground strap (not included in the deliv-
ery)
22760253/EN – 08/2016
[2] Serrated lock washer DIN 6798 [5] Hex head screw ISO 4017 M8 × 18,
[3] Washer ISO 7089/ISO 7090

Improving the grounding (EMC), HF grounding 5
5.6.5 DR..160 – 315, DRN132M – 315 motors with HF(+LF) grounding
[1]
[2]
[3]
[4]
[3]
[5]
9007202821668107
[1] Use of the tapped holes at the terminal box

[2] Serrated lock washer DIN 6798
[3] Washer ISO 7089/ISO 7090
[4] Ground strap (not included in the delivery)
[5] • Hex head screw ISO 4017 M8 × 18 (with aluminum terminal boxes of DR..160
– 225, DRN132M – 225 motors), tightening torque 10 Nm
• Hex head screw ISO 4017 M10 × 25 (with gray cast iron terminal boxes of
DR..160 – 225, DRN132M – 225 motors), tightening torque 10 Nm
• Hex head screw ISO 4017 M12 x 30 (terminal boxes of DR../DRN250 – 315
motors), tightening torque 15.5 Nm
22760253/EN – 08/2016

5 Special aspects in switching operation
5.7 Special aspects in switching operation

When the motors are used in switching operation, possible interference of the
switchgear must be excluded by ensuring suitable wiring. According to EN 60204
(electrical equipment of machines), motor windings must have interference suppres-
sion to protect the numerical or programmable logic controllers. As it is primarily
switching operations that cause interference, SEW‑EURODRIVE recommends in-
stalling protective circuit in the switching devices.
If the drive has been delivered with a suppressor circuit in the motor, you must ob-
serve the provided wiring diagram.
5.8 Special aspects of torque motors and low-speed motors

Due to the design of torque motors and low-speed motors, very high induction
voltages may be generated when they are switched off. Consequently,
SEW‑EURODRIVE recommends using the varistor circuit shown below for protection.
The size of the varistors depends, among other factors, on the starting frequency –
note the project planning.
U U U
U1 V1 W1
(T1) (T2) (T3)
2454566155
22760253/EN – 08/2016

Special aspects of DRK.. single-phase motors 5
5.9 Special aspects of DRK.. single-phase motors
Scope of delivery and motor design

DRK.. single-phase motors are delivered with installed running capacitor in the ter-
minal box. Starting relay, centrifugal switch or start-up capacitor are not supplied.
[112]
[1660]
[1659]
[131]
[277 / 1667]
[132]
[123]
9007211192388619
[112] Terminal box [277]/[1667] Capacitor

[1660] Seal [132] Terminal box cover
[1659] Adapter piece [123] Screw
[131] Seal
22760253/EN – 08/2016

5 Special aspects of DRK.. single-phase motors
5.9.1 Connecting DRK.. single-phase motors
WARNING
Electric shock due to charged capacitor.
• After disconnection from the power supply, wait 5 seconds before opening the
terminal box.
DRK.. single-phase motors are delivered with 1 or 2 installed and connected running
capacitors. The data specified in the chapter "Technical Data" (→ 2 192) apply.
INFORMATION
If a running capacitor installed by SEW‑EURODRIVE must be replaced, only use ca-
pacitors with the same technical data.
INFORMATION
Start-up against the complete rated torque is not possible with only the running capa-
citors.
Parts which are not supplied must be ordered from specialist retailers and must be
connected according to the corresponding instructions and "wiring
diagrams" (→ 2 213).
Proceed as follows during connection:
• Remove terminal box cover [132]
• Remove adapter piece [1659] with the running capacitors [277]/[1667]
• Perform the connection according to supplied wiring diagrams.
22760253/EN – 08/2016

Ambient conditions during operation 5
5.10 Ambient conditions during operation
5.10.1 Ambient temperature

The temperature range of -20 °C to +40 °C must be ensured unless specified other-
wise on the nameplate. Motors approved for use in higher or lower ambient temperat-
ures have specific designations on the nameplate.
5.10.2 Installation altitude

The rated data specified on the nameplate applies to an installation altitude of max-
imum 1000 m above sea level. Installation altitudes of more than 1000 m above sea
level must be taken into account for project planning of motors and gearmotors.
5.10.3 Hazardous radiation

Motors must not be subjected to hazardous radiation (such as ionizing radiation). Con-
sult SEW‑EURODRIVE, if necessary.
5.10.4 Hazardous gases, vapors and dusts

DR.. AC motors are equipped with gaskets that are suitable for the designated use.
If the motor is operated in environments with high environmental impact, such as in-
creased ozone values, the DR.. /DRN.. motors can be optionally equipped with gas-
kets of a higher quality. If you have doubts regarding the stability of the gaskets in
connection with the respective environmental impacts, contact SEW‑EURODRIVE.
22760253/EN – 08/2016

5 Notes regarding the connection of the motor
5.11 Notes regarding the connection of the motor
INFORMATION
It is essential to comply with the valid wiring diagram. Do not connect or start up the
motor if this wiring diagram is missing. You can obtain the valid wiring diagrams free
of charge from SEW‑EURODRIVE.
WARNING
Danger due to contaminated terminal box.
• Seal the terminal box and unused cable entries against dust and humidity.
• Remove present foreign objects, dirt and humidity from the terminal box.
Observe the following points when connecting the motor:

• Check cable cross section
• Arrange terminal links correctly
• Screw on the connections and the PE conductor correctly
• Make sure that the connection cables are not cramped to avoid damage to the
cable insulation.
• Observe air gaps, see chapter "Electrical connection" (→ 2 15).
• In the terminal box: Check winding connections and tighten them if necessary
• Perform the connection in accordance with the enclosed wiring diagram
• Avoid protruding wire ends
• Connect the motor according to the prescribed direction of rotation
22760253/EN – 08/2016

Connecting the motor via terminal block 5
5.12 Connecting the motor via terminal block
5.12.1 According to wiring diagram R13
Arrangement of terminal links with W connection
[1]
[2]
[3]
U1
V1
)
(T1
W1
(T2
)
[4]
(T3
[5]
27021598003155723
Arrangement of terminal links with m connection
DR..71 – 280, DRN80 – 280 motors DR../DRN250 – 315 motors

(Single-sided supply): (Double-sided supply):
[1] [6]
)
(T6
)
(T4
[1]
W2
)
U2
(T5
)
(T6
[2]
)
(T4
V2
W2
[3]
)
U2
(T5
U1
[2]
V1
V2
)
(T1
[3]
)
W1
(T2
[4]
U1
V1
)
(T3
)
(T1
W1
)
[4]
(T2
)
(T3
[5]
9007199493672075
[6]
9007199734852747
[1] Terminal link [4] Terminal board

[2] Terminal studs [5] Customer connection
[3] Flange nut [6] Customer connection with divided connec-
tion cable
22760253/EN – 08/2016
INFORMATION
For DR../DRN250 – 315 motors, SEW‑EURODRIVE recommends a double-sided
supply for load currents higher than
• M12: 250 A
• M16: 315 A

5 Connecting the motor via terminal block
3
/W
/U3
W2
U2
T6/T [2]
/V3
9
V2
T4/
T7
U1
T5/T
V1
8
T1 [3]
W1
T2
[4]
T3
[5]
Arrangement of terminal links with WWconnection
[1]
W2
[2]
U2
T6
V2
T4
U3
V3
T5
U1
V1
[3]
W3
T1
T7
T2
W1
T8
T3
T9 [4]
[5]
[1] Terminal link [4] Terminal board

[2] Terminal studs [5] Customer connection
[3] Flange nut
INFORMATION
Three winding lead ends must be rewired to change from high to low voltage:
The lines designated U3 (T7), V3 (T8) and W3 (T9) must be reconnected.
• U3 (T7) from U2 (T4) to U1 (T1)
• V3 (T8) from V2 (T5 ) to V1 (T2)
• W3 (T9) from W2 (T6) to W1 (T3)
→ Changing from low to high voltage is carried out in reverse order. In both cases,
22760253/EN – 08/2016
the customer connection is made to U1 (T1), V1 (T2) and W1 (T3). You can
change the direction of rotation by interchanging 2 supply cables.

V3/T
8 W3
/T9
/T5
U3/T
7
V2
/T4
U2
1
/T1
V4
[1]
[2]
[3]
0
/T1
V1/T
U4
1 [6]
V1/T
2W
1/T3
[4]
[5]
18014400828555147
Arrangement of terminal links with mmconnection
DR..71 – 280, DRN80 – 280 motors DR../DRN250 – 315 motors

(Single-sided supply): (Double-sided supply):
L2 [5]
L3
V3/T L1
8W
3/T9
V3/T
8W
/T5
U3/T 3/T9
7
V2
/T5
T1 U3/T
7
V2
T1
/T4
U2
/T4
1
U2
/T1
V4
1
/T1
[1]
V4
[2] [1]
[3] [2]
0
/T1
V1/T
U4
[6] [3]
0
1
/T1
V1/T V1/T
U4
2W
1/T3 L1 1 [6]
[4] V1/T
2 W1
/T3
[4]
L2
[5]
L3
[5]
18014400845874315
9007208157343883
[1] Terminal link [6] Wiring designation plate

[2] Terminal studs L1 Conductor 1
[3] Flange nut L2 Conductor 2
[4] Terminal board L3 Conductor 3
[5] Customer connection
INFORMATION
22760253/EN – 08/2016
For DR../DRN250 – 315 motors, SEW‑EURODRIVE recommends a double-sided

supply for load currents higher than
• M10: 160 A

5.12.4 Connection variants via terminal block

The motors are supplied and connected differently depending on the electrical design.
Arrange the terminal links as shown in the wiring diagram and screw them on firmly.
Observe the tightening torques specified in the following tables.
DR..71 – 100, DRN80 – 100 motors
Terminal Tightening torque Connection Design Connection type Scope of delivery PE connec- PE design
studs hex nut tion screw
Ø Cross sec- Ø
tion
M4 1.6 Nm ≤ 1.5 mm2 1a Conductor end Pre-assembled ter- M5 4
sleeve minal links
≤ 2.5 mm2 1a Solid wire Pre-assembled ter-
minal links
≤ 6 mm2 1b Ring cable lug Pre-assembled ter-
minal links
≤ 6 mm2 2 Ring cable lug Connection ac-
cessories enclosed
M5 2.0 Nm ≤ 2.5 mm2 1a Solid wire Pre-assembled ter-
Conductor end minal links
sleeve
minal links
cessories enclosed
M6 3.0 Nm ≤ 35 mm2 3 Ring cable lug Connection ac-
cessories enclosed
DR..112 – 132, DRN112 – 132M motors

Terminal Tightening torque Customer Design Connection type Scope of delivery PE connec- PE design
studs hex nut connection tion screw
Ø Cross sec- Ø
tion
M5 2.0 Nm ≤ 2.5 mm2 1a Solid wire Pre-assembled ter- M5 4
Conductor end minal links
sleeve
minal links
cessories enclosed
M6 3.0 Nm ≤ 35 mm2 3 Ring cable lug Connection ac-
cessories enclosed
DR..160, DRN132L motors

Terminal Tightening torque Customer Design Connection type Scope of delivery PE connec- PE design
stud hex nut connection tion screw
Ø Cross sec- Ø
tion
M6 3.0 Nm ≤ 35 mm2 3 Ring cable lug Connection ac- M8 5
cessories enclosed
cessories enclosed
DR..180 – 225, DRN160 – 225 motors

Terminal Tightening torque Customer Design Connection type Scope of delivery PE terminal PE design
22760253/EN – 08/2016
studs hex nut connection stud

Ø Cross sec- Ø
tion
cessories enclosed
M10 10 Nm ≤ 95 mm2 3 Ring cable lug Connection ac- M10 5
cessories enclosed
cessories enclosed

DR../DRN250 – 280 motors
Ø Cross sec- Ø
tion
M10 10 Nm ≤ 95 mm2 3 Ring cable lug Connection ac- M12 5
cessories enclosed
cessories enclosed
DR../DRN315 motors
Ø Cross sec- Ø
tion
M12 15.5 Nm ≤ 95 mm2 3 Ring cable lug Premounted con- M12 5
M16 30 Nm ≤ 120 mm2 nection pieces
The designs in bold print apply to S1 duty cycle for the standard voltages and stand-
ard frequencies according to the data in the catalog. Other designs may have different
connections, for example, different terminal stud diameters and/or a different scope of
delivery.
22760253/EN – 08/2016

Variant 1a
[2]
[1]
[1]
[3]
≥ 8 – 10 mm [4]
[5]
[6]
M4: > 2.5 mm2
M5: > 2.5 mm2
27021597853089931
[1] External connection [4] Terminal link

[2] Terminal stud [5] Terminal washer
[3] Flange nut [6] Winding connection with Stocko terminal
22760253/EN – 08/2016

Variant 1b:
[2] [1]
[1]
[3]
[4]
[5]
[6]
18014398598346763
[1] External connection with ring cable lug, [4] Terminal link
according to DIN 46237 or DIN 46234,
for example
[2] Terminal stud [5] Terminal washer
[3] Flange nut [6] Winding connection with Stocko
terminal
Variant 2
[1] [2]
[3]
[5]
[6] [4]
[7]
9007199440180363
[1] Terminal board [5] Bottom nut

[2] Flange nut [6] Terminal washer
[3] Terminal link [7] Winding connection
[4] External connection with ring cable lug, according to DIN 46237 or DIN 46234,
for example
22760253/EN – 08/2016

Variant 3
[2]
[1]
[3]
[4]
[5]
[6]
[7] [8]
9007199454382091
[1] External connection with ring cable [5] Terminal link

lug, according to DIN 46237 or
DIN 46234, for example
[2] Terminal stud [6] Bottom nut
[3] Upper nut [7] Winding connection with ring cable lug
[4] Washer [8] Serrated lock washer
Variant 4
[5]
[4]
[5]
[2] [2] [4]
[3]
[2] [3]
[1]
[2]
[1]
18014399649088651
[1] Terminal box [4] Lock washer

[2] Terminal clip [5] Hex head screw
[3] PE conductor
22760253/EN – 08/2016

Variant 5
[1]
[2]
[1]
[3]
[2]
[4]
[5]
[3]
[4]
[5]
[6]
[6]
1139608587
[1] Hex nut [4] Serrated lock washer

[2] Washer [5] Stud
[3] PE conductor on cable lug [6] Terminal box
22760253/EN – 08/2016

5 Connecting the motor plug connector
5.13 Connecting the motor plug connector
5.13.1 IS/ISU plug connector
1009070219
The lower part of the /IS, /ISU plug connector option is completely wired at the factory
including the additional feature such as brake control.
The upper connector section of the /IS option is included in the delivery. It must be
connected according to the wiring diagram.
The /ISU option is delivered without upper connector section.
The /IS, /ISU plug connector option has CSA approval up to 600 V. Note for applica-
tion according to CSA regulations: Tighten the M3 clamping screws with a tightening
torque of 0.5 Nm.
Cable cross section

Make sure that the type of cable complies with the applicable regulations. The rated
currents are specified on the nameplate. The cable cross sections that can be used
are listed in the following table.
Without vari- With variable Link cable Double assignment

able terminal terminal link (Motor and brake/SR)
link
0.25 – 4.0 mm2 0.25 – 2.5 mm2 Max. 1.5 mm2 max. 1 x 2.5 and 1 x 1.5 mm2
22760253/EN – 08/2016

Connecting the motor plug connector 5
Wiring the upper section of the plug connector
• Loosen the housing cover screws:
– Remove the housing cover
• Loosen the screws from the upper section of the plug connection:
– Remove upper connector section from the cover
• Strip the insulation off the connection cable:
– Strip off about 9 mm of insulation
• Pass the cable through the cable gland
Wiring up as shown in wiring diagram R83

• Connect the lines as shown in the wiring diagram:
– Tighten the clamping screw with a tightening torque of 0.5 Nm.
• Install the plug connector (see chapter "Installing the connector" (→ 2 75))
Wiring up as shown in wiring diagram R81

For Wor mstartup:
• Connect with 6 lines:
– Tighten the clamping screws carefully.
– Motor contactors in the control cabinet
For Wor moperation:
• Connect as shown in the wiring diagram
• Install the variable terminal link as shown in the following figures according to the
required motor operation (W or m).
9007200053347851
22760253/EN – 08/2016
9007200053349515

Brake control system BSR – preparing the variable terminal link

For Woperation:
On the W side of the variable terminal link as shown in the following figure: Remove
only the bare metal pin of the marked prong horizontally – install a touch guard!
9007200053520139
For moperation:
On the m side of the variable terminal link as shown in the following figure: Com-
pletely remove two prongs horizontally.
9007200053518475
Wiring according to the R81 wiring diagram for W or m operation with double terminal assignment
• At terminal for double assignment:
– Connect the link cable
• When operation is as required:
– Insert the link cable in the variable terminal link
• Installing the variable terminal link
• At terminal for double assignment:
– Connect the motor lead above the variable terminal link
• Connect the other lines as shown in the wiring diagram
9007200053521803
22760253/EN – 08/2016

Installing the plug connector
The housing cover of the IS plug connector can be screwed onto the lower housing
part depending on the required position of the cable lead. You have to install the upper
part in the housing cover according to the position of the lower part:
1. Define the required mounting position.
2. Install the upper section of the plug connector into the housing cover in accord-
ance with the mounting position.
3. Close the plug connector.
4. Tighten the cable gland.
5. Check all screws of tightening and contact connections for tight fit.
WARNING
No grounding due to incorrect installation.
• Tighten the retaining screws of the IS plug connector properly with 2 Nm as
these screws also act as protective earth contacts.
IS female connector 9007200053719819

22760253/EN – 08/2016

Mounting position of the upper section of the plug connector in the housing cover
9007200053526155
22760253/EN – 08/2016

5.13.2 AB.., AD.., AM.., AK.., AC.., AS.. plug connectors
1009065611
The installed AB.., AD.., AM.., AK.., AC.. and AS connector systems are based on the
connector systems made by Harting.
• AB.., AD.., AM.., AK.. Han Modular®
• AC.., AS.. Han 10E / 10ES
The connectors are located at the side of the terminal box. They are locked either us-
ing two clamps or one clamp on the terminal box.
The internal motor wiring is performed at the factory according to the order informa-
tion. The mating connector must be prefabricated by the user.
The mating connector (grommet housing) with socket contacts is not included in the
delivery.
INFORMATION
The degree of protection is only applied when the mating connector is mounted and
locked.
22760253/EN – 08/2016

5 Connecting the motor via terminal strip
5.14 Connecting the motor via terminal strip
5.14.1 KCC terminal strip

• In accordance with the wiring diagram provided
• Check the max cable cross section:
– 4 mm2, rigid
– 4 mm2, flexible
– 2.5 mm2, flexible with conductor end sleeve
• In the terminal box: Check winding connections and tighten them if necessary
• Strip 10 – 12 mm of insulation
Arrangement of terminal links for W connection
18014399506064139
Arrangement of terminal links for m connection
22760253/EN – 08/2016
18014399506066059

Connecting the motor via terminal strip 5
5.14.2 KC1 terminal strip
• Perform the connection in accordance with the enclosed wiring diagram
• Check the maximum cable cross section:
– 2.5 mm2 rigid
– 2.5 mm2 flexible
– 1.5 mm2 flexible with conductor end sleeve
• Strip 8 – 9 mm of insulation
9007200257397387
9007200257399307
22760253/EN – 08/2016

5 Connecting the brake
5.15 Connecting the brake

The BE.. brakes are powered by energized DC voltage and are released electrically.
The brake is applied mechanically when the voltage supply is disconnected.
WARNING
Delayed brake application or unintentional brake release due to incorrect control or
connection.
Severe or fatal injuries, e.g. due to falling hoist.
• Comply with the applicable regulations issued by the relevant employer's liability
insurance association regarding phase failure protection and the associated cir-
cuit/circuit modification.
• Connect the brake according to the enclosed wiring diagram.
• In case of emergency off, always disconnect al poles of the brake control from
the supply voltage.
• Only use suitable contactors with sufficient contact rating (utilization category to
EN 60947-4-1/EN 60947-5-1, see chapter "Brake voltage supply" (→ 2 82)).
• For contactor selection, observe the inductive load to switch, and the high current
load while switching the brake.
5.15.1 Connecting the brake control

The brake is powered by a brake control system with protection circuit. The brake con-
trol is either installed in the motor's terminal box or in the control cabinet. When the
motor is prepared for the brake control in the control cabinet, the brake supply cables
are connected to a terminal strip in the motor terminal box.
Usually screw terminals are used as terminals on the terminal strip or on the brake
control. Terminals with cage clamp can also be used.
The connectable cable cross sections are restricted to 2.5 mm2. In case you use larger
cable cross sections due to application reasons, additional intermediate terminals
must be used.
The brake is internally connected to the motor PE. An additional connection for the
brake is not necessary.
WARNING
Delayed brake application or unintentional brake release due to incorrect control or
connection.
• Observe the specifications of this documentation for connecting the brake.
• If you are uncertain about brake control, voltage supply type and design, or over-
voltage and short circuit protection, contact the plant manufacturer or
SEW‑EURODRIVE.
22760253/EN – 08/2016

Connecting the brake 5
5.15.2 Permitted brake controls
INFORMATION
The following specifications refer to motors designed for operation at ambient tem-
peratures of -20 °C to +40 °C, and with thermal class 130 (B) or 155 (F). Deviations
may occur depending in the installed motor options.
For each individual case always observe the specifications on the order confirmation
and on the motor "Nameplate" (→ 2 22).
The brake is designed for operation with AC voltage or DC voltage, depending on the
design. A brake control by SEW‑EURODRIVE is used that is either installed in the mo-
tor terminal box or in the control cabinet.
BE05 – 2 brakes can also be operated without brake control by SEW‑EURODRIVE
with DC voltage. Observe the information on the motor "Nameplate" (→ 2 22). In this
case, a suitable overvoltage protection must be installed at the terminal strips in the
terminal box using varistors. The varistors are not included in the delivery of the motor.
Observe the project planning information in the "AC Motors" catalog.
The following brake control types are not permitted:
• Operation with AC voltage without brake control by SEW‑EURODRIVE with
BE05 – BE122 brakes.
• Operation with DC voltage without brake control by SEW‑EURODRIVE with BE5 –
BE122 brakes.
• Operation with third-party brake control.
For an overview of available brake controls by SEW‑EURODRIVE and of the technical
data, refer to chapter "Brake control" (→ 2 174).
5.15.3 Optional separation of DC and AC circuits

In case of brakes operated with AC voltage, make sure the disconnection type desig-
nated by the manufacturer is applied correctly during the brake connection. The fol-
lowing types are distinguished:
• Cut-off in just the AC circuit with normal application time
• Cut-off in AC circuit and DC circuit with shortened application time
The correct switch-off type must be ensured by a respective wiring. Certain brake con-
trols by SEW-EURODRIVE realize the same AC and DC cut-off via integrated switch-
ing relays (e.g. BMP1.5), or via mounted relays (e.g. BSR or BUR).
The switch-off type is specified on the included wiring diagrams by a pictogram.
WARNING
Delayed brake application or unintentional ongoing brake release due to incorrect
switch-off.
22760253/EN – 08/2016
• Only use the faster cut-off in the DC and AC circuit for hoists and hoist-like ap-
plications.
• When you are not sure if your application is a hoist-like application, contact
SEW‑EURODRIVE.

5.15.4 Brake voltage supply

In general, the brake voltage supply must match the values specified on the motor
"Nameplate" (→ 2 22). The brake must be supplied via the designated brake control.
The specifications on the nameplate have a tolerance of +/-5% of the stated nominal
value, or of the mean value of the stated connection range. Observer order-specific
deviations.
Make sure the voltage supply is sufficiently stable by using cable cross sections and
voltage sources that are dimensioned accordingly. Make sure the supply voltage does
not drop below 90 % of the nominal value during the starting procedure. This may be
caused by an increased inrush current (see chapter "Operating currents" (→ 2 167)).
In case of single-speed drives (not pole-changing) operated directly at the supply sys-
tem (meaning without frequency inverter or soft start devices), the brake supply
voltage can also be taken from the terminal board of the motor. Adhere to the follow-
ing restrictions:
• The nominal brake voltage must either match the phase-to-neutral voltage, or the
phase-to-phase voltage of the motor (observe nameplate and motor switching
type).
• In case of hoists or hoist-like applications the BSR brake control must be used for
cut-off in the DC and AC circuits.
• For combinations with BMP3.1 brake control (BE60 – 122) a voltage supply via the
terminal board is not permitted.
22760253/EN – 08/2016

5.15.5 Switching equipment
The high current utilization during switching the brake (inductive load) requires suit-
able contactors/switch contacts, to obtain the correct function of the brake.
Depending on brake type and type design, the switch contacts must meet the specific-
ations in the following utilization categories:
• Switch contacts for the supply voltage at AC voltage operation: AC-3 according to
EN 60947-4-1, or AC-15 according to EN 60947-5-1.
• Switch contact for the supply voltage at DC voltage operation: Preferably AC-3 or
DC-3 according to EN 60947-4-1. As an alternative, contacts in utilization category
DC-13 according to EN 60947-5-1 are also permitted.
• Switch contacts for optional separation on DC side: AC-3 according to
EN 60947-4-1.
Observe the specifications on the provided wiring diagram.
Using a semi-conductor relay is not permitted.
5.15.6 Damage protection against overvoltage and short circuit

To obtain protection against overvoltage damages (e.g. due to short circuit), a suffi-
ciently dimensioned fusing must be used at the supply cables.
Observe the notes on dimensioning in the catalog, or contact SEW‑EURODRIVE.
22760253/EN – 08/2016

5.15.7 Connecting diagnostic unit /DUB

Connect the diagnostic unit as shown in the wiring connection diagrams provided with
the motor. The maximum permitted connection voltage is AC 250 V with a maximum
current of 6 A. With low voltage the maximum voltage is AC 24 V or DC 24 V with
max. 0.1 A. A subsequent change to low voltage is not permitted.
Function monitoring Wear monitoring Function and wear monit-

oring
[1] [1] [1]
[3]
[2]
[2] [2]
BN1
BN1 BN1
BU1
BU1 BU1
[4]
BN2 [2]
BU2
[1] Brake [1] Brake [1] Brake

[2] Microswitch [2] Microswitch [2] Microswitch
MP321-1MS MP321-1MS MP321-1MS
[3] Function monitoring
[4] Wear monitoring 22760253/EN – 08/2016

5.15.8 Connecting the diagnostic unit /DUE option for function and wear monitoring
The /DUE diagnostic unit (Diagnostic Unit Eddy Current) is a contactless measuring
system for function and wear monitoring of the brake and the continuous measure-
ment of the current working air gap.
The measuring system consists of:
• Sensor, integrated in the magnet body of the brake
• Evaluation unit in the motor terminal box that is supplied via a DC 24 V voltage.
If the diagnostic unit /DUE was ordered, the function and wear monitoring is installed
and calibrated at the factory. The customer must connect the diagnostic unit, see wir-
ing diagram. The switching point of the wear monitoring is preset to the maximally per-
mitted value. According to the "code table", a reduced value can be set.
For the state of the evaluation unit, refer to chapter "Status display of the evaluation
unit".
For information on retrofitting the diagnostic unit /DUE, refer to chapter "Retrofitting
the diagnostic unit /DUE for function and wear monitoring".
Designation of the components

The system comprises a sensor and single-channel evaluation unit. The function mon-
itoring of the brake is realized via a digital signal (NO contact). A digital output (NC
contact) signals if the wear limit was reached. Further, a current output allows for con-
tinuous monitoring of the brake wear.
[1]
11k
0k
DC 24V
1
[6] 9k
GND
8k
AGND 7k
6k
INF
ZERO
5k
WEAR1
4k
FCT1
OUT1
6s
5s
B1
4s
GND1
A1
[5]
95 6 09
211
[2]
0
-1 K-0
E
DU
[4]
[3]
14950549515
[1] Terminals 4k – 11k

22760253/EN – 08/2016
[2] LEDs for function and wear, brake

[3] DIP switches S1 – S5
[4] Fastening of terminal box (PE)
[5] Line clip
[6] Terminals 4s – 6s

The connection designation of the terminals are as follows:
Terminal Designation Description Color coding

4s A1 Sensor 1 connection 1 Brown (BN)
5s GND1 Sensor 1 shield Black (BK)
6s B1 Sensor 1 connection 2 White (WH)
Terminal Designation Description

4k OUT1 Analog output working air gap brake
5k FCT1 Digital output function brake
6k WEAR1 Digital output wear brake
7k ZERO Input calibration zero value
8k INF Input calibration infinite value
9k AGND Signal ground AGND
10k GND Ground potential GND
11k DC 24 V DC 24 V supply
The LEDs have the follow meaning:
LEDs Designation Description

Green [2] FCT1 The brake is open. Electromagnet is active. Pressure
plate is in contact with magnet body.
Red [2] WEAR1 The current working air gap of the brake reached or ex-
ceeded the preset maximum working air gap.
22760253/EN – 08/2016

Options 5
5.16 Options
Connect the options as shown in the wiring connection diagrams provided with the
motor. You can obtain the valid wiring diagrams free of charge from
SEW‑EURODRIVE.
INFORMATION
Do not connect any options if the wiring diagram is missing.
5.16.1 Temperature sensor /TF
NOTICE
Impermissible heating of the motor due to defective /TF temperature sensor.
Damage to property.
• Do not connect any voltages > 30 V to the /TF temperature sensor.
• Observe the provided wiring diagram for the connection of the temperature
sensor /TF.
The PTC thermistors comply with DIN 44082.

Resistance measurement (measuring instrument with V ≤ 2.5 V or I < 1 mA):
• Standard measured values: 20 – 500 Ω, hot resistance > 4000 Ω
When using the temperature sensor for thermal monitoring, the evaluation function
must be activated to maintain reliable isolation of the temperature sensor circuit. If the
temperature reaches an excessive level, a thermal protection function must be
triggered immediately.
If there is a second terminal box for the /TF temperature sensor, this is where you
must connect the temperature sensor.
Observe the provided wiring diagram for the connection of the TF temperature sensor.
If the wiring diagram is missing, you can obtain it from SEW‑EURODRIVE free of
charge.
22760253/EN – 08/2016

5 Options
Below figure shows the characteristic curve of the /TF with reference to the nominal
response temperature (referred to as TNF).
R [Ω]
4000
1330
550
250
[T]
-20°C
TNF - 20 K
TNF - 5 K
TNF + 5 K
TNF + 15 K
TNF
5470153483
5.16.2 TH winding thermostats

The thermostats are connected in series and open when the permitted winding tem-
perature is exceeded. They can be connected in the drive monitoring loop.
VAC VDC
Voltage V in V 250 60 24
Current (cos ϕ = 1.0) in A 2.5 1.0 1.6
Current (cos ϕ = 0.6) in A 1.6
Contact resistance max. 1 Ω at DC 5 V / 1 mA
22760253/EN – 08/2016

Options 5
5.16.3 Temperature detection /KY (KTY84 – 130)
NOTICE
Excessive self-heating of the temperature sensor can damage the insulation of the
temperature sensor as well as the motor winding.
• Use currents > 3 mA in the KTY circuit.
• Observe the correct connection of the KTY to ensure correct evaluation of the
temperature sensor.
• Observe the polarity during connection.
The characteristic curve in the following figure shows the resistance curve subject to
the motor temperature with a measuring current of 2 mA and correct pole connection:
3000
2500
2000
R [Ω] 1500
1000
500
0
-100 -50 0 50 100 150 200 -250 300 350
T [°C]
1140975115
Technical data KTY84 – 130

Connection Red (+)
Blue (−)
Total resistance at 20 – 25 °C 540 Ω < R < 640 Ω
Test current < 3 mA
22760253/EN – 08/2016

5 Options
5.16.4 Temperature sensor /PT (PT100)
NOTICE
Excessive self-heating of the temperature detection can damage the insulation of
the temperature detection as well as the motor winding.
• Avoid currents > 3 mA in the circuit of the PT100.
• Observe the correct connection of the PT100 to ensure correct evaluation of the
temperature detection.
the motor temperature.
300
250
200
R [Ω] 150
100
50
0
-100 -50 0 50 100 150 200 250
T [°C]
1145838347
Technical data PT100

Connection Red/white
Resistance at 20 – 25 °C per PT100 107.8 Ω < R < 109.7 Ω
Test current < 3 mA
22760253/EN – 08/2016

Options 5
5.16.5 Temperature detection /PK (PT1000)
NOTICE
Excessive self-heating of the temperature sensor can damage the insulation of the
temperature detection as well as the motor winding.
• Avoid currents > 3 mA in the circuit of the PT1000.
• Observe the correct connection of the PT1000 to ensure correct evaluation of the
temperature detection.
the motor temperature.
3000
2500
2000
R [Ω] 1500
1000
500
0
-100 -50 0 50 100 150 200 250
T [°C]
17535480203
Technical data PT1000

Connection Black/red
Resistance at 20 – 25 °C per PT1000 1077 Ω < R < 1098 Ω
Test current < 3 mA
22760253/EN – 08/2016

5 Options
5.16.6 Forced cooling fan /V

• Connection in separate terminal box
• Max. connection cross section 3 × 1.5 mm2 (3 × AWG 15)
• Cable gland M16 × 1.5
Motors Operating mode/connec- Frequency Voltage

tion Hz V
DR..71 – 132, 1 ~ AC1) (m) 50 100 – 127
DRN80 – 132
DR..71 – 132, 3 ~ AC W 50 175 – 220
DRN80 – 132
DR..71 – 132, 3 ~ AC m 50 100 – 127
DRN80 – 132
DR..71 – 180, 1 ~ AC1) (m) 50 230 – 277
DRN80 – 180
DR..71 – 315, 3 ~ AC W 50 346 – 500
DRN80 – 315
DR..71 – 315, 3 ~ AC m 50 200 – 290
DRN80 – 315
1) Steinmetz circuit
Motors Operating mode/connec- Frequency Voltage

tion Hz V
1)
DR..71 – 132, 1 ~ AC (m) 60 100 – 135
DRN80 – 132
DR..71 – 132, 3 ~ AC W 60 175 – 230
DRN80 – 132
DR..71 – 132, 3 ~ AC m 60 100 – 135
DRN80 – 132
DR..71 – 180, 1 ~ AC1) (m) 60 230 – 277
DRN80 – 180
DR..71 – 315, 3 ~ AC W 60 380 – 575
DRN80 – 315
DR..71 – 315, 3 ~ AC m 60 220 – 330
DRN80 – 315
1) Steinmetz circuit
Motors Operating mode/connec- Voltage

tion V
DR..71 – 132, DC 24 V 24
22760253/EN – 08/2016
DRN80 – 132
INFORMATION
For information on how to connect the forced cooling fan /V, refer to chapter "Forced
cooling fan /V" (→ 2 211).

Options 5
5.16.7 UWU52A switched-mode power supply
The forced cooling fan type V for DC 24 V includes the UWU52A switched-mode
power supply, if you have ordered it. It can be ordered using the part number from
SEW‑EURODRIVE even after the order has been placed.
The following figure depicts the UWU52A switched-mode power supply:
76
101 38
111
576533259
Input: AC 110 – 240 V; 1.04 – 0.61 A; 50/60 Hz

DC 110 – 300 V; 0.65 – 0.23 A
Output: DC 24 V; 2.5 A (40 °C)
DC 24 V; 2.0 A (55 °C)
Connection: Screw terminals 1.5 – 2.5 mm2, separable
Degree of protec- IP20; attachment to EN 60715 TH35 mounting rail in the control cab-
tion: inet
Part number: 0188 1817
22760253/EN – 08/2016

5 Options
5.16.8 Overview of add-on encoders

Refer to the wiring connection diagrams on information on how to connect add-on en-
coders:
En- Motors Encoder Mounting type Supply Signal Wiring dia-

coder type DC V gram
ES7S DR..71 – 132, Incremental Shaft-centered 7 – 30 1 Vss sin/cos 68180xx08

DRN80 – 132S
ES7R DR..71 – 132, Incremental Shaft-centered 7 – 30 TTL (RS422) 68179xx08
DRN80 – 132S
ES7C DR..71 – 132, Incremental Shaft-centered 4.5 – 30 HTL / TTL (RS422) 68179xx08
DRN80 – 132S
AS7W DR..71 – 132, Absolute Shaft-centered 7 – 30 1 Vss sin/cos 68181xx08
DRN80 – 132S value
AS7Y DR..71 – 132, Absolute Shaft-centered 7 – 30 1 Vss sin/cos + SSI 68182xx07
DRN80 – 132S value
EG7S DR..160 – 280, Incremental Shaft-centered 7 – 30 1 Vss sin/cos 68180xx08
DRN132M – 280
EG7R DR..160 – 280, Incremental Shaft-centered 7 – 30 TTL (RS422) 68179xx08
DRN132M – 280
EG7C DR..160 – 280, Incremental Shaft-centered 4.5 – 30 HTL / TTL (RS422) 68179 xx08
DRN132M – 280
AG7W DR..160 – 280, Absolute Shaft-centered 7 – 30 1 Vss sin/cos 68181xx08
DRN132M – 280 value
AG7Y DR..160 – 280, Absolute Shaft-centered 7 – 30 1 Vss sin/cos + SSI 68182xx07
DRN132M – 280 value
EH7S DR../DRN315 Incremental Shaft-centered 10 – 30 1 Vss sin/cos 08511xx08
EH7C DR../DRN315 Incremental Shaft-centered 10 – 30 HTL 08511xx08
EH7R DR../DRN315 Incremental Shaft-centered 10 – 30 TTL (RS422) 08511xx08
EH7T DR../DRN315 Incremental Shaft-centered 5 TTL (RS422) 08511xx08
AH7Y DR../DRN315 Absolute Shaft-centered 9 – 30 TTL (RS422) +SSI 08259xx07
value
EV7S DR..71 – 225, Incremental Flange centered 7 – 30 1 Vss sin/cos 68180xx08
DRN80 – 225
EV7R DR..71 – 225, Incremental Flange centered 7 – 30 TTL (RS422) 68179xx08
DRN80 – 225
EV7C DR..250/280, Incremental Flange centered 4.5 – 30 HTL / TTL (RS422) 68179xx08
DRN250/280
AV7W DR..250/280, Absolute Flange centered 7 – 30 1 Vss sin/cos 68181xx08
22760253/EN – 08/2016
DRN250/280 value
AV7Y DR..250/280, Absolute Flange centered 7 – 30 1 Vss sin/cos + SSI 68182xx07
DRN250/280 value

Options 5
INFORMATION
• Maximum oscillation load for encoders ≤ 10 g ≈ 100 m/s2 (10 Hz to 2 kHz)
• Shock resistance = 100 g ≈ 1000 m/s2 for DR..71 – 132, DRN80 – 132S motors
• Shock resistance = 200 g ≈ 2000 m/s2 for DR..160 – 315, DRN132M – 315 motors
5.16.9 Overview of built-in encoders and visual feedback
INFORMATION
For information on how to connect the built-in encoder, refer to the wiring diagram.
• Observe chapter "Wiring diagrams" for connection via terminal strip.
• Observe the enclosed wiring diagram for connection via M12 connectors.
Encoder Motors Supply Signals

in VDC
EI711) DR..71 – 132 9 – 30 HTL 1 period/revolu-
DRN80 – 132S tion
EI721) HTL 2 periods/revolu-
tion
EI761) HTL 6 periods/revolu-
tion
EI7C1) HTL 24 periods/re-
volution
1) The letter B after the type designation mark indicates the unit generation of the encoder in the docu-
mentation. It is not indicated on the nameplate.
22760253/EN – 08/2016

5 Options
EI7. B – visual feedback

The EI7. encoders use 2 bi-colored LEDs (red + green each) for visual feedback on
the operating state.
LED H1 (at cable output of the encoder) – status and errors
The green LED indicates the status or the configuration of the encoder. It flashes. The
flashing frequency indicates the set number of periods.
LED H1 green
Frequency Status/configuration
LED off Encoder without voltage or faulty
0.6 Hz EI71 (1 period per revolution)
1.2 Hz EI71 (2 periods per revolution)
3 Hz EI76 (6 periods per revolution)
15 Hz EI7C (24 periods per revolution)
LED lit continuously Encoder defective
The red LED is lit when the encoder detects an error.
LED H1 red
Blinking code Meaning
10 s with 1 Hz and 2 s continu- No valid number of periods can be set
ous
Other Output driver signals a fault (e.g. short circuit or
overtemperature)
The H2 LED display gives visual feedback on the signal track status.
LED color Track A Track B Track A Track B

Orange (green and red) 0 0 1 1
Red 0 1 1 0
Green 1 0 0 1
Off 1 1 0 0
22760253/EN – 08/2016

Options 5
5.16.10 Installation notes for encoders
When connecting the encoders to the inverters, observe the provided wiring diagrams
and the information in these operating instructions as well as the operating instruc-
tions/wiring diagrams of the respective inverter and the operating instructions/wiring
diagrams provided with the non-SEW encoder if applicable.
Proceed according to chapter "Motor and brake maintenance" to connect the en-
coders mechanically. Observe the following notes:
• Maximum line length (inverter to encoder):
– 100 m with a capacitance per unit length conductor – shield ≤ 110 nF/km
– 100 m with a capacitance per unit length conductor – conductor ≤ 85 nF/km
• Core cross section: 0.20 – 0.5 mm2 recommendation ≥ 0.25 mm2
• Use shielded cable with twisted pair conductors and apply shield over large area
on both ends:
– In the cable gland of the encoder connection cover or in the encoder connector
– To the inverter on the electronics shield clamp and to the housing of the D-sub
connector
• Install the encoder cables separately from the power cables, keeping a distance of
at least 200 mm.
• Compare the operating voltage with the permitted operating voltage range on the
encoder nameplate. Deviations in the operating voltage may overheat and damage
the encoder.
• SEW‑EURODRIVE recommends the use of stabilized voltage sources and separ-
ate supply systems for encoder or other sensor components and active compon-
ents such as switches and light barriers.
• Supplies with voltage transients and interferences higher than the supply voltage
UB are not permitted.
• Observe the clamping area of 5 to 10 mm of the cable gland of the connection
cover. If you use cables with a different cross section, you have to replace the
provided cable gland with another suitable EMC-compliant cable gland.
• The cable glands for the cable entry must meet the following conditions:
– Cramping area is suitable for the used cable(s)
– The IP level of the encoder connection is at least as high as the IP degree of
protection of the actual encoder
– The operating temperature range matches the designated ambient temperature
range.
• Check the flawless state and the proper seat of the connection cover gasket during
assembly.
• Tighten the screws of the connection cover with a tightening torque of 2 Nm.
22760253/EN – 08/2016

5 Options
5.16.11 Anti-condensation heating /Hx

To protect a shutdown motor from freezing up (rotor blockage) or condensation inside
the motor, it can be equipped with an optional anti-condensation heating. The anti-
condensation heating consists of strip heaters that are integrated in the winding over-
hang and supplied with voltage when the motor is switched off. The motor is heated by
the current flowing through the strip heaters.
The strip heaters are controlled according to the following principle:
• Motor switched off → anti-condensation heating activated
• Motor switched on → anti-condensation heating deactivated
Observe the permitted voltage according to the nameplate and the enclosed terminal
assignment diagram.
22760253/EN – 08/2016

Startup
6
6 Startup
INFORMATION
• It is essential to comply with the safety notes in chapter 2 during installation.
• In case of problems, refer to the chapter "Malfunctions" (→ 2 193).
If the motor includes safety-relevant components, observe the following safety note:
WARNING
ponents.
void.
WARNING
Electric shock due to incorrect installation.
• Use switch contacts in utilization category AC-3 according to EN 60947-4-1 for
switching the motor.
• When motors are powered by inverters, you must adhere to the wiring instruc-
tions in the frequency inverter operating instructions.
CAUTION
Risk of burns.
NOTICE
The specified maximum limit torque (Mpk) and the maximum current (Imax) may not be
exceeded, not even for acceleration.
• Limit the maximum current at the inverter.
INFORMATION
22760253/EN – 08/2016
Limit the maximum speed at the inverter. For information on the procedure, refer to
the documentation of the inverter.

Startup
6 Before startup
INFORMATION
When using the DR..250 – 280, DRN250 – 280 motor with the BE brake and an en-
coder, note the following:
• The brake must be used as a holding brake only.
• The brake may only be applied when the speed is ≤ 20 1/min. For higher speeds,
please contact SEW‑EURODRIVE.
• Emergency stops from a higher motor speed are allowed.
6.1 Before startup

Prior to startup make sure that:
• The drive is undamaged and not blocked.
• Any transport locks have been removed.
• The measures stipulated in chapter "Extended storage of motors" (→ 2 30) are
performed after extended storage periods.
• All connections have been made correctly.
• The direction of rotation of the motor/gearmotor is correct.
– Motor rotating clockwise: U, V, W (T1, T2, T3) to L1, L2, L3
• All protective covers are installed correctly.
• All motor protection equipment is active and set for the rated motor current.
• There are no other sources of danger.
• Loose elements like keys are appropriately secured.
• The brake is not manually released.
– The set screw of /HF option is loosened correctly.
– The hand lever of the /HR option has been removed and correctly attached to
the stator using the designated clamps.
6.2 Motors with reinforced bearing
NOTICE
Damage to bearings due to impermissible heating of bearing and motor.
Damage to property.
• Do not operate cylindrical roller bearings without overhung load.
22760253/EN – 08/2016

Startup
Motors with backstop /RS 6
6.3 Motors with backstop /RS
A /RS backstop is used to block/preclude a direction of rotation of the motor. The dir-
ection of rotation is indicated by an arrow on the fan guard of the motor or on the gear-
motor housing.
Observe the direction of rotation of the end shaft and the number of stages when you
mount the motor to the gear unit. Do not startup the motor in the blocking direction
(note the correct phase angle when connecting the motor). For inspection purposes,
you can operate the backstop once with half the motor voltage in the blocking direc-
tion.
If a conversion is required to change the blocking direction, follow the instructions in
chapter Altering the blocking direction on motors with a backstop.
22760253/EN – 08/2016

Inspection/maintenance
7
7 Inspection/maintenance
WARNING
Risk of crushing if the hoist falls or in the event of uncontrolled device behavior.
• Secure or lower the hoist drives.
• Secure and/or fence in the driven machine.
• Disconnect the motor and the connected options from the power supply before
you start working on the unit.
• Secure the motor against unintended power-up.
• Use only genuine spare parts in accordance with the valid spare parts list.
• Always replace the brake coil together with the brake control.
In case safety-rated components are installed in the motor, observe the following
safety note:
WARNING
ponents.
void.
CAUTION
Risk of burns.
• Let the motor cool down sufficiently before you start working on it. 22760253/EN – 08/2016

7
NOTICE
Damage to the oil seals if the temperatures is too low during installation.
Possible damage to the oil seals.
• Before assembly, make sure that ambient temperature and the temperature of
the oil seal are not below 0 °C.
INFORMATION
Apply grease with a grease depot to the lip of the oil seal before assembly. For in-
formation on the lubricants, refer to chapter "Order information for lubricants, anti-
corrosion agents and sealants" (→ 2 181).
INFORMATION
Friction disks at brakemotors may only be replaced by the SEW‑EURODRIVE ser-
vice.
Only SEW‑EURODRIVE repair workshops or plants that provide the necessary ex-
pertise may repair or modify the motor/brakemotor.
Before re-startup of the motor, make sure that all regulations are complied with and
document this with a label on the motor or a written test report.
Always perform safety and functional checks following all maintenance and repair
work (thermal protection).
22760253/EN – 08/2016

7 Inspection and maintenance intervals
7.1 Inspection and maintenance intervals

The following table lists the inspection and maintenance intervals:
Unit / unit part Time interval What is to be done?

BE brake • If used as a working brake: Brake inspection
At least every 3000 operating hours1) • Measure the brake disk thickness
• If used as a holding brake: • Brake disk, lining
Every 0.5 to 4 years, depending on oper- • Measure and adjust working air gap
ating conditions1) • Pressure plate
• Driver/gearing
• Pressure rings
• Sucking off any abrasion
• Inspect the switch contacts and replace
them, if necessary (e.g. in case of burn-
out)
Motor • Every 10000 operating hours2) 3) Inspect the motor:
• Check rolling bearing and change if ne-
cessary
• Replace the oil seal
• Clean cooling air ducts
3)
Drive • Different • Touch up or renew the surfaces/
anti‑corrosion coating.
• Check and clean the air filter.
• if applicable, clean condensation drain
hole at the bottom of the fan guard
• Clean clogged bores
1) Wear times are subject to many factors and can be quite short. The machine designer must calculate the required inspection/main-
tenance intervals individually in accordance with the project planning documents (e.g. "Project Planning for Drives").
2) For the DR../DRN250 – 315 motors with relubrication device, note the shortened relubrication periods in the chapter "Bearing lubric-
ation".
3) The interval depends on outer influences and can be very short, e.g. in the event of high dust concentration in the environment.
If you open the motor during inspection/maintenance, you have to clean it before you
close it.
7.1.1 Connection cables

Check the connection cable for damage at regular intervals and replace if necessary.
22760253/EN – 08/2016

Bearing lubrication 7
7.2 Bearing lubrication
7.2.1 Bearing lubrication for DR..71 – 280, DRN80 – 280 motors

In standard design, the bearings are lubricated for life.
7.2.2 Bearing lubrication for DR..250 – 315, DRN225 – 315 motors with relubrication device /NS
Motors of nominal sizes 225, 250, 280, and 315 can be equipped with a relubrication
device. The following figure shows the positions of the lubrication devices.
375353099
[1] Lubrication device in type A in accordance with DIN 71412
Under normal operating conditions and at an ambient temperature between -20 °C to

+40 °C, SEW‑EURODRIVE uses Mobil Polyrex EM (K2P-20 DIN 51825), a polyurea-
based mineral high-performance, high-temperature grease for initial lubrication.
For motors in the low temperature range up to -40 °C SEW‑EURODRIVE uses SKF
GXN or LGHP2, which are also a polyurea-based mineral greases.
Relubrication
You can purchase the lubricants in 400 g cartridges from SEW‑EURODRIVE. Refer to
chapter "Order information for lubricants, anti-corrosion agents and
sealants" (→ 2 181) for order information.
INFORMATION
Only mix lubricants of the same thickness type, the same base oil and the same con-
sistency (NLGI class)!
Grease the motor bearings in accordance with the information on the lubricant plate.
The used grease collects inside the motor and should be removed every 6 to 8 re-
lubrication cycles during an inspection. Each time you relubricate, ensure that the
bearing is two-thirds full.
22760253/EN – 08/2016
After relubricating the motors, you should start up slowly, if possible, so that the
grease is distributed evenly.

7 Reinforced bearings
Re-lubrication period
The table below lists the bearing relubrication intervals for the following conditions:
• Ambient temperature -20 °C to +40 °C
• Rated speed that corresponds to that of a 4-pole AC motor
• normal load
At greater speeds, higher loads or higher ambient temperatures, the re-lubrication in-
tervals are shorter. Use 1.5 times the quantity for the initial filling.
Motors with option Horizontal mounting Vertical mounting posi-

position tion
Duration Quantity Duration Quantity
DR../DRN225 – 315 /NS 5000 h 50 g 3000 h 70 g
DR../DRN225 – 315 /ERF /NS 3000 h 50 g 2000 h 70 g
7.3 Reinforced bearings

In the /ERF "reinforced bearings" option, cylindrical rolling bearings are installed on
the A-side.
NOTICE
Damage to bearings due to impermissible heating of bearing and motor.
Damage to property.
• Do not operate cylindrical roller bearings without overhung load.
The reinforced bearings are only offered with the /NS "relubrication" option so as to fa-
cilitate optimal lubrication of the bearing. Observe the notes on bearing lubrication in
chapter "Bearing lubrication for DR..250 – 315, DRN225 – 315 motors with
relubrication device /NS" (→ 2 105).
22760253/EN – 08/2016

Motor and brake maintenance – preliminary work 7
7.4 Motor and brake maintenance – preliminary work
WARNING
Risk of crushing if the drive starts up unintentionally.
• Disconnect the motor and all connected options from the power supply before
you start working.
7.4.1 Removing rotary encoders from DR..71 – 132, DRN80 – 132S motors

The following figure illustrates the disassembly procedure using the ES7. rotary en-
coder as an example:
[362] [733] [367] [619]
[B] [220] [A]
[35]
[34] [361]
3475618443
[34] Tapping screw [367] Retaining screw

[35] Fan guard [619] Encoder cover
[220] Encoder [733] Screws
[361] Safety cover [A] Screws
[362] Torque bracket [B] Cone
Disassembling ES7./AS7.encoders
1. Loosen the screws [34] and remove the safety cover [361].
2. Unscrew and remove the connection cover [619]. Do not disconnect the encoder
connection cable.
3. Loosen screws [733].
4. Loosen the central retaining screw [367] by about 2 to 3 turns and unfasten the
spread shaft cone by tapping lightly on the head of the screw.
22760253/EN – 08/2016
Keep the cone [B]. It will be needed for re-assembly.

5. Carefully remove the expansion anchor of the torque bracket [362] from the cover
grid and the encoder form the rotor.

7 Motor and brake maintenance – preliminary work
Re-assembly
1. Attach the expansion anchor at the encoder torque bracket [362] and push the en-
coder into the shaft end bore to the stop.
2. Tighten the central retaining screw [367] with a tightening torque of 2.75 Nm.
3. Tighten the screw [733] in the expansion anchor with a tightening torque of max.
2.25 Nm.
4. Assemble the encoder cover [619] and tighten the screws [A] with a tightening
torque of 2.25 Nm.
5. Install the safety cover [361] with the screws [34].
7.4.2 Removing rotary encoders from DR..160 – 280, DRN132M – 280 motors

The following figure illustrates the disassembly procedure using the EG7. rotary en-
[715] [35] [1] [220] [232] [619] [706] [657] [707]
[361]
[367]
[34]
9007201646566283
[1] Rotor [367] Retaining screw

[34] Tapping screw [619] Connection cover
[35] Fan guard [657] Canopy
[220] Encoder [706] Spacer bolt
[232] Screws [707][715] Screws
[361] Extended fan guard [A] Screws
Removing EG7., AG7. encoders

1. Loosen the screws [22] and remove the forced cooling fan guard [170].
22760253/EN – 08/2016
2. Remove the cable grommet [269] with encoder cable from the forced cooling fan
guard [170].
3. Loosen the screws [232] and [936] and remove the torque bracket [935].
4. Loosen the retaining screw [220] on the encoder and remove the encoder from the
rotor [1].

Re-assembly
1. Place the encoder onto the rotor [1] and attach it with the central retaining screw of
the encoder [A]. The tightening torque must be 8 Nm.
2. Place the torque bracket [935] on the spacing bushings [934] and tighten the
screws [936] with 11 Nm.
3. Attach the torque bracket of the encoder [A] to the torque bracket [935] using the
screws [232]. The tightening torque must be 6 Nm.
cable grommet [269] into the forced cooling fan guard [170].
5. Mount the forced cooling fan guard [170] and tighten the screws [22] with 28 Nm.
7.4.3 Removing the rotary encoder from DR..160 – 225, DRN132M – 315 motors with /V forced
cooling fan option
The following figure illustrates the disassembly procedure using the EG7. rotary en-
[934]
[A]
[935]
[232]
[936]
[269]
[170]
[22]
[1]
7715961995
[22] Screw [935] Torque bracket

[170] Forced cooling fan guard [936] Screw
[232] Screws [934] Spacer bushing
[269] Grommet [A] Encoder
Removing EG7., AG7. encoders

22760253/EN – 08/2016
guard [170].
3. Loosen the screws [232] and [936] and remove the torque bracket [935].
4. Loosen the retaining screw [220] on the encoder and remove the encoder from the
rotor [1].

Re-assembly
1. Place the encoder onto the rotor [1] and attach it with the central retaining screw of
the encoder [A]. The tightening torque must be 8 Nm.
2. Place the torque bracket [935] on the spacing bushings [934] and tighten the
screws [936] with 11 Nm.
3. Attach the torque bracket of the encoder [A] to the torque bracket [935] using the
screws [232]. The tightening torque must be 6 Nm.
cable grommet [269] into the forced cooling fan guard [170].
5. Mount the forced cooling fan guard [170] and tighten the screws [22] with 28 Nm.
7.4.4 Removing rotary encoders from DR..315, DRN315 motors

The following figure illustrates the disassembly procedure using the EH7. and AH7.
rotary encoders as an example:
[734] [367] [220]
[35] [1] [659] [657]

EH7.
AH7.
[748] [367] [220]

9007199662370443
[35] Fan guard [659] Screw

[220] Encoder [734] Nut
[367] Retaining screw [748] Screw
[657] Cover plate
Removing EH7. encoders

1. Remove the cover plate [657] by loosening the screws [659].
22760253/EN – 08/2016
2. Separate the encoder [220] from the fan guard by loosening the nut [734].
3. Loosen the retaining screw [367] on the encoder and remove the encoder [220]
from the rotor [1].

Removing AH7. encoders
1. Remove the protection cover [657] by loosening the screws [659].
2. Separate the encoder [220] from the fan guard by loosening the screws [748].
3. Loosen the retaining screw [367] on the encoder and remove the encoder [220]
from the shaft.
Re-assembly
1. Mount fan guard [35].
2. Push the encoder [220] on the shaft and fasten it with the retaining screw [367] ap-
plying a tightening torque according to the following table:
Encoder Tightening torque

EH7. 0.7 Nm
AH7. 3.0 Nm
3. Install the screw [748] and the nut [734].
4. Install the cover plate [657].
22760253/EN – 08/2016

7.4.5 Mounting/removing rotary encoders with XV.A encoder mounting adapter for DR..71 – 225,
DRN80 – 225 motors
The following figure illustrates the disassembly procedure using a third-party encoder
as an example:
[212] [225] [220] [269] [22] [361] / [170]
[E] [D] [251] [232] [A] [B]
9007202887906699

[170] Forced cooling fan guard [269] Grommet
[212] Fan guard with encoder mount [A] Adapter
[220] Encoder [B] Clamping screw
[225] Intermediate flange (not with XV1A) [D] Coupling (spread- or solid shaft coupling)
[232] Screws (enclosed with XV1A and XV2A) [E] Clamping screw
[251] Conical spring washers (enclosed with
XV1A and XV2A)
Removing the XV.., EV.., AV.. encoders

1. Remove the extended fan guard [361] or forced cooling fan guard [170] by loosen-
ing the screws [22].
2. Loosen the retaining screws [232] and turn the conical spring washers [251] out-
wards.
3. Loosen the clamping screw [E] of the coupling.
4. Remove the adapter [A] and the encoder [220].
Re-assembly
22760253/EN – 08/2016
1. To mount the encoder, proceed as described in chapter Connecting XV.A encoder

mounting adapter to DR.71 – 225 motors.

7.4.6 Mounting/removing rotary encoders with EV../AV.. encoder mounting adapter for DR250 –
280, DRN250 – 280 motors
If you have ordered the EV../AV.. encoder mounting adapter, the coupling is enclosed
with the motor and must be installed by the customer.
The following figure shows an example of how the coupling is installed:
[35]
[A]
[1458]
[233]
[225]
[226]
[220]
[251]
[232]
[269]
[361]
[22] [1496]
[1497]
[1498]
[1459] [1489]
[1460] [1461] [1462] [33]

[34]
9007206970704907

[33] Washer [1458] Screw
[34] Screw [1459] Cage nut
[35] Fan guard [1460] Serrated lock washer
[220] Encoder [1461] Washer
[226] Screw [1489] Ground strap
[232] Screws (enclosed with .V1A and .V2A) [1496] Serrated lock washer
[233] Coupling [1497] Washer
[251] Conical spring washers (enclosed with .V1A [1498] Screw
and .V2A)
[269] Grommet [A] Encoder mounting adapter
Removing the encoder mounting adapter

1. Loosen the screws [34] and washers [33] at the safety cover. Remove the safety
cover [361].
2. Remove the encoder, see chapter "Removing EV.., AV.. encoders" (→ 2 114).
22760253/EN – 08/2016
3. Loosen the ground strap of the encoder mounting adapter [A] with serrated lock
washer [1496], washers [1497], and screw [1498].
4. Loosen the screws [22] and remove the fan guard [35].

5. Loosen the encoder mounting adapter [A] with screw [1458] in the encoder bore of
the rotor and remove it.
If the encoder mounting adapter cannot easily be removed: Screw in a set screw
M6 with 20 – 35 mm length into the rotor bore (bore for screw [1458]) and tighten it
hand-tight. Screw in a set screw M8 with > 10 mm length or a screw M8 with min.
80 mm length into the same bore and push out the encoder mounting adapter [A]
from the rotor [1]. Then remove the set screw M6 from the rotor again.
Removing EV.., AV.. encoders

1. Loosen the screws [34] and remove the safety cover [361].
2. Remove the cable grommet [269] with encoder cable from the safety cover [361].
3. Loosen the screws [232] and turn the conical spring washers of the encoder [220]
outwards. Loosen the screw of the coupling clamping hub [233] on the encoder
end through the slots in the encoder mounting adapter [A].
4. Loosen the encoder [220] from the encoder mounting adapter [A] or intermediate
flange [225].
Re-assembly
1. To mount the encoder, proceed as described in chapter Mounting an encoder with
EV.A / AV.A mounting adapter to DR.250 – 280 motors.
INFORMATION
When re-installing the fan guard [35], make sure that the torque is supported:
The damping elements [1486] on both sides of the encoder mounting adapter [A]
must engage with the ventilation grid (see figure below). The torque plate [935] must
protrude from the grid to the left and to the right of the damping element.
[1486] [35] [935]
22760253/EN – 08/2016
9007207498780299

7.4.7 Mounting/removing the rotary encoder with EV../AV../XV.. encoder mounting adapter for
DR..250 – 280, DRN250 – 280 motors with /V forced cooling fan option
as an example:
[934]
[A]
[936]
[226]
[220]
[251]
[232]
[269]
[170]
[22]
[935]
[1463]
[1458]
[233]
[225]
7715965835
[22] Screw [269] Grommet

[170] Forced cooling fan guard [934] Spacer bushing
[220] Encoder [935] Torque bracket
[226] Screw [1458] Screw
[232] Screws (enclosed with .V1A and .V2A) [1463] Screw
[233] Coupling [A] Encoder mounting adapter
[251] Conical spring washers (enclosed with .V1A
and .V2A)
Removing the encoder mounting adapter

2. Remove the cable grommet [269] from the fan guard [170].
3. Loosen the screws [232] and turn the conical spring washers [251] to the side.
Loosen the screw of the coupling clamping hub [233] on the encoder end and re-
move the encoder [220]. The intermediate flange [225] and screws [226] can re-
main at the encoder mounting adapter [A].
4. Loosen the screws [1458] and [936] and remove the encoder mounting adapter
[A]. The torque brackets [935] and screws [1463] can remain at the encoder
mounting adapter [A].
• If the encoder mounting adapter [A] cannot easily be removed: Screw in a set
22760253/EN – 08/2016
screw M6 with 20 – 35 mm length into the rotor bore (bore for screw [1458])
and tighten it finger-tight. Screw in a set screw M8 with > 10 mm length or a
screw M8 with min. 80 mm length into the same bore and push out the encoder
mounting adapter [A] from the rotor [1]. Then remove the set screw M6 from the
rotor again.

Removing EV.., AV.., and XV. encoders

guard [170].
3. Turn the conical spring washers of the encoder [220] outwards and loosen the
screws [232]. Loosen the screw of the coupling clamping hub [233] on the encoder
end.
4. Loosen the encoder [220] from the encoder mounting adapter [A] or intermediate
flange [225].
Re-assembly
1. To mount the encoder, proceed as described in chapter Mounting an encoder with
EV.A / AV.A mounting adapter to DR.250 – 280 motors.
22760253/EN – 08/2016

7.4.8 Mounting/removing hollow shaft encoders with XH.A encoder mounting adapter for
DR..71 – 225, DRN80 – 225 motors
as an example:
Encoder mounting with XH1A encoder mounting adapter Encoder mounting with XH7A and XH8A encoder mounting adapter
[269] [361] / [170]
[E] [F]
[35] [1] [D] [220] [A] [B1] [C] [33] [34]

[35] [G] [1] [D] [220] [361] / [170]
3633161867
[1] Rotor [A] Retaining screw

[33] Tapping screw [B] Encoder cover
[34] Washer [C] Screw for torque bracket
[35] Fan guard [D] Nut of the torque bracket
[170] Forced cooling fan guard [E] Screw
[220] Encoder [F] Clamping ring
[269] Grommet [G] Nut of the torque bracket
[361] Safety cover
Removing hollow shaft encoders form XH1A encoder mounting adapter

1. Remove cover [361] or forced cooling fan guard [170].
2. Loosen encoder cover [B] via screws [C].
3. Remove screw [A].
4. Loosen screw and nut of the torque bracket [D] and remove torque arm.
5. Remove encoder [220] from rotor [1].
22760253/EN – 08/2016

Removing hollow shaft encoders from XH7A and XH8A encoder mounting adapter
1. Remove cover [361] or forced cooling fan guard [170].
2. Loosen screw [E] on clamping ring [F].
3. Remove nut of torque bracket [G].
4. Remove encoder [220] from rotor [1].
Reassembly of hollow shaft encoders to XH1A encoder mounting adapter

1. Push encoder [220] on rotor [1].
2. Mount torque bracket via screws [D].
3. Fasten the encoder [220] via screw [A] with a tightening torque of 2.9 Nm.
4. Fasten encoder cover [B] via screws [C] with a tightening torque of 3 Nm.
5. Install cover [361] or forced cooling fan guard [170].
Reassembly of hollow shaft encoders to XH7A and XH8A encoder mounting adapter
1. Push encoder [220] on rotor [1].
2. Mount torque bracket via nut [D] with a tightening torque of 10.3 Nm.
3. Fasten clamping ring [F] via screw [E] with a tightening torque of 5 Nm.
4. Install cover [361] or forced cooling fan guard [170].
22760253/EN – 08/2016

Inspection/maintenance work for DR..71 – 315, DRN80 – 315 motors 7
7.5 Inspection/maintenance work for DR..71 – 315, DRN80 – 315 motors
7.5.1 Basic structure DR..71 – 132/DRN80 – 132S motors
[132]
[123]
[131]
[156]
[119]
[117]
[113]
[118] [115]
[116] [262]
[112]
[111] [134]
[129]
[707]
[9] [103] [100] [705]
[706]
[35]
[30]
[42]
[22]
[106] [41]
[392] [32]
[107] [13]
[24] [36]
[108] [3] [44]
[109] [11]
[16] [1480] [10]
[12]
[7]
[2] [1]
[91]
[93] [93]
[90]
[90]
9007212623958923
[1] Rotor [30] Oil seal [106] Oil seal [123] Hex head screw
[2] Retaining ring [32] Retaining ring [107] Oil flinger [129] Screw plug with O-ring
[3] Key [35] Fan guard [108] Nameplate [131] Gasket for cover
[7] Flanged endshield [36] Fan [109] Grooved pin [132] Terminal box cover
[9] Screw plug [41] Shim [111] Gasket for lower part [134] Screw plug with O-ring
[10] Retaining ring [42] B-side endshield [112] Terminal box lower part [156] Information sign
[11] Deep groove ball bear- [44] Deep groove ball bear- [113] Pan head screw [262] Connection terminal,
ing ing complete
[12] Retaining ring [90] Base plate [115] Terminal board [392] Seal
[13] Cap screw [91] Hex nut [116] Terminal clip [705] Canopy
[16] Stator [93] Pan head screws [117] Hex head screw [706] Spacer
[22] Hex head screw [100] Hex nut [118] Lock washer [707] Pan head screw
[24] Lifting eyebolt [103] Stud [119] Pan head screw [1480] O-ring
22760253/EN – 08/2016

7 Inspection/maintenance work for DR..71 – 315, DRN80 – 315 motors
7.5.2 Basic structure DR..160 – 180, DRN132M – 180 motors

[117] [137]
[219] [262]
[616]
[123] [118]
[132] [116]
[131]
[119] [128]
[140]
[156]
[139]
[112]
[111] [134]
[115] [113] [129]
[390]
[109]
[108]
[24]
[12]
[9]
[7]
[106] [707]
[705]
[107] [706]
[35]
[715]
[30]
[19]
[41] [42] [22]
[17]
[91]
[90] [32]
[100]
[103] [94] [93]
[15] [16] [44]
[36]
[14] [31]
[3] [1]
[11] [2]
[104]
[10]
18014399036804619
[1] Rotor [31] Key [108] Nameplate [132] Terminal box cover
[2] Retaining ring [32] Retaining ring [109] Grooved pin [134] Screw plug with O-ring
[3] Key [35] Fan guard [111] Gasket for lower part [137] Screw
[7] Flange [36] Fan [112] Terminal box lower part [139] Hex head screw
[9] Screw plug [41] Cup spring [113] Screw [140] Washer
[10] Retaining ring [42] Rear endshield [115] Terminal board [156] Information label
[11] Deep groove ball bearing [44] Deep groove ball [116] Serrated lock washer [219] Hex nut
bearing
[12] Retaining ring [90] Foot [117] Stud [262] Connection terminal
[14] Washer [91] Hex nut [118] Washer [390] O-ring
[15] Hex head screw [93] Washer [119] Cap screw [616] Retaining plate
[16] Stator [94] Cap screw [123] Hex head screw [705] Canopy
[17] Hex nut [100] Hex nut [128] Serrated lock washer [706] Spacer
[19] Cap screw [103] Stud [129] Screw plug with O-ring [707] Hex head screw
22760253/EN – 08/2016
[22] Hex head screw [104] Supporting ring [131] Gasket for cover [715] Hex head screw
[24] Eyebolt [106] Oil seal
[30] Sealing ring [107] Oil flinger

7.5.3 Basic structure DR..200 – 225, DRN200 – 225 motors
[117] [137]
[219] [262]
[123] [118] [616]
[116]
[132]
[131]
[156]
[119] [129]
[134]
[112]
[128]
[111] [140]
[113] [139]
[109] [390]
[108] [115]
[24]
[15]
[105]
[9]
[106]
[107]
[707]
[705]
[706]
[715]
[35]
[30]
[25]
[19] [26]
[22] [32]
[42] [36]
[40]
[93]
[90] [44] [43]
[21]
[94] [31]
[103] [7]
[100] [16] [1]
[3]
[11]
[2]
9007200332597387
[1] Rotor [31] Key [107] Oil flinger [132] Terminal box cover
[2] Retaining ring [32] Retaining ring [108] Nameplate [134] Screw plug
[3] Key [35] Fan guard [109] Grooved pin [137] Screw
[7] Flange [36] Fan [111] Gasket for lower part [139] Hex head screw
[9] Screw plug [40] Retaining ring [112] Terminal box lower part [140] Washer
[11] Deep groove ball bearing [42] Rear endshield [113] Cap screw [156] Information label
[15] Hex head screw [43] Supporting ring [115] Terminal board [219] Hex nut
[16] Stator [44] Deep groove ball [116] Serrated lock washer [262] Connection terminal
bearing
[19] Cap screw [90] Foot [117] Stud [390] O-ring
[21] Oil seal flange [93] Washer [118] Washer [616] Retaining plate
[22] Hex head screw [94] Cap screw [119] Cap screw [705] Canopy
[24] Eyebolt [100] Hex nut [123] Hex head screw [706] Spacer bolt
[25] Cap screw [103] Stud [128] Serrated lock washer [707] Hex head screw
[26] Shield ring [105] Cup spring [129] Screw plug [715] Hex head screw
[30] Oil seal [106] Oil seal [131] Gasket for cover
22760253/EN – 08/2016

7.5.4 Basic structure DR..250 – 280, DRN250 – 280 motors

[137] [262] [616] [156]
[219]
[118]
[123]
[116]
[132]
[117]
[131]
[119]
[112]
[139]
[140]
[111] [128]
[159]
[160]
[161] [19]
[115]
[113] [129] [134] [22]
[24] [1453]
[105]
[9]
[7]
[106]
[107]
[707]
[705]
[706]
[715]
[35] [32]
[26] [25] [40]
[36]
[30]
[42] [43]
[109] [44]
[108] [21]
[94] [31]
[93]
[90] [1]
[15]
[16] [3]
[100]
[103] [11]
[2]
9007206690410123
[1] Rotor [32] Retaining ring [108] Nameplate [134] Screw plug
[2] Retaining ring [35] Fan guard [109] Grooved pin [137] Screw
[3] Key [36] Fan [111] Gasket for lower part [139] Hex head screw
[7] Flange [40] Retaining ring [112] Terminal box lower part [140] Washer
[9] Screw plug [42] B-side endshield [113] Cap screw [156] Information sign
[11] Deep groove ball [43] Supporting ring [115] Terminal board [159] Connection piece
bearing
[15] Cap screw [44] Deep groove ball [116] Serrated lock washer [160] Connection piece seal
bearing
[16] Stator [90] Foot [117] Stud [161] Hex head screw
[19] Cap screw [93] Washer [118] Washer [219] Hex nut
22760253/EN – 08/2016
[21] Oil seal flange [94] Cap screw [119] Hex head screw [262] Connection terminal
[22] Hex head screw [100] Hex nut [123] Hex head screw [616] Retaining plate
[24] Lifting eyebolt [103] Stud [128] Serrated lock washer [705] Canopy
[25] Cap screw [105] Compression spring [129] Screw plug [706] Spacer bolt
[26] Shield ring [106] Oil seal [131] Gasket for cover [707] Hex head screw
[30] Oil seal [107] Oil flinger [132] Terminal box cover [715] Hex head screw
[31] Key [1453] Screw plug

7.5.5 Basic structure DR..315, DRN315 motors
[452] [634]
[123] [633]
[132] [151]
[131] [117] [454]
[219]
[119] [128]
[156] [118]
[116] [140]
[112]
[111] [139]
[134] [113] [607]
[129] [115]
[109]
[108]
[707]
[24] [706]
[716]
[705] [715]
[30]
[35]
[26] [25]
[22] [40] [36]
[43]
[17] [42] [32]
[16] [94] [19] [21] [44]
[93] [1] [31]
[15] [90]
[609]
[608] [3]
[11]
[9] [606] [604]
[90] [7] [105]
[93] [94] [250]
[106]
[107]
[2]
[100]
[103]
45035996625703563
[1] Rotor [32] Retaining ring [111] Gasket for lower part [156] Information sign
[2] Retaining ring [35] Fan guard [112] Terminal box lower part [219] Hex nut
[3] Key [36] Fan [113] Cap screw [250] Oil seal
[7] Flange [40] Retaining ring [115] Terminal board [452] Terminal strip
[9] Screw plug [42] B-side endshield [116] Serrated lock washer [454] Mounting rail
[11] Rolling bearing [43] Supporting ring [117] Stud [604] Lubrication ring
[15] Cap screw [44] Rolling bearing [118] Washer [606] Grease nipple
[16] Stator [90] Foot [119] Hex head screw [607] Grease nipple
[17] Hex nut [93] Washer [123] Hex head screw [608] Oil seal flange
[19] Cap screw [94] Cap screw [128] Serrated lock washer [609] Hex head screw
[21] Oil seal flange [100] Hex nut [129] Screw plug [633] End bracket
[22] Hex head screw [103] Stud [131] Gasket for cover [634] End plate
[24] Eyebolt [105] Cup spring [132] Terminal box cover [705] Canopy
[25] Cap screw [106] Oil seal [134] Screw plug [706] Spacer bolt
22760253/EN – 08/2016
[26] Shield ring [107] Oil flinger [139] Hex head screw [707] Hex head screw
[30] Oil seal [108] Nameplate [140] Washer [715] Hex nut
[31] Key [109] Grooved pin [151] Cap screw [716] Washer

7.5.6 Inspection steps for DR..71 – 315, DRN80 – 315 motors
WARNING
you start working.
1. With gearmotors: Remove the motor from the gear unit.

Remove pinion and oil flinger [107].
2. Remove forced cooling fan and rotary encoder, if installed, see chapter "Motor and
brake maintenance – preliminary work" (→ 2 107).
3. Remove fan guard [35] and fan [36].
4. Remove stator:
• DR..71 – 132, DRN80 – 132S motors: Remove cap screws [13] from flanged
endshield [7] and B-side endshield [42]. Remove stator [16] from flanged end-
shield [7].
• DR..160 – 180, DRN132M – 180 motors: Loosen cap screws [19] and remove
B-side endshield [42]. Loosen hex head screw [15] and remove stator from
flanged endshield.
• DR..200 – 225, DRN200 – 225 motors
– Loosen hex head screw [15] and remove the flanged endshield [7] from the
stator.
– Loosen cap screws [19] and remove the complete rotor [1] together with the
B-side endshield [42].
– Loosen cap screws [25] and remove the complete rotor [1] from the B-side
endshield [42].
• DR..250 – 280, DRN250 – 280 motors without /ERF or /NS option
– Loosen cap screws [15] and remove the flange [7].
– Loosen cap screws [19] and remove the B-side endshield [42] together with
the rotor [1].
– Loosen cap screws [25] and remove the B-side endshield [42] from the rotor
[1].
• DR..250 – 280, DRN250 – 280 motors with /ERF or /NS option, or DR../
DRN315
– Loosen cap screws [19] and [25], and remove B-side endshield [42].
– Loosen cap screws [15] and remove the flange [7] together with the rotor [1].
– Loosen hex head screws [609] and remove the flange [7] from the rotor [1].
22760253/EN – 08/2016
– Before disassembly, preferably protect the oil seal seat from damage using
adhesive tape or a protective sleeve.
5. Visual inspection: Are there traces of gear oil or moisture inside the stator?
• If not, proceed with step 8.
• If there is moisture, proceed with step 6.
• If there is gear oil, have the motor repaired by a specialist workshop

6. If there is moisture inside the stator:
• With gearmotors: Remove the motor from the gear unit.
• With motors without a gear unit: Remove A-flange.
• Remove the rotor [1].
7. Clean the winding, dry it and check it electrically, see chapter "Drying the
motor" (→ 2 30).
8. Replace the rolling bearing [11], [44] with permitted rolling bearing types, see
chapter "Permitted rolling bearings" (→ 2 178).
9. DR..250 – 280, DRN225 – 280 with /ERF or /NS option, or DR../DRN315
• Fill the rolling bearing with grease until it is two thirds full, see chapter "Bearing
lubrication" (→ 2 105).
• Notice: Place the oil seal flange [608] and [21] onto the rotor shaft before in-
stalling the bearings.
• Starting on the A-side, mount the motor vertically.
• Place the springs [105] and lubrication ring [604] into the bearing bore of the
flange [7].
• Hang the rotor [1] onto the B-side thread, and guide into the flange [7].
• Fasten the oil seal flange [608] to the flange [7] using the hex head screws
[609].
10. Reseal the shaft:
• A-side: Replace the oil seal [106].
• B-side: Replace the oil seal [30].
Coat the sealing lip with grease (Klüber Petamo GHY 133).
11. Reseal the stator seat:
• Seal the sealing surface with duroplastic sealing compound (operating temper-
ature -40 to +180 °C), such as "SEW L Spezial".
• DR..71 – 132, DRN80 – 132S motors: Replace sealing [392].
• DR..71 – 132, DRN80 – 132S motors: Change O-ring [1480] if it is deformed
or damaged. As an alternative, use e.g. "SEW L Spezial" instead of the O-ring.
12. Install the motor and options.
22760253/EN – 08/2016

7 Inspection/maintenance work for DR..71 – 315, DRN80 – 315 brakemotors
7.6 Inspection/maintenance work for DR..71 – 315, DRN80 – 315 brakemotors

7.6.1 Basic structure of DR..71 – 80, DRN80 brakemotors
[1] [46] [71] [42] [70] [73] [68] [49] [718] [66] [157]
[62]
[32]
[51]
[64]
[95]
[61]
[47]
[65]
[67]
[60]
[50] / [276] [54] [59] [53] [56] [57] [58] [36] [22] [35]
18014398683682955
1)
[1] Motor [54] Magnet body, complete [67] Counter spring1)
[22] Hex head screw [56] Stud [68] Brake lining carrier1)
[32] Retaining ring [57] Conical spring [70] Driver
[35] Fan guard [58] Hex nut [71] Key
[36] Fan wheel [59] Parallel pin [73] Stainless steel washer1)
1) 1)
[42] Brake endshield [60] Stud [95] Sealing ring
[46] Bracket [61] Hex nut1) [157] Clamping strap (optional)
[47] O-ring [62] Retaining ring (DR..80, DRN80)
[49] Pressure plate1) [64] Set screw (/HF) [276] Brake spring (blue)1)
[50] Brake spring (normal)1) [65] Pressure ring1) [550] Pre-assembled brake
[51] Hand lever (/HR) [66] Sealing strip1) [718] Damping plate1)
[53] Releasing lever
1) Part of "Brake (pre-assembled) [550]"
22760253/EN – 08/2016

Inspection/maintenance work for DR..71 – 315, DRN80 – 315 brakemotors 7
7.6.2 Basic structure of DR..90 – 132, DRN90 – 132S brakemotors
[1] [46] [71] [42] [70] [157] [47] [95] [59] [53] [64] [51] [36] [32]
[56] [57] [58] [35] [22] [55]
[901] [62] [550] [900]
18014398689463947
[1] Motor [56] Stud [71] Key

[22] Hex head screw [57] Conical spring [95] Sealing ring
[32] Retaining ring [58] Hex nut [157] Clamping strap (optional)
[35] Fan guard [59] Parallel pin [550] Pre-assembled brake
[36] Fan wheel [62] Retaining ring [900] Screw
[42] Brake endshield [64] Set screw (/HF) [901] Seal
[46] Bracket [70] Driver
[47] O-ring
[51] Hand lever (/HR)
[53] Releasing lever
[55] Closing piece fan guard (DR..112 –
132, DRN112 – 132S)
22760253/EN – 08/2016

7.6.3 Basic structure of DR..160 – 315, DRN132M – 315 brakemotors

[46] [42] [71] [901] [31] [53] [64] [51] [36] [32] [22] [35] [55]
[550] [900] [157] [95]
[57] [58]
[698] [47] [56]

BE11-62
[1] [390] [418] [70] [58]

[1453]
BE120/122
[57] [255] [256] [58]

18014399036705675
[1] Motor with brake endshield [53] Releasing lever [95] Sealing ring
[22] Hex head screw [55] Closing piece [157] Clamping strap (optional)
[31] Key [56] Stud [255] Conical seat
[32] Retaining ring [57] Conical spring [256] Spherical washer
[35] Fan guard [58] Hex nut [390] O-ring (DR..160 – 225, DRN132M –
225)
[36] Fan [58] Adjusting nut [418] Cable gland
[42] Brake endshield [62] Retaining ring [550] Pre-assembled brake
[46] Bracket [64] Set screw (/HF) [698] Connector complete (BE20-BE122)
[47] O-ring [70] Driver [900] Screw
[51] Hand lever [71] Key [901] O-ring/seal (DR..160 – 225, DRN132M
– 225)
[1453] Grommet (for DRN180 instead of [418])
[1607] O-ring (DR..250 –280/DRN250 – 280)
22760253/EN – 08/2016

7.6.4 Inspection steps for DR..71 – 315, DRN80 – 315 brakemotors
WARNING
you start working.
1. With gearmotors: Remove the motor from the gear unit. Remove pinion and oil
flinger [107].
2. Remove forced cooling fan and rotary encoder, if installed. See chapter "Motor
and brake maintenance – preliminary work" (→ 2 107).
3. Remove the fan guard with encoder mount or fan guard [35] and the fan wheel
[36].
4. If present, remove sensors of the /DUE option, see chapter "Disassembling the
diagnostic unit /DUE" (→ 2 151).
5. DR..90 – 315, DRN90 – 315 motors: Remove the brake cpl. [550] (if applicable)
with mounted /HR, /HF option manual brake release.
• BE05 – 11: Remove terminal box cover, loosen brake cable and microswitch
supply cable of the /DUB option from the terminals.
• BE20 – 122: Loosen safety screws of the brake plug connector [698] and re-
move plug connector.
• Loosen screw [900], press brake [550] off the endshield, and carefully lift off the
brake.
6. Remove stator:
• DR..71 – 132, DRN80 – 132S motors: Remove cap screws [13] from flanged
endshield [7] and B-side endshield [42]. Remove stator [16] from flanged end-
shield [7].
• DR..160 – 180, DRN132M – 180 motors: Loosen cap screws [19] and remove
B-side endshield [42]. Loosen hex head screw [15] and remove stator from
flanged endshield.
• DR..200 – 225, DRN200 – 225 motors
– Loosen hex head screw [15] and remove the flanged endshield [7] from the
stator.
– Loosen cap screws [19] and remove the complete rotor [1] together with the
B-side endshield [42].
– Loosen cap screws [25] and remove the complete rotor [1] from the B-side
endshield [42].
• DR..250 – 280, DRN250 – 280 motorswithout /ERF or /NS option
22760253/EN – 08/2016
– Loosen cap screws [15] and remove the flange [7].

– Loosen cap screws [19] and remove the B-side endshield [42] together with
the rotor [1].
– Loosen cap screws [25] and remove the B-side endshield [42] from the rotor
[1].
• DR..250 – 280, DRN250 – 280 motors with /ERF or /NS option, or DR../
DRN315 motors

– Loosen cap screws [19] and [25], and remove B-side endshield [42].
– Loosen cap screws [15] and remove the flange [7] together with the rotor [1].
– Loosen hex head screws [609] and remove the flange [7] from the rotor [1].
– Before disassembly, preferably protect the oil seal seat from damage using
adhesive tape or a protective sleeve.
7. Pull the stator back by about 3 to 4 cm.
8. Visual inspection: Are there traces of gear oil or moisture inside the stator?
• If not, proceed with step 10.
• If there is moisture, proceed with step 9.
• If there is gear oil, have the motor repaired by a specialist workshop.
9. If there is moisture inside the stator:
• With gearmotors: Remove the motor from the gear unit.
• With motors without a gear unit: Remove A-flange
• Remove the rotor [1]
• Clean the winding, dry it and check it electrically, see chapter "Drying the
motor" (→ 2 30).
10. Replace the rolling bearing [11], [44] with permitted rolling bearing types, see
chapter "Permitted rolling bearings" (→ 2 178).
11. Install key [71] and driver [70]:
• Preheat the driver to allow for easier installation (joining temperature +85 °C to
+115 °C).
• DR..71 motors: Clean the driver seat at the rotor [1] before installation. Glue in
the driver using Loctite 648 or Loctite 649. Observe the correct fit to rolling
bearing [44].
• DR..80 – 315, DRN80 – 315 motors: Clean the driver at the rotor [1] and coat
with anti-corrosion agent NOCO® fluid before fitting. Then mount retaining ring
[62].
12. Seal the stator again and install it:
• DR..71 – 132, DRN80 – 132S motors: Replace seal [392]
• DR..160 – 315, DRN132M – 315 motors: Seal the sealing surfaces with duro-
plastic sealing compound (operating temperature -40 to +180 °C), such as
"SEW L-Spezial".
13. DR..250 – 280, DRN250 – 280 motors with /ERF or /NS option, or DR../DRN315
motors
• Fill the rolling bearing with grease until it is two thirds full, see chapter "Bearing
lubrication" (→ 2 105).
• Notice: Place the oil seal flange [608], [21] onto the rotor shaft before installing
the bearings.
22760253/EN – 08/2016
• Starting on the A-side, mount the motor vertically.

• Place the springs [105] and lubrication ring [604] into the bearing bore of the
flange [7].
• Hang the rotor [1] onto the B-side thread, and guide into the flange [7].
• Fasten the oil seal flange [608] to the flange [7] using the hex head screws
[609].
• Screw in the stator [16] and flange [7] with screws [15].

Notice: Protect the winding overhang from damage.
• Before mounting the B-side endshield, screw in the M8 set screw (approxim-
ately 200 mm) into the oil seal flange [21].
• Before mounting the B-side endshield [42], insert the set screw in through a
bore for the screw [25]. Screw B-side endshield to stator [16] using cap screws
[19] and hex nuts [17]. Lift the oil seal flange [21] with the set screw, and fasten
using 2 screws [25]. Remove the set screw and screw in the remaining screws
[25].
• Renew oil seals.
– A-side: Replace oil seals [106], for gearmotors replace the oil flinger [107]
and oil seal [250].
With gearmotors, fill about two-thirds of the space between the two oil seals
with suitable grease. see chapter "Order information for lubricants, anti-
corrosion agents and sealants" (→ 2 181).
– B-side: Insert the oil seal [30], and coat the sealing lip with suitable grease.
• A-side: Replace the oil seal [106]
• B-side: Replace the oil seal [30]
Apply suitable grease to the sealing lip, see chapter "Order information for
lubricants, anti-corrosion agents and sealants" (→ 2 181).
15. Seal the friction disk of the brake [550] again at the brake endshield [42]:
• DR..71 – 132, DRN80 – 132S motors: Replace seal [901]
• DR..160 – 280, DRN132M – 280 motors: Replace O-ring [901] or [1607].
• DR..315, DRN315 motors: Seal the sealing surface with duroplastic sealing
compound (operating temperature -40 to +180°C), such as "SEW L Spezial".
16. Reinstall the brake [550]: Insert the brake cable into the terminal box when in-
stalling the brake. Install the brake. Observe the alignment of the brake. (Cams at
the endshield, manual brake release position).
• DR..71 – 80, DRN80 motors: Install the cap screws [13]. Tightening torque:
5 Nm
• DR..90 – 315, DRN90 – 315 motors Install cap screws [900]
Motors DR..90 – 100, DR..112 – 160, DR..180, DR..200 – 225, DR..250 – 315,
DRN90 – 100 DRN112 – 132 DRN160 – 180 DRN200 – 225 DRN250 – 315
Tightening torque 10.3 Nm 25.5 Nm 50 Nm 87.3 Nm 230 Nm
17. Connect the brake connection cable.
• BE05 – 11: Reconnect the brake cable according to the wiring diagram.
• BE20 – 122: Plug in the brake plug connector [698] again. Tighten the retaining
screws again (tightening torque: 3 Nm)
18. Apply suitable grease to sealing ring [95], see chapter "Order information for
22760253/EN – 08/2016
lubricants, anti-corrosion agents and sealants" (→ 2 181).

19. If applicable: Install sensors of the /DUE option and recalibrate the zero value. See
chapter "Retrofitting diagnostic unit /DUE for function and wear
monitoring" (→ 2 152).
20. Install fan wheel [36] and fan guard [35]. Install available optional equipment.
21. With gearmotors: Replace oil flinger [107] and install the pinion.

7.6.5 Basic structure of BE05 – 2 brakes

[42] [67] [65] [718] [54] [60] [61]
[68] [49] [50]/[276] [66]
18932076043
[42] Brake endshield [61] Hex nut [276] Brake spring (blue)
[49] Pressure plate [65] Pressure ring [718] Damping plate
[50] Brake spring (normal) [66] Sealing strip
[54] Magnet body, complete [67] Counter spring
[60] Stud [68] Brake disk
22760253/EN – 08/2016

7.6.6 Basic structure of BE05 – 20 brakes
[702] [67] [65] [718] [63] [54] [60] [61] [66]
[69] [68] [49] [50]/[276]/[1312]

18932656907
[49] Pressure plate [65] Pressure ring [276] Brake spring (blue)
[50] Brake spring (normal) [66] Sealing strip [702] Friction disk
[54] Magnet body, complete [67] Counter spring [718] Damping plate (BE05 – 11)
[60] Stud [68] Brake disk [1312] Brake spring (white)
[61] Hex nut [69] Circular spring/clasp (BE5 –
20)
[63] Pole sheet
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7.6.7 Basic structure of BE30, 60, 120 brakes

[702] [69] [67] [68] [49] [54] [60] [28] [61]
[63] [50]/[276] [66]
18234907019
[28] Closing cap [61] Hex nut [69] Circular spring

[49] Pressure plate [63] Pole sheet [276] Brake spring (blue)
[50] Brake spring (normal) [66] Sealing strip [702] Friction disk
[54] Magnet body, complete [67] Setting sleeve
[60] Stud [68] Complete brake disk
22760253/EN – 08/2016

7.6.8 Basic structure of BE32, 62, 122 brakes
[702] [67] [69b] [68b] [50] / [276] [60] [61]
[69a] [68a] [52] [49] [63] [54] [28] [66]
18234909451
[28] Closing cap [61] Hex nut [69a] Circular spring

[49] Pressure plate [63] Pole sheet [69b] Circular spring
[50] Brake spring (normal) [66] Sealing strip [276] Brake spring (blue)
[52] Brake plate complete [67] Setting sleeve [702] Friction disk
[54] Magnet body, complete [68a] Complete brake disk
[60] Stud [68b] Complete brake disk
22760253/EN – 08/2016

7.6.9 Setting the working air gap of BE05 – BE122 brakes
WARNING
you start working.
1. Remove the following:

• Remove forced cooling fan and rotary encoder, if installed, see chapter "Motor
• Fan guard with encoder mount or fan guard [35]
2. Push the sealing strip [66] aside,
• Loosen clamping strap [157] to do this, if necessary
• Vacuum off any abrasion
3. Measure the brake disk [68]:
• Minimum brake disk thickness, see chapter "Technical data" (→ 2 164).
• If necessary, replace brake disk carrier, see chapter "Replacing the brake disk
of BE05 – BE122 brakes" (→ 2 138).
4. BE30 – 122: Loosen the setting sleeve [67] by turning it towards the B-side end-
shield.
5. Measure the working air gap A (see the following figure)
(use a feeler gauge and measure at three points offset by 120°):
• BE05 – 11: between pressure plate [49] and damping plate [718]
• BE20 – 122: between pressure plate [49] and magnet body [54]
1
12
0°
0°
12
22760253/EN – 08/2016
3 2
120°
18014398689460619

• BE05 – 20: Tighten the hex nuts [61] until the working air gap is set correctly,
see chapter "Work done, working air gap, brake disk thickness" (→ 2 166).
• BE30 – 122: Tighten the hex nuts [61] until the working air gap is 0.05 –
0.1 mm smaller than the desired setting value (for default values, see chapter
"Work done, working air gap, brake disk thickness" (→ 2 166)).
• BE120 – 122: Tighten the hex nuts [61] until the working air gap is 0.30 mm.
• If you are mounting the BE32 in a vertical mounting position, set the 3 springs
of the brake plate to the following dimension:
Mounting position X in mm
Brake at the top 7.3
Brake at the bottom 7.3
• If you are mounting the BE62 – 122 in a vertical mounting position, set the 3
springs on the brake plate to the following position:
Mounting position X in mm
Brake at the top 10.0
Brake at the bottom 10.0
[49]
[68b]
[52]
X [68a]
[900] X
27021598220181131
7. BE30 – 122: Screw the setting sleeves [67] to the magnet body until the working
air gap is correctly set, see chapter "Technical data" (→ 2 164).
8. Refit the sealing strip [66] and re-install the dismantled parts.
22760253/EN – 08/2016

7.6.10 Replacing the brake disk of BE05 – BE122 brakes

In addition to the brake elements listed in column "BE brake", see chapter "Inspection
and maintenance intervals" (→ 2 104), check the hex nuts [61] for wear when you re-
place the brake disk. You must always replace the hex nuts [61] when you replace the
brake disk.
WARNING
you start working.
INFORMATION
• The brake of DR..71 – 80, DRN80 motors cannot be removed from the motor be-
cause the BE brake is directly installed on the brake endshield of the motor.
• The brake of DR..90 – 315, DRN90 – 315 motors can be removed from the motor
for replacing the brake disk because the BE brake is pre-installed on the brake
endshield of the motor with a friction disk.

• Fan guard with encoder mount or fan guard [35], retaining ring [32/62] and fan
[36]
2. Remove the brake cable
• BE05 – 11: Loosen the terminal box cover and unfasten the brake cable from
the rectifier.
3. Remove the rubber sealing strip [66]
4. Remove manual brake release if necessary.
• Setting nuts [58], conical springs [57], studs [56], releasing lever [53], conical
seat [255], spherical washer [256]
5. Loosen the hex nuts [61], carefully pull off the magnet body [54] (brake cable!) and
take out the brake springs [50]/[276]/[1312].
6. BE05 – 11: Remove the damping plate [718], pressure plate [49] and brake disk
[68]
BE20, BE30, BE60, BE120: Remove the pressure plate [63], pole sheet [63] and
22760253/EN – 08/2016
brake disk [68]

BE32, BE62, BE122: Remove pressure plate [49], brake disks [68a] and [68b].
7. Clean the brake components.
8. Install new brake disk(s).

9. Brake parts are installed as described in chapter "Inspection steps for DR..71 –
315, DRN80 – 315 brakemotors" (→ 2 129).
• Except for the fan and the fan guard, because the working air gap has to be set
first, see chapter "Setting the working air gap of BE05 – BE122
brakes" (→ 2 136).
10. In case of manual brake release: Use the setting nuts to adjust the floating clear-
ance "s" between the conical coil springs (pressed flat) and the setting nuts (see
chapter "Retrofitting the /HR, /HF manual brake release" (→ 2 146)).
WARNING
No braking due to incorrectly set floating clearance "s".
• Make sure the floating clearance "s" is correctly set, so that the pressure plate
can move up as the brake lining wears.
11. Put the sealing strip [66] in place and re-install the dismantled parts.
INFORMATION
After replacing the brake disk, the maximum braking torque is reached only after sev-
eral cycles.
7.6.11 Changing the braking torque of BE05 – BE122 brakes

The braking torque can be altered in stages.
• By changing the type and number of brake springs
• By changing the complete magnet (only possible for BE05 and BE1)
• By changing the brake (from motor size 90)
• By changing to a double disk brake (only BE30, BE60, BE120)
For the possible braking torque steps, refer to chapter Technical data.
22760253/EN – 08/2016

7.6.12 Changing the brake spring of BE05 – BE122 brakes
WARNING
you start working.

[36]
2. Remove the brake cable.
• BE05 – 11: Remove the terminal box cover. Remove the brake cable from the
rectifier.
• BE20 – 122: Loosen the locking screws of the brake plug connector [698]. Re-
move the plug connector.
3. Remove the sealing strip [66] and (if necessary) the manual brake release:
• Setting nuts [58], conical springs [57], studs [56], releasing lever [53], conical
seat [255], spherical washer [256]
4. Loosen hex nuts [61] and pull off the magnet body [54]
• By approx. 50 mm (watch the brake cable)
5. Replace or add brake springs [50/276/1312]
• Arrange brake springs symmetrically
315, DRN80 – 315 brakemotors" (→ 2 129).
brakes" (→ 2 136).
WARNING
• This floating clearance "s" is necessary so that the pressure plate can move up
22760253/EN – 08/2016
as the brake lining wears.
INFORMATION
Replace the setting sleeves [58] if the removal procedure is repeated.

7.6.13 Changing the magnet body of BE05 – BE122 brakes
WARNING
you start working.

[36]
2. Remove the sealing strip [66] and the manual brake release:
• Setting nuts [58], conical coil springs [57], studs [56], releasing lever [53], paral-
lel pin [59].
3. Remove the brake cable
the rectifier.
4. Loosen hex nuts [61], remove complete magnet body [54], remove brake springs
[50]/[276]/[1312].
5. Install new magnet body with brake springs. For the possible braking torque steps,
refer to chapter "Technical data" (→ 2 164).
315, DRN80 – 315 brakemotors" (→ 2 129).
brakes" (→ 2 136).
WARNING
• Correctly set floating clearance "s", so that the pressure plate can move up as
the brake lining wears.
22760253/EN – 08/2016
9. Replace brake control in the event of an interturn short circuit or a short circuit to
frame.

INFORMATION
Replace the setting sleeves [58] if the removal procedure is repeated.
22760253/EN – 08/2016

7.6.14 Brake replacement for DR..71 – 80, DRN80 motors
WARNING
you start working.

[36]
2. Remove the terminal box cover and loosen the brake cable from the rectifier. If ne-
cessary, attach trailing wire to brake cables.
3. Loosen cap screws [13] and remove brake endshield with brake from stator.
4. Insert the brake cable of the new brake into the terminal box.
5. Install the new brake, observing the alignment of the cams of the brake endshield
[42].
• Replace the sealing ring [95]
• Apply grease to the sealing lip, see chapter "Order information for lubricants,
anti-corrosion agents and sealants" (→ 2 181).
7. In case of manual brake release: Use the adjusting nuts to adjust the floating
clearance "s" between the conical coil springs (pressed flat) and the setting nuts,
see chapter "Retrofitting the /HR, /HF manual brake release" (→ 2 146).
WARNING
8. Install the cap screws [13] again. Tightening torque 5 Nm.

9. Install removed motor parts again.
22760253/EN – 08/2016

7.6.15 Brake replacement for DR..90 – 225, DRN90 – 225 motors
WARNING
you start working.

• Fan guard with encoder mount or fan guard [35], retaining ring [32] and fan
[36].
2. Remove the brake cable.
the rectifier.
3. Loosen screws [900] and remove brake from brake endshield. Replace gasket/
sealing ring [901].
4. DR..90 – 132, DRN90 – 132S motors: Pay attention to the alignment of the gas-
ket [901].
5. Connect the brake cables of the new brake.
• BE20 – 62: Insert and screw tight the brake plug connector [698]. Tightening
torque 3 Nm.
6. Install the new brake, observing the alignment of the cams of the friction disk.
8. In case of manual brake release: Use the adjusting nuts to adjust the floating
clearance "s" between the conical coil springs (pressed flat) and the setting nuts,
see chapter "Retrofitting the /HR, /HF manual brake release" (→ 2 146).
WARNING
22760253/EN – 08/2016
9. Install the cap screws [900] again. Observe the following tightening torques:
Motors DR..90 – 100, DR..112 – 160, DR..180, DR..200 – 225,

DRN90 – 100 DRN112 – 132 DRN160 – 180 DRN200 – 225
Tightening torque 10.3 Nm 25.5 Nm 50 Nm 87.3 Nm

7.6.16 Brake replacement for DR..250 – 315, DRN250 – 315 motors
WARNING
you start working.

[36]
2. Loosen safety screws of the brake plug connector [698] and remove plug con-
nector.
3. Loosen screws [900] and remove brake from brake endshield.
• DR..250 – 280, DRN250 – 280 motors: Replace O-ring [1607].
4. Install the new brake, observing the alignment of the cams of the friction disk.
5. Insert plug connector [698] in the brake and tighten with a tightening torque of
3 Nm.
WARNING
8. Install the cap screws [900] again. Tightening torque: 230 Nm

22760253/EN – 08/2016

7.6.17 Retrofitting the /HR, /HF manual brake release
WARNING
you start working.

• Remove forced cooling fan and incremental encoder, if installed, see chapter
"Motor and brake maintenance – preliminary work" (→ 2 107).
• Fan guard with encoder mount or fan guard [35], retaining ring [32] and fan [36]
2. Installing manual brake release:
• BE05 – BE11:
– Remove old sealing ring [95].
– Place O-ring [47] into magnet body.
– Seal sealing ring seat using SEW-L-Spezial.
– Screw in and glue studs [56], insert sealing ring for manual brake release
[95] and hammer in parallel pin [59].
– Mount releasing lever [53], conical coil springs [57] and setting nuts [58].
• BE20 – BE62:
– Screw in and glue in stud [56].
– Mount releasing lever [53], conical coil springs [57] and setting nuts [58].
• BE120 – BE122:
– Screw in and glue in stud [56].
– Mount releasing lever [53], conical springs [57], conical seat [255], spherical
washer [256], and adjusting nuts [58].
WARNING
22760253/EN – 08/2016

3. Use setting nuts to set the floating clearance "s" between the conical coil springs
(pressed flat) and the setting nuts (see the following figure).
177241867
Brake Floating clearance s

mm
BE05, BE1, BE2, 1.5
BE5 1.7
BE11, BE20, BE30, BE32, BE60, BE62, 2
BE120, BE122
4. Reinstall the removed parts.
22760253/EN – 08/2016

7 Inspection/maintenance work diagnostic unit /DUB
7.7 Inspection/maintenance work diagnostic unit /DUB
7.7.1 Basic structure of diagnostic unit /DUB on DR..90 – 315 motors with BE..
[379]
[378]
[112]
[66] [157] [49]
[1109]
[557]
[561] [562] [558]
[945] [556]
BE5-122
[555]
[946]
[560] [560] [559]
[561]
BE2
18014399594797835
[49] Pressure plate for DUB [555] Microswitch [561] Hex nut
[66] Sealing strip for DUB [556] Angle bracket [562] Washer
[112] Terminal box lower part [557] Bolt (BE5 and larger) [945] Hex head screw (BE2)
[157] Clamping strap [558] Hex head screw [946] Mounting plate (BE2)
[378] Screw plug [559] Pan head screw [1109] Cable ties
[379] Screw fitting [560] Hex head screw
22760253/EN – 08/2016

Inspection/maintenance work diagnostic unit /DUB 7
7.7.2 Inspection/maintenance work diagnostic unit /DUB for function monitoring
WARNING
you start working.
1. Check working air gap according to chapter "Setting the working air gap of BE05 –
BE122 brakes" (→ 2 136) and adjust it if necessary.
2. Screw the hex head screw [560] against the actuator of the microswitch [555] until
it trips (brown, blue contacts closed).
While screwing, install hex nut [561] to eliminate the longitudinal play from the
thread.
3. Turn hex head screw [560] back until microswitch [555] switches back (contacts
brown-blue open).
4. To ensure operational reliability, turn hex head screw [560] further back by one-
sixth of a revolution (0.1 mm).
5. Tighten hex nut [561], while doing so, hold hex head screw [560] to keep it in the
correct position.
6. Switch the brake on and off several times. Check whether the microswitch opens
and closes reliably in any motor shaft position. Therefore, turn the motor shaft
manually several times.
22760253/EN – 08/2016

7 Inspection/maintenance work diagnostic unit /DUB
7.7.3 Inspection/maintenance work diagnostic unit /DUB for wear monitoring
WARNING
you start working.
1. Check working air gap according to chapter "Setting the working air gap of BE05 –
BE122 brakes" (→ 2 136) and adjust it if necessary.
2. Screw the hex head screw [560] against the actuator of the microswitch [555] until
it trips (brown-blue contacts closed).
While screwing, install hex nut [561] to eliminate the longitudinal play from the
thread.
3. BE2 – 5: Loosen hex head screw [560] by a 3/4 revolution towards the mi-
croswitch [555] (with BE2 by about 0.375 mm / with BE5 by about 0.6 mm).
BE11 – 122: Loosen hex head screw [560] towards the microswitch [555] by a
whole revolution (about 0.8 mm).
4. Tighten hex nut [561], while doing so, hold hex head screw [560] to keep it in the
correct position.
5. If the brake lining reaches the wear limit, the microswitch automatically switches
back (contacts brown-blue open) and activates a relay or a signal.
7.7.4 Inspection/maintenance of the diagnostic unit /DUB for function and wear monitoring
If two microswitches are mounted to one brake, both monitoring statuses can be real-
ized. In this case, set the diagnostic unit /DUB for wear monitoring before you set the
diagnostic unit /DUB for function monitoring.
22760253/EN – 08/2016

Inspection/maintenance work diagnostic unit /DUE 7
7.8 Inspection/maintenance work diagnostic unit /DUE
7.8.1 Basic structure of diagnostic unit /DUE
[1757] [1758] [378]

[379]
[112]
[1727]
[157]
[49] [718] [54] [1151]

9007213532929035
[49] Pressure plate for /DUE (BE20 and higher) [718] Damping plate (BE1 – BE11)
[54] Magnet body complete for /DUE [1151] Distance sensor
[112] Terminal box lower part [1757] Evaluation unit
[157] Clamping strap [1758] Screw
[378] Screw plug (DRN200 – 315) [1727] Grommet (DRN80 – 180)
[379] Screw fitting (DRN200 – 315)
7.8.2 Disassembling the diagnostic unit /DUE

1. Remove forced cooling fan and rotary encoder, if installed, see chapter "Motor and
brake maintenance – preliminary work" (→ 2 107).
2. Remove the fan guard [35] / fan guard with encoder mount [212], or the forced
cooling fan [170] by loosening the retaining screws [22].
3. If applicable: Remove the retaining ring [32] and the fan wheel [36] using a suitable
tool.
4. Loosen the screw [1154] for the cable fixture clamp [1153].
5. Loosen the union nut of the sensor screw fitting. The sensor cable is free.
22760253/EN – 08/2016
6. Loosen the sensor [1151] on the mounting flange. Remove the sensor.

7 Inspection/maintenance work diagnostic unit /DUE
7.8.3 Retrofitting diagnostic unit /DUE for function and wear monitoring
WARNING
you start working.
For the component designation of the evaluation unit, refer to chapter "Designation of
the components" (→ 2 85).
Setting and installing the evaluation unit

The evaluation unit has a 5-pin DIP switch that is labeled with the numbers 1 to 5. Use
it to set the measuring range and the maximum permitted wear limit (maximum work-
ing air gap).
To activate the DIP switch ≙1, push the switch upwards. To deactivate the DIP switch
≙ 0, push the switch downwards.
The following table shows the DIP switch settings of the evaluation unit for the max-
imum working air gap.
1. Set the wear limit using the DIP switches.
INFORMATION
Set the DIP switch only in a de-energized state.
S1 S2 S3 S4 S5 Wear limit BE1 – 2 BE5 BE 1 – 2 (FS) BE5 (FS)

Sensor Ø 6 mm
0 0 0 0 0 1.2 mm
0 0 0 0 1 1.1 mm
0 0 0 1 0 1.0 mm
0 0 0 1 1 0.9 mm X
0 0 1 0 0 0.8 mm
0 0 1 0 1 0.7 mm X
0 0 1 1 0 0.6 mm X X
0 0 1 1 1 0.5 mm
S1 S2 S3 S4 S5 Wear limit BE11 – 122 BE11 – 30 (FS) BE32 (FS)

Sensor Ø 8 mm
1 0 0 0 0 1.2 mm X
1 0 0 0 1 1.1 mm
1 0 0 1 0 1.0 mm
1 0 0 1 1 0.9 mm
1 0 1 0 0 0.8 mm X
22760253/EN – 08/2016
1 0 1 0 1 0.7 mm X
1 0 1 1 0 0.6 mm
1 0 1 1 1 0.5 mm
X= Factory setting
Setting possible in addition
2. Screw the evaluation unit into the terminal box after consultation with
SEW‑EURODRIVE.

3. Connect the sensor, see chapter "Connecting the sensor" (→ 2 155).
4. Calibrate the infinite value, see chapter "Calibration of infinite value" (→ 2 157).
5. Install the sensor in the brake, see chapter "Installing the sensor" (→ 2 158).
6. Route the cable, see chapter "Cable routing" (→ 2 159).
7. Calibrate the zero value, see chapter "Calibration zero value" (→ 2 159).
8. To check the function, measure the voltage via terminal 5k to 10k. Switch the
brake and check if 24 V are applied.
9. To check if the working air gap is within the permitted range, measure the current
between terminals 4k and 10k. Compare the value to the range in the diagram in
chapter "Output signals for function and wear monitoring" (→ 2 156).
Connecting electronics
The function and wear monitoring is connected according to the following wiring dia-
gram. The maximum permitted cable cross section at the terminals "k" is 1.5 mm2 with
conductor end sleeve without plastic collar, 0.75 mm2 with conductor end sleeve. The
required cable cross section at the terminal "k" is 0.5 mm2 with conductor end sleeve
without plastic collar.
INFORMATION
Use shielded cables to wire the evaluation unit. Connect the shield to the GND poten-
tial, or use the shield plate at the user's signal evaluation.
• Unless they are shielded, sensor cables must always be routed separately from
other power cables with phased currents.
• Provide for a suitable equipotential bonding between drive and control cabinet.
22760253/EN – 08/2016

A C
4k
(BN) 4s
(BK) 5k
5s
(WH)
6s 6k
B
7k
8k
9k
10k
11k
18014412038672651
[A] Brake [4k] Analog output wear 1 (air gap)

[B] Eddy current sensor [5k] Digital output function 1 (NO contact)
[C] Evaluation unit [6k] Digital output wear 1 (NC contact)
[7k] Input calibration zero value
[4s] Connection sensor A1 (brown [8k] Input calibration infinite value
cable)
[5s] Connection sensor GND 1 (black [9k] Signal ground AGND
cable)
[6s] Connection sensor B1 (white cable) [10k] Ground potential GND
[11k] DC 24 V supply
The evaluation unit is supplied with DC 24 V via the terminals GND [10k] and DC 24 V
[11k].
Brake monitoring provides digital signals for:
• Function FCT1 [5k] and wear WEAR1 [6k] of the brake.
The working air gap can be monitored continuously via the analog signal (4 – 20 mA)
regarding the signal ground [9k]:
• Terminal OUT1 [4k]
Use terminals ZERO [7k] and INF [8k] for calibration.
22760253/EN – 08/2016
INFORMATION
If values deviate from the factory setting, the wear point setting must be adjusted.
See chapter "Setting and installing the evaluation unit" (→ 2 152).

Connecting the sensor
[1]
BN WH
BK
4s 5s6s 4k 5k 6k 7k 8k 9k 10k 11k
DC 24V
WEAR1
AGND
ZERO
OUT1
FCT1
GND1
GND
A1
B1
INF
1
OFF
DUE-1K-00 21195609
9007214229800843
[1] Brake sensor
The connection cross section of the sensor is 0.14 mm². The litz wires of the sensor
cables must be equipped with conductor end sleeves. The cable shield must be isol-
ated against other potentials using a heat shrink tubing. The litz wires can be pushed
into the terminals without using tools. Put the sensor cables in the provided line clip,
see figure in chapter "Calibration of infinite value" (→ 2 157). To remove the sensor
cables, use an insulated screwdriver to disengage the clips.
22760253/EN – 08/2016

Output signals for function and wear monitoring

The diagnostic unit /DUE provides an analog signal (4 – 20 mA, DIN IEC 60381‑1) for
the current working air gap of the brake.
D6 D8
IOut [mA] IOut [mA]
20 20
13,6 13,6
10 10
[5] [4] [3] [5] [4] [3]

4 4
x [mm] x [mm]
0 x 0,9 1,5 0 x 1,2 2,0
U [V] U [V]
[1] [1]
24 24
FCT FCT
0 0
U [V] U [V]
[2] [2]
24 24
WEAR WEAR
0 0
14668091147 15221727499
[1] FCT: Digital output function (DC 24 V, DIN EN 61131-2)

[2] WEAR: Digital output wear (DC 24 V, DIN EN 61131-2)
[3] Measuring range of the sensor
[4] Max. working air gap of the brake (exemplary)
[5] Currently measured working air gap (exemplary)
22760253/EN – 08/2016

Calibration of infinite value
Before you can install the sensor in the brake, the electronics must be calibrated to the
actual cable length. During calibration of the infinite value, electronics is adjusted to
the sensor cable length. Electronics is reset and previous settings are overwritten.
The sensor must be removed from the brake for the following steps.
Procedure to calibrate the infinite value for the sensor:
1. Make sure that no metallic objects are within a 10 cm radius from the sensor head.
The mounting springs may be in contact with the back of the sensor head during
calibration.
2. Connect the supply voltage to INF (8k) and AGND (9k) for approx. 5 s. You can
use GND (10k) as reference potential instead of AGND (9k). The evaluation unit is
supplied via the calibration input during calibration.
The analog output OUT1 signals 0 mA during the calibration procedure.
The infinite value was successfully calibrated when OUT1 (4k) displays 20 mA. The
red LED briefly flashes once per second as visual signal.
The corresponding wiring diagram for the calibration process.
+24 V GND
4s 5s6s 4k 5k 6k 7k 8k 9k 10k 11k
DC 24V
WEAR1
AGND
ZERO
OUT1
FCT1
GND1
GND
A1
B1
INF
1
OFF
DUE-1K-00 21195609
14975067787
During calibration, the digital outputs WEAR1 (6k), FCT1 (5k) send a 0 signal which
may lead to error messages (wear limit reached).
22760253/EN – 08/2016

Installing the sensor

After calibration, the eddy current sensor can be installed in the magnet body of the
brake. When installing the sensor, make sure that the sensor head can be inserted in
the stepped bore without pressure being applied.
First install the lower part of the cable gland. Then mount the upper part of the cable
gland.
INFORMATION
To ensure that the sensor is correctly inserted in the stepped bore, twist the sensor
carefully with the cable before screwing in the cable gland. Protect the sensor cable
against damage.
[1]
15126940043
[1] Brake sensor
22760253/EN – 08/2016

Cable routing
Prevent the cable from colliding with the fan cable. If necessary, attach the cable to
the included clamping strap [157] on the brake using cable ties.
Calibration zero value

During calibration of the zero value, the current working air gap with released (open)
brake is written in the evaluation unit. The electronics is reset and previous settings
are overwritten. You can save the zero value at any time without changing the infinite
value.
Procedure during calibration of the zero value:
1. Open the brake.
2. Apply the supply voltage to ZERO (7k) and AGND (9k) for approx. 3 seconds.
Electronics is in calibration mode. You can use GND (10k) as reference potential
instead of AGND (9k). The evaluation unit is supplied via the calibration input dur-
ing calibration.
The evaluation unit saves the smallest working air gap of the brake. Each write pro-
cess is indicated by a brief flashing of the red LED.
The activated calibration mode is indicated by the following LED state:
LED State
Green [6] Off
Red [6] Flashing (2 Hz)
+24 V GND
4s 5s6s 4k 5k 6k 7k 8k 9k 10k 11k

DC 24V
WEAR1
AGND
ZERO
OUT1
FCT1
GND1
GND
A1
B1
INF
1
OFF
DUE-1K-00 21195609
14977696651
During calibration, the digital outputs WEAR1 (6k), FCT1 (5k) send a 0 signal which
may lead to error messages (wear limit reached).
The analog output OUT1 (4k) signals 0 mA during the calibration procedure. After suc-
22760253/EN – 08/2016
cessful calibration, the value is saved. The output has 4 mA with released brake. If a
smaller value is available within 3 seconds, the last value is deleted and the new value
is saved. The 4 mA at the output remain unchanged.

Status messages of the evaluation unit

Brake Sensor Calibration LEDs and outputs
State
ZERO INF Green Red FCT WEAR OUT
Open Installed – – To Off HI HI 3.6 – Brake open, no wear
5.6 mA
Go to Installed – – Off Off LO HI 6 – 20 mA Brake closed, no wear
Go to Installed – – Off To LO LO 6 – 20 mA Brake closed, set wear limit of
brake reached
– – – – Off To LO LO >20 mA Measuring range exceeded or
sensor not connected correctly
– Not in- – HI Off Blinking LO LO 0 mA Infinite value calibration active
stalled 1 Hz
– Not in- – HI Off Flashing LO LO 20 mA Infinite calibration successful
stalled 1 Hz
– – – – Blinking Blinking Clock Clock 1 Hz 0 mA Not completely calibrated:
1 Hz 1 Hz 1 Hz • ZERO calibration missing
• Delivery state (both calibra-
tions missing)
Open Installed HI – Off Blinking LO LO 0 mA Zero value calibration active
2 Hz
Open Installed HI – Off Blinking LO LO 4 mA First zero value calibration suc-
2 Hz cessful
Open Installed HI – Off Flicker- LO LO 4 mA Smaller zero value detected and
ing saved
22760253/EN – 08/2016

Altering the blocking direction on motors with a backstop 7
7.9 Altering the blocking direction on motors with a backstop
7.9.1 Basic structure of DR..71 – 80, DRN80 motors with backstop

[71] [1] [44] [392] [42] [48] [74] [75] [77] [36] [35] [78]
[41] [62] [37] [32]
18014399652340235
[1] Motor with brakemotor [48] Spacing ring

[32] Retaining ring [62] Retaining ring
[35] Fan guard [71] Key
[36] Fan wheel [74] Backstop
[37] Sealing ring [75] Sealing flange
[41] Shim [77] Cap screw
[42] Backstop endshield, complete [78] Direction of rotation information sign
[44] Deep groove ball bearing [392] Seal
22760253/EN – 08/2016

7 Altering the blocking direction on motors with a backstop
7.9.2 Basic structure of DR..90 – 315, DRN90 – 315 motors with backstop

[1] [392] [42] [71] [30] [48] [74] [62] [703] [37] [32] [78] [55]
[901] [376] [1406] [702] [36] [35]

[390] [1607]
18014399652338315
[1] Motor [74] Backstop

[30] Sealing ring (DR../DRN250-315) [78] Information sign for direction of rotation
[35] Fan guard [702] Backstop housing
[36] Fan wheel [703] Cap screw
[37] Sealing ring [376] Screw plug (DR..160 – 315, DRN132M – 315)
[42] Brake endshield [392] Seal (DR..90 – 132, DRN90 – 132S)
[48] Spacing ring [901] Seal (DR..90 – 225, DRN90 – 225)
[55] Closing piece [1406] Spacing ring (DR..250 – 315, DRN250 – 315)
[62] Retaining ring [1607] O-ring (DR..250 – 280, DRN250 – 280)
[71] Key
22760253/EN – 08/2016

Altering the blocking direction on motors with a backstop 7
7.9.3 Changing the blocking direction
WARNING
you start working.
Proceed as follows to change the blocking direction:

1. Remove forced cooling fan and rotary encoder, if installed.
See chapter "Motor and brake maintenance – preliminary work" (→ 2 107).
2. Remove fan guard with encoder mount or fan guard [35].
3. DR..71 – 80, DRN80 motors: Remove the sealing flange [75].
DR../DRN90 – 315 motors: Completely remove the backstop housing [702].
4. Loosen retaining ring [62] and spacer [1406] (if necessary).
5. Remove the sprag ring [74] via screws in the forcing threads or using a puller.
6. Spacing ring [48], if provided, remains installed.
7. Turn around the sprag ring [74], check the old grease and replace according to the
specifications below and reinstall the sprag ring.
8. Install retaining ring [62].
9. DR..71 – 80, DRN80 motors: Apply SEW-L-Spezial to the sealing flange [75] and
install it. Replace sealing ring [37] if necessary.
DR../DRN90 – 315 motors: Replace seal [901] and [1607]. Also replace seal [37]
if necessary. Completely install the backstop housing [702].
10. Reinstall the removed parts.
11. Replace the label [78] indicating the direction of rotation.
Lubricating the backstop

The backstop is greased at the factory with the corrosion protection low-viscosity
grease Acinol 8300EP. If you want to use another type of grease, make sure it com-
plies with NLGI class 00/000 with a base oil viscosity of 42 mm2/s at 40 °C on a lithium
saponified and mineral oil base. The application temperature range is from -50 °C to
+90 °C. See the following table for the amount of grease required:
DR.. motors 71 80 90/100 112/132 160 180 200/225 250/280 315

DRN.. motors – 80 90/100 112/132S 132M/L 160/180 200/225 250/280 315
Amount of grease 9 11 15 20 30 45 80 80 120
in g
22760253/EN – 08/2016
The tolerance regarding the grease level is ± 30 %.

Technical data
8 Braking torques
8 Technical data
8.1 Braking torques

Table shows the possible braking torque combinations for various sizes of the BE..
brake.
WARNING
Insufficient or too high braking torque due to impermissible spring pack.
• Maintenance work may only be performed by a trained specialists.
• In case of a conversion, make sure the new braking torque stage is approved for
your individual drive combination, and suitable for your application.
• Observe the specifications on project planning in the "AC motors" catalog. In
case of any uncertainties, contact SEW‑EURODRIVE.
Brake Part number Braking torque settings

Damping plate Braking torque Type and number of brake springs Purchase order number for
[718] brake springs
Pole sheet [63]
Nm Normal [50] Blue [276] White [1312] Normal Blue/white
BE05 13740563 5.0 3 – – 0135017X 13741373
3.5 – 6 –
2.5 – 4 –
1.8 – 3 –
BE1 13740563 10 6 – – 0135017X 13741373
137498621) 7.0 4 2 –
5.0 3 – –
BE2 13740199 20 6 – – 13740245 13740520
137498702) 14 2 4 –
10 2 2 –
7.0 – 4 –
5.0 – 3 –
BE5 13740695 55 6 – – 13740709 13740717
137498892) 40 2 4 –
28 2 2 –
20 – – 6 13747738
14 – – 4
BE11 13741713 110 6 – – 13741837 13741845
137498542) 80 2 4 –
55 2 2 –
40 – 4 –
13741713 + 28 – 3 –
13746995
137498542) + 20 – – 4 13747789
13746995
BE20 – 200 6 – – 13743228 13742485
22760253/EN – 08/2016
– 150 4 2 –
– 110 3 3 –
– 80 3 – –
13749307 55 – 4 –
13746758 40 – 3 –

Technical data
Braking torques 8
Brake Part number Braking torque settings
Damping plate Braking torque Type and number of brake springs Purchase order number for
[718] brake springs
Pole sheet [63]
Nm Normal [50] Blue [276] White [1312] Normal Blue/white
BE30 – 300 8 – – 01874551 13744356
– 200 4 4 –
– 150 4 – –
– 100 – 8 –
13749455 75 – 6 –
BE32 – 600 8 – – 01874551 13744356
– 500 6 2 –
– 400 4 4 –
– 300 4 – –
– 200 – 8 –
13749455 150 – 6 –
13749455 100 – 4 –
BE60 – 600 8 – – 01868381 13745204
– 500 6 2 –
– 400 4 4 –
– 300 4 – –
– 200 – 8 –
BE62 – 1200 8 – – 01868381 13745204
– 1000 6 2 –
– 800 4 4 –
– 600 4 – –
– 400 – 8 –
BE120 – 1000 8 – – 13608770 13608312
– 800 6 2 –
– 600 4 4 –
– 400 4 – –
BE122 – 2000 8 – – 13608770 13608312
– 1600 6 2 –
– 1200 4 4 –
– 800 4 – –
1) for option /DUE
The following table shows the brake spring layout:

BE05 – 11:
6 springs 3 + 3 springs 4 + 2 springs 2 + 2 springs 4 springs 3 springs
BE20:
6 springs 4 + 2 springs 3 + 3 springs 4 springs 3 springs
22760253/EN – 08/2016
BE30 – 122:
8 springs 6 + 2 springs 4 + 4 springs 6 springs 4 springs

Technical data
8 Work done, working air gap, brake disk thickness
8.2 Work done, working air gap, brake disk thickness

If you use encoders and brakes with functional safety technology, the values for the
maximum working air gaps and the work done until maintenance are reduced. For the
new values, refer to the addendums to the operating instructions "Safety-Rated En-
coders" or "Safety-Rated Brakes".
Brake Switching energy Working air gap Brake disk

until maintenance1) 2)
min. max. min.
106 J mm mm mm
BE05 120 0.25 0.6 11.0
BE1 120 0.25 0.6 11.0
BE2 180 0.25 0.6 11.0
BE5 390 0.25 0.9 11.0
BE11 640 0.3 1.2 12.5
BE20 1000 0.3 1.2 12.5
BE30 1500 0.3 1.2 12.5
BE32 1500 0.4 1.2 12.5
BE60 2500 0.3 1.2 14.0
BE62 2500 0.4 1.2 14.0
BE120 390 0.6 1.2 14.0
BE122 300 0.8 1.2 14.0
1) The specified values are nominal values that were determined during rating operation. The actual switching energy that can be
reached before maintenance may vary depending on the actual load during operation.
2) When checking the working air gap, note: Parallelism tolerances on the brake disk may give rise to deviations of ± 0.15 mm after a
test run.
INFORMATION
In case of drives with BE32, BE62, or BE122 brake in pivoted mounting position, the
specified value may be reduced by up to 50%, depending on the pivoting angle.
22760253/EN – 08/2016

Technical data
Operating currents 8
8.3 Operating currents
The depicted values apply to a supply with nominal voltage and the standard temper-
ature range of -20 to +40 °C. Deviating operating currents may occur in other temper-
ature ranges, especially in case of drives with permitted temperature above +60 °C, or
in case of non-ventilated drives, due to modified winding configurations. The values
are available from SEW‑EURODRIVE on request.
Key:
IB Acceleration current – brief inrush current
IH Holding current, rms value in the supply cable to the SEW‑EURODRIVE brake
rectifier
IB/IH Inrush current ratio ESV
IG Direct current with direct DC voltage supply
VN Nominal voltage (rated voltage range)
8.3.1 BE05, BE1, BE2 brake

The current values IH (holding current) listed in the tables are rms values. Use only ap-
propriate instruments for measuring rms values. The inrush current (acceleration cur-
rent) IB only flows for a short time (max. 160 ms) when the brake is released. There is
no increased inrush current if a BG or BMS brake rectifier is used or if there is a direct
DC voltage supply – only possible with brakes up to size BE2.
BE05, BE1 BE2

Rated brake coil power in W 32 43
Inrush current ratio ESV 4 4
Nominal voltage VN BE05, BE1 BE2

IH IG IH IG
AC V DC V AC A DC A AC A DC A
24 (23-26) 10 2.25 2.90 2.95 3.80
60 (57-63) 24 0.90 1.17 1.18 1.53
120 (111-123) 48 0.45 0.59 0.59 0.77
184 (174-193) 80 0.29 0.37 0.38 0.49
208 (194-217) 90 0.26 0.33 0.34 0.43
230 (218-243) 96 0.23 0.30 0.30 0.39
254 (244-273) 110 0.20 0.27 0.27 0.35
290 (274-306) 125 0.18 0.24 0.24 0.31
330 (307-343) 140 0.16 0.21 0.21 0.28
360 (344-379) 160 0.14 0.19 0.19 0.25
400 (380-431) 180 0.13 0.17 0.17 0.22
22760253/EN – 08/2016
460 (432-484) 200 0.11 0.15 0.15 0.19

500 (485-542) 220 0.10 0.13 0.14 0.18
575 (543-600) 250 0.09 0.12 0.12 0.16

Technical data
8 Operating currents
8.3.2 Brakes BE5, BE11, BE20, BE30, BE32, BE60, BE62

rent) IB only flows for a short time (max. 160 ms) when the brake is released. A separ-
ate voltage supply is not possible.
BE5 BE11 BE20 BE30, BE32 BE60, BE62

Rated brake coil power in W 49 77 100 120 195
Inrush current ratio ESV 5.9 6.6 7.5 8.5 9.2
Nominal voltage VN BE5 BE11 BE20 BE30, BE32 BE60, BE62

IH IH IH IH IH
AC V DC V AC A AC A AC A AC A AC A
60 (57-63) 24 1.28 2.05 2.55 – –
120 (111-123) 48 0.64 1.04 1.28 1.66 –
184 (174-193) 80 0.41 0.66 0.81 1.05 –
208 (194-217) 90 0.37 0.59 0.72 0.94 1.50
230 (218-243) 96 0.33 0.52 0.65 0.84 1.35
254 (244-273) 110 0.29 0.47 0.58 0.75 1.20
290 (274-306) 125 0.26 0.42 0.51 0.67 1.12
330 (307-343) 140 0.23 0.37 0.46 0.59 0.97
360 (344-379) 160 0.21 0.33 0.41 0.53 0.86
400 (380-431) 180 0.18 0.30 0.37 0.47 0.77
460 (432-484) 200 0.16 0.27 0.33 0.42 0.68
500 (485-542) 220 0.15 0.24 0.29 0.38 0.60
575 (543-600) 250 0.13 0.22 0.26 0.34 0.54
22760253/EN – 08/2016

Technical data
Operating currents 8
8.3.3 Brake BE120, BE122
rent) IB only flows for a short time (max. 400 ms) when the brake is released. A separ-
ate voltage supply is not possible.
BE120/BE122
Rated brake coil power in W 220
Inrush current ratio ESV 6
Nominal voltage VN BE120/BE122

IH
AC V AC A
230 (218-243) 1.45
254 (244-273) 1.30
290 (274-306) 1.16
360 (344-379) 0.92
400 (380-431) 0.82
460 (432-484) 0.73
500 (485-542) 0.65
575 (543-600) 0.58
22760253/EN – 08/2016

Technical data
8 Resistors
8.4 Resistors
The depicted values apply to the standard temperature range of -20 to +40 °C. Deviat-
ing resistances may occur in other temperature ranges, especially in case of drives
with permitted temperature above +60 °C, or in case of non-ventilated drives, due to
modified winding configurations. The values are available from SEW‑EURODRIVE on
request.
8.4.1 Resistance measurement BE05, BE1, BE2, BE5, BE30, BE32, BE60, BE62
Cut-off in the AC circuit

The following illustration shows how to measure resistance with cut-off in the AC cir-
cuit.
RD
RB
WH
RT
BU
BU
RD
WH
9007199497350795
Cut-off in the DC and AC circuits

The following illustration shows how to measure resistance with cut-off in the DC and
AC circuits.
RD
RB
WH
RT
BU
BU
RD
WH
18014398752093451
BS Accelerator coil RD Red

TS Coil section WH White
RB Accelerator coil resistance at 20 °C in Ω BU Blue
RT Coil section resistance at 20 °C in Ω
22760253/EN – 08/2016
INFORMATION
When measuring the resistance of the coil section RT or the accelerator coil RB, re-
move the white core from the brake rectifier; if it remains connected, the internal res-
istance of the brake rectifier will cause erroneous results.

Technical data
Resistors 8
8.4.2 Brake BE05, BE1, BE2, BE5
BE05, BE1 BE2

Rated brake coil power in W 32 43
Inrush current ratio ESV 4 4
Nominal voltage VN BE05, BE1 BE2

AC V DC V RB RT RB RT
60 (57-63) 24 4.85 14.8 3.60 11.0
120 (111-123) 48 19.4 59.0 14.4 44.0
184 (174-193) 80 48.5 148 36.0 110
208 (194-217) 90 61.0 187 45.5 139
230 (218-243) 96 77.0 235 58.0 174
254 (244-273) 110 97.0 296 72.0 220
290 (274-306) 125 122 372 91 275
330 (307-343) 140 154 469 115 350
360 (344-379) 160 194 590 144 440
400 (380-431) 180 244 743 182 550
460 (432-484) 200 308 935 230 690
500 (485-542) 220 387 1178 290 870
575 (543-600) 250 488 1483 365 1100
22760253/EN – 08/2016

Technical data
8 Resistors
8.4.3 Brakes BE11, BE20, BE30, BE32, BE60, BE62
BE5 BE11 BE20 BE30, BE32 BE60, BE62

Rated brake coil 49 77 100 120 195
power in W
Inrush current ratio 5.9 6.6 7.5 8.5 9.2
ESV
Nominal voltage BE5 BE11 BE20 BE30, BE32 BE60, BE62

VN
AC V RB RT RB RT RB RT RB RT RB RT
60 (57-63) 2.20 10.5 1.22 7.0 0.9 5.7 – – – –
120 (111-123) 8.70 42.0 4.90 28.0 3.4 22.8 2.3 17.2 – –
184 (174-193) 22.0 105 12.3 70 8.5 57.2 5.8 43.2 – –
208 (194-217) 27.5 132 15.5 88 10.7 72.0 7.3 54.4 4.0 32.6
230 (218-243) 34.5 166 19.5 111 13.5 90.6 9.2 68.5 5.0 41.0
254 (244-273) 43.5 210 24.5 139 17.0 114.1 11.6 86.2 6.3 51.6
290 (274-306) 55.0 265 31.0 175 21.4 143.6 14.6 108.6 7.9 65.0
330 (307-343) 69.0 330 39.0 220 26.9 180.8 18.4 136.7 10.0 81.8
360 (344-379) 87.0 420 49 280 33.2 223 23.1 172.1 12.6 103
400 (380-431) 110 530 62 350 42.7 287 29.1 216.6 15.8 130
460 (432-484) 138 660 78 440 53.2 357 35.1 261.8 19.9 163
500 (485-542) 174 830 98 550 67.7 454 45.2 336.4 25.1 205
575 (543-600) 220 1050 123 700 83.5 559 56.3 419.2 31.6 259
22760253/EN – 08/2016

Technical data
Resistors 8
8.4.4 Resistance measurement BE120, BE122
The following illustration shows how to measure resistance with BMP 3.1.
RD
RB
WH
RT
BU
RD WH BU
BS Accelerator coil RD Red

TS Coil section WH White
RB Accelerator coil resistance at 20 °C in Ω BU Blue
RT Coil section resistance at 20 °C in Ω
INFORMATION
When measuring the resistance of the coil section RT or the accelerator coil RB, re-
move the white core from the brake rectifier; if it remains connected, the internal res-
istance of the brake rectifier will cause erroneous results.
8.4.5 Brake BE120, BE122
BE120, BE122
Rated brake coil power in W 220
Inrush current ratio ESV 6
Nominal voltage VN BE120, BE122

AC V RB RT
230 (218-243) 7.6 37.9
254 (244-273) 9.6 47.7
290 (274-306) 12.1 60.1
360 (344-379) 19.2 95.2
400 (380-431) 24.2 119.9
22760253/EN – 08/2016
460 (432-484) 30.4 150.9

500 (485-542) 38.3 189.9
575 (543-600) 48.2 239.1

Technical data
8 Brake control
8.5 Brake control

The depicted combinations apply to drives in insulation class B or F, and to the stand-
ard temperature range of -20 °C to +40 °C.
For the brake control assigned to your drive, refer to the specifications on the motor
nameplate.
INFORMATION
The depicted combinations may be limited depending in the present drive configura-
tion (e.g. insulation class H, deviating temperature ranges, etc.). In case of a conver-
sion, check if brake control is permitted for your drive combination. Contact
SEW‑EURODRIVE if necessary.
8.5.1 Permitted combinations

The table below shows the standard and optional combinations of brakes and brake
rectifiers.
BE05 BE1 BE2 BE5 BE11 BE20 BE30, BE60, BE120,

BE32 BE62 BE122
BG.. BG 1.4 X3 X3 X3 − − − − − −
BG 1.5 X1 X1 X1 • − − − − −
2 2 2
BG 3 X X X − − − − − −
BGE.. BGE 1.4 o o o X3 X3 X3 X3 X3 −
1 1 1 1
BGE 1.5 • • • X X X X X −
BGE 3 • • • X2 X2 X2 X2 X −
BS.. BS 24 X X X • − − − − −
BMS.. BMS 1.4 o o o − − − − − −
BMS 1.5 • • • − − − − − −
BMS 3 • • • − − − − − −
BME.. BME 1.4 o o o o o o o o −
BME 1.5 • • • • • • • X −
BME 3 • • • • • • • X −
BMH.. BMH 1.4 o o o o o o o – −
BMH 1.5 • • • • • • • − −
BMH 3 • • • • • • • − −
BMK.. BMK 1.4 o o o o o o o o −
BMK 1.5 • • • • • • • − −
22760253/EN – 08/2016
BMK 3 • • • • • • • − −
BMKB.. BMKB 1.5 • • • • • • • − −
BMP.. BMP 1.4 o o o o o o o o −
BMP 1.5 • • • • • • • − −
BMP 3 • • • • • • • − −
BMP 3.1 − − − − − − − • X

Technical data
Brake control 8
BE05 BE1 BE2 BE5 BE11 BE20 BE30, BE60, BE120,
BE32 BE62 BE122
BMV.. BMV 5 • • • • • • − − −
BSG.. BSG • • • X X X − − −
BSR.. BGE1.5 + • • − − − − − − −
SR10
BGE 1.4 + o o o o o o o o −
SR 15
BGE 3 + • • • • • − − − −
SR 11
BGE 3 + • • • • • • • − −
SR 15
BGE3 + • • − − − − − − −
SR10
BGE 1.5 + • • • • • − − − −
SR 11
BGE 1.5 + • • • • • • • − −
SR 15
BUR.. BGE 3 + • • • • − − − − −
UR 11
BGE 1.5 + • • • • • • • − −
UR 15
X Standard version
X1 Standard design with nominal brake voltage of 150 – 500 VAC
X2 Standard design with nominal brake voltage of 24/42 – 150 VAC
X3 Standard design with nominal brake voltage of 575 VAC
• Optional
o Optional with 575 VAC nominal brake voltage
– Not permitted
22760253/EN – 08/2016

Technical data
8 Brake control
8.5.2 Motor wiring space

The following tables list the technical data of brake control systems for installation in
the motor wiring space. The different housings have different colors (= color code) to
make them easier to distinguish.
Type Function Voltage Holding Type Part num- Color

current ber code
IHmax in A
BG.. Half-wave rectifier AC 230 – 575 V 1.0 Size 1.4 8278814 Black
AC 150 – 500 V 1.5 Size 1.5 8253846 Black
AC 24 – 500 V 3.0 Size 3 8253862 Brown
BGE.. Half-wave rectifier with AC 230 – 575 V 1.0 BGE 1.4 8278822 Red
electronic switching
AC 150 – 500 V 1.5 BGE 1.5 8253854 Red
AC 42 – 150 V 3.0 BGE 3 8253870 blue
BSR.. Half-wave rectifier + cur- AC 150 – 500 V 1.0 BGE1.5 + SR10 8253854
rent relay for cut-off in the 0826760X
DC circuit
1.0 BGE 1.5 + SR 11 8253854
8267618
1.0 BGE 1.5 + SR 15 8253854
8267626
AC 42 – 150 V 1.0 BGE 3 + SR11 8253870
8267618
1.0 BGE 3 + SR15 8253870
8267626
BUR.. Half-wave rectifier + AC 150 – 500 V 1.0 BGE 1.5 + UR 15 8253854
voltage relay for cut-off in 8267596
the DC circuit
AC 42 – 150 V 1.0 BGE 3 + UR 11 8253870
8267588
BS.. Varistor protection circuit DC 24 V 5.0 BS24 8267634 Water
blue
BSG.. Electronic switching DC 24 V 5.0 BSG 8254591 White
1)
BMP.. Half-wave rectifier with AC 230 – 575 V 2.8 BMP 3.1 8295077
electronic switching, in-
tegrated voltage relay for
cut-off in the DC circuit.
1) Only sizes 250 – 315
22760253/EN – 08/2016

Technical data
Brake control 8
8.5.3 Control cabinet
The following tables list the technical data of brake control systems for installation in
the control cabinet. The different housings have different colors (= color code) to make
them easier to distinguish.
Type Function Voltage Holding Type Part num- Color

current ber code
IHmax in A
BMS.. Half-wave rectifier as BG AC 230 – 575 V 1.0 BMS 1.4 8298300 Black
AC 150 – 500 V 1.5 BMS 1.5 8258023 Black
AC 42 – 150 V 3.0 BMS 3 8258031 Brown
BME.. Half-wave rectifier with AC 230 – 575 V 1.0 BME 1.4 8298319 Red
electronic switching as
AC 150 – 500 V 1.5 BME 1.5 8257221 Red
BGE
AC 42 – 150 V 3.0 BME 3 825723X Blue
BMH.. Half-wave rectifier with AC 230 – 575 V 1.0 BMH 1.4 8298343 Green
electronic switching and
AC 150 – 500 V 1.5 BMH 1.5 825818X Green
heating function
AC 42 – 150 V 3 BMH 3 8258198 Yellow
BMP.. Half-wave rectifier with AC 230 – 575 V 1.0 BMP 1.4 8298327 White
electronic switching, in-
AC 150 – 500 V 1.5 BMP 1.5 8256853 White
tegrated voltage relay for
cut-off in the DC circuit AC 42 – 150 V 3.0 BMP 3 8265666 Light
blue
AC 230 – 575 V 2.8 BMP 3.11) 8295077
BMK.. Half-wave rectifier with AC 230 – 575 V 1.0 BMK 1.4 8298335 Water
electronic switching, blue
24 VDC control input and
AC 150 – 500 V 1.5 BMK 1.5 8264635 Water
separation in the DC cir-
blue
cuit.
AC 42 – 150 V 3.0 BMK 3 8265674 Bright
red
BMV.. Brake control unit with DC 24 V 5.0 BMV 5 13000063 White
electronic switching,
24 VDC control input and
fast switch-off
1) Only sizes 250 – 315
22760253/EN – 08/2016

Technical data
8 Permitted rolling bearings
8.6 Permitted rolling bearings
8.6.1 Rolling bearing for DR..71 – 280 motors
Motors A-side bearing B-side bearing

AC motor Gearmotor AC motor Brakemotor
DR..71 6204-2Z-C3 6303-2Z-C3 6203-2Z-C3 6203-2RS-C3
DR..80, 6205-2Z-C3 6304-2Z-C3 6304-2Z-C3 6304-2RS-C3
DR..90 – 100 6306-2Z-C3 6205-2Z-C3 6205-2RS-C3
DR..112 – 132 6308-2Z-C3 6207-2Z-C3 6207-2RS-C3
DR..160 6309-2Z-C3 6209-2Z-C3 6209-2RS-C3
DR..180 6312-2Z-C3 6213-2Z-C3 6213-2RS-C3
DR..200 – 225 6314-2Z-C3 6314-2Z-C3 6314-2RS-C3
DR..250 – 280 6317-2Z-C4 6315-2Z-C3 6315-2RS-C3
8.6.2 Rolling bearing for DRN80 – 280 motors

AC motor Gearmotor AC motor Brakemotor
DRN80 6205-2Z-C3 6304-2Z-C3 6304-2Z-C3 6304-2RS-C3
E2.6205-2Z-C3-K24 E2.6304-2Z-C3-K24
DRN90 6305-2Z-C3 6205-2Z-C3 6205-2RS-C3
DRN100 6306-2Z-C3 6205-2Z-C3 6205-2RS-C3
DRN112 6308-2Z-C3 6207-2Z-C3 6207-2RS-C3
DRN132S 6308-2Z-C3 6308-2Z-C3 6207-2Z-C3 6207-2RS-C3
E2.6308-2Z-C3-K24 E2.6207-2Z-C3-K24
DRN132M/L 6308-2Z-C3 6309-2Z-C3 6209-2Z-C3 6209-2RS-C3
DRN160 6310-2Z-C3 6312-2Z-C3 6212-2Z-C3 6212-2RS-C3
DRN180 6311-2Z-C3 6312-2Z-C3 6212-2Z-C3 6212-2RS-C3
DRN200 6312-2Z-C3 6314-2Z-C3 6314-2Z-C3 6314-2RS-C3
DRN225 6314-2Z-C3 6314-2Z-C3 6314-2RS-C3
DRN250 – 280 6317-2Z-C4 6315-2Z-C3
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Technical data
Permitted rolling bearings 8
8.6.3 Rolling bearing for DR..315, DRN315 motors

AC motor Gearmotor AC motor Gearmotor
DR..315K, 6319-C3 6319-C3 6319-C3 6319-C3
DRN315S
DR..315S,
DRN315M
DR..315M, 6319-C3 6322-C3 6319-C3 6322-C3
DRN315L
DR..315L,
DRN315H
8.6.4 Rolling bearing for DR..250 – 315, DRN250 – 315 motors, with reinforced bearings /ERF

AC motor Gearmotor
DR..250 – 280, DRN250 – 280 NU317E-C3 6315-C3
DR..315K, DRN315S NU319E 6319-C3 6319-C3
DR..315S, DRN315M
DR..315M, DRN315L 6322-C3
DR..315L, DRN315H
8.6.5 Rolling bearing for DR..200 – 315, DRN200 – 315 motors, with current-insulated rolling
bearings /NIB
Motors B-side bearing

AC motor Gearmotor
DR..200 – 225, DRN200 – 225 6314-C3-EI 6314-C3-EI
DR..250 – 280, DRN250 – 280 6315-Z-C3-EI 6315-Z-C3-EI
DR..315K, DRN315S 6319-C3-EI 6319-C3-EI
DR..315S, DRN315M
DR..315M, DRN315L 6322-C3-EI
DR..315L, DRN315H
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Technical data
8 Lubricant tables
8.7 Lubricant tables
8.7.1 Lubricant table for rolling bearings
INFORMATION
Use of wrong bearing grease can damage the bearings.
Motors with sealed bearings

The bearings are 2Z or 2RS closed bearings and cannot be re-lubricated. They are
used for DR..71 – 280, DRN80 – 280 motors.
Ambient temperature Manufacturer Type DIN designation

1)
Motor rolling bear- -20 °C to +80 °C Mobile Polyrex EM K2P-20
ings
+20 °C to +100 °C Klüber Barrierta L55/22) KX2U
2)
-40 °C to +60 °C Kyodo Yushi Multemp SRL KE2N-40
1) mineral lubricant (= mineral-based rolling bearing grease)
2) Synthetic lubricant (= synthetic-based roller bearing grease)
Motors with open bearings

Motors in the sizes DR..315 and DRN315 always have open bearings. If DR..250 –
280 and DRN225 – 280 motors have the relubrication option /NS, these sizes also
have open bearings.
Ambient temperature Manufacturer Type DIN designation

Rolling bearing -20 °C to +80 °C Mobile Polyrex EM1) K2P-20
1)
-40 °C to +60 °C SKF LGHP 2 K2N-40
1) mineral lubricant (= mineral-based rolling bearing grease)
22760253/EN – 08/2016

Technical data
Lubricant tables 8
8.7.2 Order information for lubricants, anti-corrosion agents and sealants
Lubricants, anti-corrosion agents, and sealants may be obtained directly from
SEW‑EURODRIVE using the following order numbers.
Use Manufacturer Type Quan- Purchase order

tity number
Lubricant for rolling bear- Mobile Polyrex EM 400 g 03259420
ings
SKF LGHP2 400 g 09101276
Lubricant for sealing rings
Material: NBR/FKM Klüber Petamo GHY 133N 10 g 04963458
FUCHS LUBRITECH gleitmo 100 S 1 kg 03258092
Material: EPDM/EPP Klüber Klübersynth BLR 46-122 10 g 03252663
®
Corrosion protection and SEW‑EURODRIVE NOCO fluid 5.5 g 09107819
lubricant
Sealant Marston Domsel SEW L Spezial 80 g 09112286
22760253/EN – 08/2016

Technical data
8 Encoders
8.8 Encoders
8.8.1 ES7. and EG7.

Encoder type ES7S EG7S ES7R EG7R ES7C EG7C
For motors DR..71 – 132 DR..160 – 280 DR..71 – 132 DR..160 – 280 DR..71 – 132 DR..160 – 280
DRN80 – 132S DRN132M – DRN80 – 132S DRN132M – DRN80 – 132S DRN132M –
280 280 280
Supply voltage VB DC 7 V – 30 V DC 7 – 30 V DC 4.75 – 30 V
Max. current consumption Iin 140 mARMS 160 mARMS 250 mARMS
Max. pulse frequency fmax 150 kHz 120 kHz 120 kHz
Periods per revolution A, B 1024 1024 1024
C 1 1 1
Output amplitude per track Vhigh 1 VSS ≥ DC 2.5 V ≥ DC 2.5 V
Vlow ≤ DC 0.5 V ≤ DC 1.1 V
Signal output Sin/cos TTL HTL
Output current per track Iout 10 mARMS 25 mARMS 60 mARMS
Pulse duty factor Sin/cos 1 : 1 ± 10 % 1 : 1 ± 10 %
Phase angle A: B 90° ± 3° 90° ± 20° 90° ± 20°
Vibration resistance ≤ 100 m/s² ≤ 100 m/s² ≤ 200 m/s² ≤ 100 m/s²
Shock resistance ≤ 1000 m/s² ≤ 2000 m/s² ≤ 1000 m/s² ≤ 2000 m/s² ≤ 1000 m/s² ≤ 2000 m/s²
Maximum speed nmax 6000 1/min 6000 1/min 6000 1/min
Degree of protection IP66 IP66 IP66
Connection Terminal box on incremental encoder
8.8.2 EH7.
Encoder type EH7R EH7T EH7C EH7S
For motors DR..315
DRN315
Supply voltage UB DC 10 V – 30 V DC 5 V DC 10 V - 30 V
Max. current consumption Iin 140 mA 225 mA 140 mA
Max. pulse frequency fmax kHz 300 180
Periods per revolution A, B 1024
C 1
Output amplitude Uhigh ≥ 2.5 V VB -3 V 1 Vss
Ulow ≤ 0.5 V ≤ 2.5 V
Signal output TTL (RS-422) HTL Sin/Cos
Output current per track Iout 20 mA 30 mA 10 mA
Pulse duty factor 1: 1 ± 20% 90° ± 10°
Phase angle A : B 90° ± 20° -
Vibration resistance at 10 Hz ≤ 100 m/s2 (EN 60088-2-6)
– 2 kHz
Shock resistance ≤ 2000 m/s2 (EN 60088-2-27)
Maximum speed nmax rpm 6000, 2500 at 60°C
Degree of protection IP65 (EN 60529)
Connection 12-pin plug connector
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Technical data
Encoders 8
8.8.3 AS7Y and AG7Y
Encoder type AS7Y AG7Y
For motors DR..71 – 132 DR..160 – 280
DRN80 – 132S DRN132M – 280
Supply voltage VB DC 7 – 30 V
Max. current consumption Iin 150 mARMS
Max. pulse frequency fmax 200 kHz
C -
Output amplitude per track Vhigh 1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Pulse duty factor Sin/cos
Phase angle A: B 90° ± 3°
Scanning code Gray code
Single-turn resolution 4096 increments/revolution
Multi-turn resolution 4096 revolutions
Data transmission synchronous-serial
Serial data output Driver to EIA RS-422
Serial pulse input Recommended receiver to EIA RS-422
Clock frequency Permitted range: 100 – 2000 kHz (max. 100 m cable length with 300 kHz)
Clock-pulse space period 12 – 30 µs
Vibration resistance ≤ 100 m/s²
Shock resistance ≤ 1000 m/s² ≤ 2000 m/s²
Maximum speed nmax 6000 1/min
Degree of protection IP66
Connection Terminal strip in pluggable connection cover
22760253/EN – 08/2016

Technical data
8 Encoders
8.8.4 AS7W and AG7W

Encoder type AS7W AG7W
For motors DR..71 – 132 DR..160 – 280
DRN80 – 132S DRN132M – 280
Max. current consumption Iin 140 mARMS
C –
Output amplitude per track Vhigh 1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Pulse duty factor Sin/cos
Phase angle A: B 90° ± 3°
Scanning code Binary code
Data transmission RS485
Serial data output Driver to EIA RS485
Serial pulse input Recommended driver to EIA RS-422
Clock frequency 9600 Bd
Clock-pulse space period – –
Vibration resistance ≤ 100 m/s² ≤ 200 m/s²
Connection Terminal strip in pluggable connection cover
22760253/EN – 08/2016

Technical data
Encoders 8
8.8.5 AH7Y
Encoder type AH7Y
For motors DR..315
DRN315
Supply voltage UB DC 9 V – 30 V
Max. current consumption Iin 160 mA
C –
Output amplitude Uhigh ≥ 2.5 VSS
Ulow ≤ 0.5 VSS
Max. pulse frequency 120 kHz
Signal output TTL (RS-422)
Output current per track Iout 20 mA
Pulse duty factor 1: 1 ± 20%
Phase angle A : B 90° ± 20°
Absolute encoder scanning code Gray Code
Data transmission of absolute value Synchronous, serial (SSI)
Serial data output Driver to EIA RS-485
Serial pulse input Optocoupler, recommended driver to EIA RS-485
Clock frequency Permitted range: 100 – 800 kHz (max. 100 m cable length with 300 kHz)
Clock-pulse space period 12 ms – 30 ms
Vibration resistance at 10 Hz – 2 kHz ≤ 100 m/s2 (EN 60088-2-6)
Shock resistance ≤ 2000 m/s2 (EN 60088-2-27)
Maximum speed nmax nmax 3500 rpm
Degree of protection IP56 (EN 60529)
Connection Terminal strip on encoder
22760253/EN – 08/2016

Technical data
8 Encoders
8.8.6 EI7. B
Encoder type EI7C EI76 EI72 EI71
For motors DR..71 – 132
DRN80 – 132S
Max. current consumption (with Imax 120 mARMS
no load)
Max. pulse frequency at nmax fmax 1.44 kHz
Periods per revolution A, B 24 6 2 1
(signal tracks) C –
Output amplitude per track Vhigh ≥ VB -3.5 V
Vlow ≤ 3 V
Signal output HTL
Maximum output current per track Iout_max 60 mARMS
Pulse duty factor 30 – 70 % (typically: 50 %)
(DIN IEC 60469-1)
t = tlog_1/(tperiod)
n = constant
Phase offset A: B 70°– 110° (typically: 90°)
φphase, A:B
n = constant
Vibration resistance 10 g (98.1 m/s2); 5 – 2000 Hz (EN 60068-2-6:2008)
Shock resistance 100 g (981 m/s2); 6 ms (EN 60068-2-27:2009)
Permitted magnetic interference Bextmax 25 mT
field on the outer contour of the Hextmax 20 kA/m
motor
Connection Terminal strip in the terminal box or M12 (4- or 8-pin)
22760253/EN – 08/2016

Technical data
Encoders 8
8.8.7 EV2.
Encoder type EV2T EV2S EV2R EV2C
For motors DR..71 – DR..225
DRN80 – 225
Supply voltage VB DC 5 V DC 9 V – 26 V
Max. current consumption Iin 160 mARMS 120 mARMS 160 mARMS 250 mARMS
C 1
Output amplitude per track Vhigh ≥ 2.5 V 1 VSS ≥ 2.5 V ≥ VB – 3.5 V
Vlow ≤ 0.5 V ≤ 0.5 V ≤ 3 V
Signal output TTL Sin/cos TTL HTL
Output current per track Iout 25 mARMS 10 mARMS 25 mARMS 60 mARMS
Pulse duty factor 1 : 1 ± 20 % Sin/cos 1 : 1 ± 20 %
Phase angle A: B 90 ° ± 20 ° 90 ° 90 ° ± 20 °
Data memory –
Vibration resistance ≤ 100 m/s²
Shock resistance ≤ 1000 m/s² ≤ 3000 m/s² ≤ 1000 m/s²
Weight m 0.36 kg
Connection Terminal box on incremental encoder
22760253/EN – 08/2016

Technical data
8 Encoders
8.8.8 EV7.
Encoder type EV7S EV7R EV7C
For motors DR..71 – 132 DR..71 – 132 DR..71 – 132
DRN80 – 132S DRN80 – 132S DRN80 – 132S
Supply voltage VB DC 7 V – 30 V DC 7 – 30 V DC 4.75 – 30 V
Max. current consumption Iin 140 mARMS 160 mARMS 250 mARMS
Max. pulse frequency fmax 150 kHz 120 kHz 120 kHz
Periods per revolution A, B 1024 1024 1024
C 1 1 1
Output amplitude per track Vhigh 1 VSS ≥ DC 2.5 V ≥ DC 2.5 V
Vlow ≤ DC 0.5 V ≤ DC 1.1 V
Signal output Sin/cos TTL HTL
Output current per track Iout 10 mARMS 25 mARMS 60 mARMS
Pulse duty factor Sin/cos 1 : 1 ± 10 % 1 : 1 ± 10 %
Phase angle A: B 90° ± 3° 90° ± 20° 90° ± 20°
Vibration resistance ≤ 100 m/s² ≤ 100 m/s² ≤ 100 m/s²
Shock resistance ≤ 1000 m/s² ≤ 1000 m/s² ≤ 1000 m/s²
Maximum speed nmax 6000 1/min 6000 1/min 6000 1/min
Degree of protection IP66 IP66 IP66
Connection Terminal box on incre-
mental encoder
22760253/EN – 08/2016

Technical data
Encoders 8
8.8.9 AV7W and AV7Y
Encoder type AV7W AS7Y
For motors DR..71 – 132 DR..160 – 280
DRN80 – 132S DRN132M – 280
Supply voltage VB DC 7 – 30 V DC 7 – 30 V
Max. current consumption Iin 140 mARMS 150 mARMS
Max. pulse frequency fmax 200 kHz 200 kHz
Periods per revolution A, B 2048 2048
C – –
Output amplitude per track Vhigh 1 VSS 1 VSS
Vlow
Signal output Sin/cos Sin/cos
Output current per track Iout 10 mARMS 10 mARMS
Pulse duty factor Sin/cos Sin/cos
Phase angle A: B 90° ± 3° 90° ± 3°
Scanning code Binary code Gray code
Single-turn resolution 8192 increments/revolution 4096 increments/revolution
Multi-turn resolution 65536 revolutions 4096 revolutions
Data transmission RS485 synchronous-serial
Serial data output Driver to EIA RS485 Driver to EIA RS-422
Serial pulse input Recommended driver to EIA RS-422 Recommended receiver to EIA RS-422
Clock frequency 9600 Bd Permitted range: 100 – 2000 kHz (max.
100 m cable length with 300 kHz)
Clock-pulse space period – 12 – 30 µs
Vibration resistance ≤ 100 m/s² ≤ 100 m/s²
Maximum speed nmax 6000 1/min 6000 1/min
Degree of protection IP66 IP66
Connection Terminal strip in pluggable connection cover Terminal strip in pluggable connection cover
22760253/EN – 08/2016

Technical data
8 Diagnostic unit /DUE
8.9 Diagnostic unit /DUE

Sensors Ø 6 mm Ø 8 mm
DUE-d6-00 DUE-d8-00
Measuring range (MB) mm 1.5 2.0
Protection class IP66 IP66
Operating temperature (sensor and cable) -50 to +150 °C -50 to +150 °C
Evaluation unit DUE-1K-00

Part number 21195609
Signal outputs (1 channel) Out1: 4 – 20 mA
FCT1: DC 24 V (150 mA)
WEAR1: DC 24 V (150 mA)
Current consumption Max. mA 190
Min. mA 40
Supply voltage DC 24 V (± 15%)
Electromagnetic compatibility DIN EN 61800‑3
Operating temperature (evaluation unit) -40 to +105 °C
Humidity ≤ 90 % rF
Protection class IP20 (in the closed terminal box up to IP66)
22760253/EN – 08/2016

Technical data
Characteristic values of functional safety 8
8.10 Characteristic values of functional safety
8.10.1 Characteristic safety values of the brakes BE05 – BE122

Definition of the characteristic safety value B10d:
The value B10d specifies the number of cycles at which 10 % of components have
failed dangerously (definition according to standard EN ISO 13849-1). Failed danger-
ously means in this context that the brake is not applied when required. This means
the brake does not deliver the necessary braking torque.
Size B10d
Switching cycles
BE05 16,000,000
BE1 12,000,000
BE2 8,000,000
BE5 6,000,000
BE11 3,000,000
BE20 2,000,000
BE30 1,500,000
BE32 1,500,000
BE60 1,000,000
BE62 1,000,000
BE120 250,000
BE122 250,000
In addition to the brakes listed above, SEW‑EURODRIVE also offers safety-rated
brakes up to size BE32. For further information, refer to the addendum to the operat-
ing instructions "Safety-Rated Brakes BE(FS) – DR..71 – 225, DRN80 – 225 AC Mo-
tors – Functional Safety".
8.10.2 Safety characteristics of safety-rated encoders

Definition of the characteristic safety value MTTFd:
The value MTTFd (Mean Time To Failure) specifies the mean time to dangerous fail-
ure / component fault.
Motors Designation MTTFd1) Service life

In years
DR..71 – 132 ES7S 61 20
DRN80 – 132S AS7W 41 20
AS7Y 41 20
22760253/EN – 08/2016
EI7C FS 202 20
DR..160 – 315 EG7S 61 20
DRN132M – 315 AG7W 41 20
AG7Y 41 20
1) Referring to an ambient temperature of 40 °C

Technical data
8 S1 duty cycle DRK.. single-phase motor
8.11 S1 duty cycle DRK.. single-phase motor

The following section describes the data for DRK.. single-phase motor in S1 continu-
ous duty.
The specified starting torques result from the connection of a running capacitor or a
running capacitor with start-up capacitor connected in parallel respectively.
S1 operation with 1500/1800 min-1 (230 V)

MA / MN with CB CA for MA/MN
PN nN IN cos φ CB 100% 150%
Motors
-1
Hz kW min A μF % μF μF
50 1450 1.53 0.81 20 50 14 25
DRK71S4 0.18
60 1755 1.38 0.87 18 45 14 25
50 1455 2.05 0.80 25 45 16 35
DRK71M4 0.25
60 1760 1.80 0.89 25 50 14 30
50 1420 2.40 0.98 18 50 12 25
DRK80S4 0.37
60 1730 2.45 0.94 15 45 12 20
50 1430 3.45 0.97 25 50 12 30
DRK80M4 0.55
60 1740 3.45 0.94 20 50 12 25
50 1430 4.75 0.93 15+15 50 20 40
DRK90M4 0.75
60 1740 4.80 0.90 25 50 18 35
50 1415 6.6 0.97 20+25 50 30 70
DRK90L4 1.1
60 1725 6.8 0.93 15+20 55 30 50
CB Running capacitor
CA Start-up capacitor
22760253/EN – 08/2016

Malfunctions
9
9 Malfunctions
WARNING
you start working.
CAUTION
Risk of burns.
NOTICE
Improper troubleshooting measures may damage the drive.
• Use only genuine spare parts in accordance with the valid spare parts list.
22760253/EN – 08/2016

Malfunctions
9 Motor malfunctions
9.1 Motor malfunctions
Fault Possible cause Measure

Motor does not start up Supply cable interrupted Check the connections and (intermediate) ter-
minal points, correct if necessary
Brake does not release See "Brake malfunctions"
Supply cable fuse has blown Replace fuse
Motor protection (switch) has Check that the motor protection (switch) is set
triggered correctly; current specification is on the name-
plate
Motor protection does not trip Check motor protection control
Malfunction in control or in the Observe the switching sequence; correct if
control process necessary
Motor only starts with Motor power designed for delta Correct the connection from star to delta;
difficulty or does not connection but connected in star Observe wiring diagram
start at all
Motor power designed for star-star Correct the connection from star to star-star;
connection but only connected in Observe wiring diagram
star
Voltage or frequency differs con- Provide better power supply system; reduce
siderably from the setpoint, at the power supply load;
least when switching on the motor
Check cross section of supply cable, replace
with cable of larger cross section if necessary
Motor does not start in Star connection does not provide If the delta inrush current is not too high (ob-
star connection, only in sufficient torque serve the regulations of the power supplier),
delta connection start up directly in delta;
Check the project planning and use a larger
motor or special design if necessary. Contact
SEW‑EURODRIVE.
Contact fault on star/delta switch Check the switch, replace if necessary;
Check the connections
Incorrect direction of Motor connected incorrectly Swap two phases of the motor supply cable
rotation
Motor hums and has Brake does not release See "Brake malfunctions"
high current consump-
Winding defective Send motor to specialist workshop for repair
tion
Rotor rubbing Send motor to specialist workshop for repair
Fuses blow or motor Short circuit in the motor supply Eliminate short circuit
protection trips immedi- cable
ately
Supply cables connected incor- Correct the connection;
22760253/EN – 08/2016
rectly Observe wiring diagram

Short circuit in the motor Send motor to specialist workshop for repair
Ground fault on motor Send motor to specialist workshop for repair

Malfunctions
Motor malfunctions 9
Severe speed loss un- Motor overload Measure power, check project planning and
der load use larger motor or reduce load if necessary
Voltage drops Check cross section of supply cable, replace
with cable of larger cross section if necessary
Motor heats up excess- Overload Measure power, check project planning and
ively (measure temper- use larger motor or reduce load if necessary
ature)
Insufficient cooling Provide for cooling air supply or clear cooling
air passages, retrofit forced cooling fan if ne-
cessary. Check the air filter, clean or replace if
necessary
Ambient temperature too high Observe the permitted temperature range, re-
duce the load if necessary
Motor in delta connection instead Correct the wiring, observe the wiring diagram
of star connection as intended
Loose contact in incoming cable Tighten loose contact, check connections, ob-
(one phase missing) serve wiring diagram
Fuse blown Look for and rectify cause (see above); re-
place fuse
Line voltage deviates from the Adjust motor to line voltage
rated motor voltage by more than
5% (range A) / 10% (range B).
Operating mode (S1 to S10, Adjust the operating mode of the motor to the
DIN 57530) exceeded, e.g. caused required operating conditions;
by excessive switching frequency
Consult a professional to determine the cor-
rect drive
Excessively loud Ball bearing compressed, dirty or Re-align motor and the driven machine, in-
damaged spect rolling bearing and replace if necessary.
Vibration of rotating parts Look for the cause, possibly an imbalance;
correct the cause, observe method for balan-
cing
Foreign objects in cooling air ducts Clean cooling air ducts
For DR.. motors with rotor desig- Reduce load
nation "J": Load too high
22760253/EN – 08/2016

Malfunctions
9 Brake malfunctions
9.2 Brake malfunctions

Brake does not re- Incorrect voltage on brake control Apply the correct voltage; brake voltage specified
lease unit on the nameplate
Brake control unit failed Renew brake control, check resistors and isolation
of the brake coils.
Check switchgear, replace if necessary
Max. permitted working air gap ex- Measure and set working air gap.
ceeded because brake lining worn If the brake disk is too thin, replace the brake disk.
down
Voltage drop along supply cable > Provide correct connection voltage: brake voltage
10 % specifications on the nameplate. Check the cross
section of the brake supply cable; increase cross
section if necessary
Inadequate cooling, brake over- Provide for cooling air supply or clear cooling air
heats passages, check air filter, clean or replace if ne-
cessary. Replace type BG brake rectifier with type
BGE
Brake coil has interturn fault or Check resistors and isolation of the brake coils;
short circuit to frame Replace complete brake and brake control (spe-
cialist workshop);
Check switchgear, replace if necessary
Rectifier defective Replace rectifier and brake coil; it may be more
economical to replace the complete brake
Brake does not Working air gap not correct Measure and set working air gap.
brake If the brake disk is too thin, replace the brake disk.
Brake lining worn down Replace entire brake disk.
Incorrect braking torque Check the dimensioning and, if necessary,
change braking torque by type and number of
brake springs, or by selecting a different brake.
Brake does not Working air gap so large that set- Set the working air gap.
brake ting nuts for the manual brake re-
lease come into contact
Manual brake release device not Set the adjusting nuts for the manual brake re-
set correctly lease correctly
Brake locked by manual brake re- Loosen the set screw, remove if needed.
lease HF
Brake is applied Brake is switched only on AC Switch both the DC and AC circuits (e.g. by retro-
with time lag voltage side fitting a SR current relay to BSR or a UR voltage
22760253/EN – 08/2016
relay to BUR);
Observe wiring diagram

Malfunctions
Malfunctions when operated with a frequency inverter 9
Noises in vicinity Gearing wear on the brake disk or Check the project planning, replace the brake disk
of brake the driver caused by jerky start-up if necessary
Have a specialist workshop replace the driver
Alternating torques due to incor- Check correct setting of frequency inverter ac-
rectly set frequency inverter cording to its operating instructions, correct if ne-
cessary.
9.3 Malfunctions when operated with a frequency inverter

The symptoms described in chapter Motor malfunctions may also occur when the mo-
tor is operated with a frequency inverter. Please refer to the frequency inverter operat-
ing instructions for the meaning of the problems that occur and to find information
about rectifying the problems.
22760253/EN – 08/2016

Malfunctions
9 Customer service
9.4 Customer service

Have the following information available if you require customer service assist-
ance:
• Nameplate data (complete)
• Nature and extent of the problem
• Time the failure occurred and any accompanying circumstances
• Assumed cause
• Ambient conditions e.g.:
– Ambient temperature
– Humidity
– Installation altitude
– Dirt
– etc.
9.5 Disposal
Dispose of the motors in accordance with the material structure and the regulations in
force:
• Iron
• Aluminum
• Copper
• Plastics
• Electronic parts
• Oil and grease (not mixed with solvents)
22760253/EN – 08/2016

Appendix
Wiring diagrams 10
10 Appendix
10.1 Wiring diagrams
INFORMATION
The motor should be connected as shown in the connection wiring diagram or the ter-
minal assignment diagram, which are supplied with the motor. The following chapter
only shows a selection of the common types of connections. You can obtain the rel-
evant wiring diagrams free of charge from SEW‑EURODRIVE.
10.1.1 Delta and star connection in wiring diagram R13 (68001 xx 06)
For all motors with one speed, direct on-line, or W/m start-up.
Delta connection
The following figure shows m connection for low voltage.
[1] [2]
W2 U2 V2
U2 V2 W2
(T6) (T4) (T5)
(T4) (T5) (T6)
U1 V1 W1
(T1) (T2) (T3) U1 V1 W1
[3] (T1) (T2) (T3)
L1 L2 L3
9007199497344139
[1] Motor winding [3] Incoming cables

[2] Motor terminal board
Star connection
The following figure shows W connection for high voltage.
[1] [2]
U2 V2 W2 W2 U2 V2
(T4) (T5) (T6) (T6) (T4) (T5)
U1 V1 W1
(T1) (T2) (T3)
U1 V1 W1
22760253/EN – 08/2016
[3] (T1) (T2) (T3)

L1 L2 L3
9007199497339147

Direction of rotation reversal: Swap connection of 2 incoming cables, L1 – L2

Appendix
10 Wiring diagrams
10.1.2 Delta connection with wiring diagram R72 (68192 xx 09)

For all motors with one speed and direct power-on.
Delta connection, Double-delta connection

The following figure shows m connection for high voltages and m m connection for
low voltages.
U1 V1 W1
T1 T2 T3
U2 V2 W2
T4 T5 T6
[1]
U3 V3 W3
T7 T8 T9
U4 V4 W4
T10 T11 T12
[2] [2]
V3 W3 U3 V3 W3 U3
T8 T9 T7 T8 T9 T7
V2 W2 U2 V2 W2 U2
T5 T6 T4 T5 T6 T4
V4 W4 U4
T11 T12 T1 V4 W4 U4
T11 T12 T10
U1 V1 W1
T1 T2 T3 U1 V1 W1
T1 T2 T3
[3] L1 L2 L3 [3]
L1 L2 L3
9007201560668427
[1] Motor winding

[3] Incoming cables
Direction of rotation reversal: Swap connection of 2 incoming cables, L1 – L2

22760253/EN – 08/2016

Appendix
Wiring diagrams 10
10.1.3 Star connection with wiring diagram R76 (68043 xx 06)
For all motors with one speed and direct power-on.
Star connection, double-star connection

The following figure shows W connection for high voltages and W W connection for low
voltages.
U1 V1 W1
T1 T2 T3
[1]
U2 V2 W2
T4 T5 T6
U3 V3 W3
T7 T8 T9
[4]
W2 U2 V2 W2 W3 U2 U3 V2 V3
T6 T4 T5 [2] T6 T9 T4 T7 T5 T8 [2]
U1 U3 V1 V3 W1 W3 U1 V1 W1
T1 T7 T2 T8 T3 T9 T1 T2 T3
[3] L1 L2 L3 [3] L1 L2 L3
2305925515

[2] Motor terminal board [4] Star point connected in motor
Direction of rotation reversal: Swap connection of 2 incoming cables, L1 - L2
22760253/EN – 08/2016

Appendix
10 Wiring diagrams
10.1.4 Motor protection with /TF or /TH for DR..71 – 280, DRN80 – 280 motors
INFORMATION
The following shows an example terminal assignment. The actual terminal assign-
ment is included in the motor delivery as wiring diagram.
/TF, /TH
The following figures show examples for connection of motor protection with /TF PTC
thermistor sensors or /TH bimetallic thermostats.
Either a two-pin terminal clip or a five-pin connection terminal is available for connect-
ing to the trip switch.
Example: /TF, /TH to 2-pin terminal strip
1b
2b
9007199728684427
1b 2b
TF/TH TF/TH
Example: 2x /TF, /TH to 5-pin terminal strip
18014398983427083
1b 2b 3b 4b 5b
1.TF/TH 1.TF/TH 2.TF/TH 2.TF/TH –
2x /TF, /TH with anti-condensation heating

The following illustration shows the connection of the motor protection with 2 /TF PTC
thermistor sensors or /TH bimetallic thermostats and Hx anti-condensation heating.
1b
2b
9007199728684427
1b 2b
22760253/EN – 08/2016
Hx Hx

Appendix
Wiring diagrams 10
18014398983427083
1b 2b 3b 4b 5b
1.TF/TH 1.TF/TH 2.TF/TH 2.TF/TH –
10.1.5 Motor protection with /TF or /TH for DR..315, DRN315 motors
INFORMATION
The following shows an example terminal assignment. The actual terminal assign-
ment is included in the motor delivery as wiring diagram.
/TF, /TH
The following figures show examples for connection of motor protection with /TF PTC
thermistor sensors or /TH bimetallic thermostats.
Depending on the version, an "x-pin" terminal strip is available for connection to the
trip switch.
Example: /TF, /TH to terminal strip
1.TF/ 1.TF/
1.TH 1.TH
473405707
Example: 2x /TF, /TH to terminal strip
1.TF/ 1.TF/ 2.TF/ 2.TF/

1.TH 1.TH 2.TH 2.TH
473410187
22760253/EN – 08/2016

Appendix
10 Wiring diagrams
10.1.6 EI7.B built-in encoder
Connection via terminal strip

The encoder is equipped with a 10-pole terminal strip.
a
c
d
b
1 10 1 4
9007207579353739
INFORMATION
The ranges 1a – 10a, 1c – 4c und 1d – 4d have been pre-configured by
SEW‑EURODRIVE. The must not be changed.
Range 1b – 10b is intended for customer adjustments.
Basic connection:
Connections 1a – 10a, 1c – 4c and 1d – 4d lead to the encoder or to the motor.
Connections 1b – 10b lead to the cable gland.
1 2 3 4 5 6 7 8 9 10 1 2 3 4
a TF11) TF11) TF21) TF21) +UB1) GND1) A1) A1) B1) B1) see below c
Opt. Opt. (GY) (PK) (BN) (WH) (YE) (GN)
b TF1 TF1 TF2 TF2 +UB GND A A B B see below d
Opt. Opt.
1) Pre-configured by SEW‑EURODRIVE. Do not alter the setting!
Pin assignment EI7C B Pin assignment EI76 B

1 2 3 4 1 2 3 4
1) 1) 1) 1) 1) 1) 1)
GND n. c. n. c. n. c. c GND n. c. n. c. n. c.1) c
(BU) (BU)
EI7C1) n. c.1) n. c.1) n. c.1) d n. c.1) EI761) n. c.1) n. c.1) d
(RD) (RD)
Pin assignment EI72 B Pin assignment EI71 B

1 2 3 4 1 2 3 4
1) 1) 1) 1) 1) 1) 1)
GND n. c. n. c. n. c. c GND n. c. n. c. n. c.1) c
(BU) (BU)
22760253/EN – 08/2016
1) 1) 1) 1)
n. c. n. c. EI72 n. c. d n. c.1) n. c.1) n. c.1) EI711) d
(RD) (RD)

Appendix
Wiring diagrams 10
Connection via M12 plug connector
A 8-pin or a 4-pin M12 plug connector is available for the connection.
4-pin M12 plug connector AVSE 8-pin M12 plug connector AVRE
• A coded Pin 1: +UB • A coded Pin 1: +UB
• Male Pin 2: B • Male Pin 2: GND
2 1
Pin 3: GND 2 1 Pin 3: A
3 7
3 4 Pin 4: A 8 6 Pin 4: A
4 5
Pin 5: B
Pin 6: B
Pin 7: TF1
Pin 8: TF1
22760253/EN – 08/2016

Appendix
10 Wiring diagrams
10.1.7 BGE, BS, BSG, BUR brake control
BG / BGE
The following illustration shows the wiring for BG and BGE brake rectifiers for the AC-
side shut-off as well as the DC and AC-side shutoff.
DC
AC AC
BGE BGE
BG BG
1 2 3 4 5 1 2 3 4 5
WH RD BU WH RD
[1] [1]
BU
U AC U AC
242604811
[1] Brake coil
BS24/BSG
The following illustration shows the DC 24 V connection of the BS24 brake protection
or BSG control unit.
BS24
BSG
1 2 3 4 5
WH RD BU
[1]
- +
24V DC
9007199497347467
22760253/EN – 08/2016
[1] Brake coil

Appendix
Wiring diagrams 10
BUR
NOTICE
Malfunction caused by incorrect brake connection for frequency inverter operation.
• Do not connect the brake to the terminal board of the motor.
The following figure shows the wiring for BUR brake control
BGE
BG
1 2 3 4 5
RD
[4]
[1]
U~ WH RD BU
(VAC ) BU
[3] [3] [2]

BN / BK
BN / BK
242608139
[1] Brake coil BN = UR 11 (42 – 150 V)

[2] UR11/UR15 voltage relay BK = UR 15 (150 – 500 V)
22760253/EN – 08/2016

Appendix
10 Wiring diagrams
10.1.8 BSR brake control

BE brake
BSR brake control for single speed drives in line operation (basic wiring diagram R13)
Brake voltage = Phase-to-neutral voltage
The white litz wires are the ends of a converter loop and, depending on the motor con-
nection, must be connected to the motor terminal block instead of the m or W bridge.
The following figure shows the factory wiring for BSR brake control.
Example
Motor: AC 230 V/AC 400 V
Brake: AC 230 V
BGE BGE
BG BG
1 2 3 4 5 1 2 3 4 5
WH RD WH RD
[1] [1]
RD BU RD BU
BU BU
[2] [2]
WH WH WH WH
W2 U2 V2
W2 U2 V2 (T6) (T4) (T5)
(T6) (T4) (T5) W1
U1 V1 W1 U1 V1 (T3)
(T1) (T2) (T3) (T1) (T2)
L1 L2 L3
L1 L2 L3
R13 connection 18014398752081803
[1] Brake coil

[2] SR10/11/15 current relay
22760253/EN – 08/2016

Appendix
Wiring diagrams 10
BGE
BG
1 2 3 4 5
WH RD
[1]
BU
RD BU
[2]
WH WH
W2 U2 V2
U1 V1 W1 [3]
L1 L2 L3
R13C connection 17564599179
[1] Brake coil

[2] SR10/11/15 current relay
[3] Terminal board
Further wiring diagrams for BSR brake control

Wiring diagrams for BSR brake control in combination to the following drives are avail-
able from SEW‑EURODRIVE upon request.
• Multi-voltage motors according to basic wiring diagram R76 or R72
• Single speed drives with cage clamp terminal KCC (basic wiring diagram C13)
22760253/EN – 08/2016

Appendix
10 Wiring diagrams
10.1.9 BMP3.1 brake control in the terminal box
INFORMATION
Separate supply cables are required for the voltage supply.
BMP3.1
The following illustration shows the wiring for the BMP3.1 brake rectifier for cut-off in
the AC circuit and cut-off in the DC and AC circuit.
U AC U AC
1 2 3 DC 1 2 3
AC AC
BMP3.1 BMP3.1
13 14 15 13 14 15
RD WH RD WH BU
[1] [1]
BU
9007199620491403
[1] Brake coil
22760253/EN – 08/2016

Appendix
Wiring diagrams 10
10.1.10 Forced cooling fan /V
Delta Steinmetz
The following figure shows the wiring of the V forced cooling fan for delta-Steinmetz
connection for 1-phase operation.
PE L1 N
U1 V1 W1
(T1) (T2) (T3)
W2 U2 V2
(T4) (T5) (T6)
U1 V1 W1
(T1) (T2) (T3)
U2 V2 W2
(T4) (T5) (T6)
L N
9007199778089483
Star connection
The following figure shows the wiring of the /V forced cooling fan for star connection.
PE L1 L2 L3
U1 V1 W1
(T1) (T2) (T3)
W2 U2 V2
(T4) (T5) (T6)
U1 V1 W1
(T1) (T2) (T3)
U2 V2 W2
(T4) (T5) (T6)
L1 L2 L3
9007199778091147
Delta connection
The following figure shows the wiring of the /V forced cooling fan for delta connection.
PE L1 L2 L3
U1 V1 W1
(T1) (T2) (T3)
W2 U2 V2
(T4) (T5) (T6)
U1 V1 W1
(T1) (T2) (T3)
22760253/EN – 08/2016
U2 V2 W2
(T4) (T5) (T6)
L1 L2 L3
18014399032833803

Appendix
10 Wiring diagrams
DC 24 V connection
The following figure shows the wiring of the /V forced cooling fan for DC 24 V.
[3]
BU RD
[2]
M [1]
=
+ -
DC 24 V
9007201648125067
[1] Forced cooling fan A Factory

[2] Terminal strip B Customer wiring
[3] Polarity reversal protection diode
NOTICE
Damage to the forced cooling fan due to incorrect connection.
• Observe the polarity when connecting the forced cooling fan.
22760253/EN – 08/2016

Appendix
Wiring diagrams 10
10.1.11 DRK... single-phase motor
ER10 wiring dia- [4] [5]
gram U1 Z1
[1]
U1 Z2 U1 Z2
U2 Z2 [2] [2]
Z1 U2
Z1 U2
[8] [8]
[7] CB [3] [3] CB
[7]
CA CA [6]
[6]
[9] [9]
11919510027
[1] Motor winding [6] Starting capacitor, switchable

[2] Motor terminal [7] Running capacitor
[3] Incoming cables [8] Further running capacitors (if avail-
[4] Counterclockwise rotation able)
[5] CW rotation, connected at factory [9] All-pole power switch
ER11 wiring dia- [4] [5]

gram W2 U2 V2 W2 U2 V2
[2] [2]
U1 V1 W1 U1 V1 W1
[1]
U2 V2 W2
T4 T5 T6
[7] [7]
[6] [6]
U1 V1 W1
T1 T2 T3
[3] CA [3] CA
[8] [8]
11919511947
[1] Motor winding [5] CW rotation, connected at factory

22760253/EN – 08/2016
[2] Motor terminal board [6] Starting capacitor, switchable

[3] Incoming cables [7] Running capacitor
[4] Counterclockwise rotation [8] All-pole power switch

Appendix
10 Auxiliary terminals 1 and 2
10.2 Auxiliary terminals 1 and 2

The following figure shows the arrangement of the auxiliary terminals for the different
terminal box positions.
Terminal box position 2 and X, here X1) Terminal box position 1 and 3, here 3
[2]
[A]
[1] [3]
[B]
[x]
3572208523
1) If auxiliary terminal 2 is not provided, you can install auxiliary terminal 1 in the same position.
[1] Terminal box position 1 [X] Terminal box position X

[2] Terminal box system 2 [A] Auxiliary terminal 1
[3] Terminal box system 3 [B] Auxiliary terminal 2
Regardless of the terminal box position, auxiliary terminal 1 must always be mounted
parallel to the terminal board.
The terminal structure can vary depending on the terminal box design.
22760253/EN – 08/2016

Address list
11
11 Address list
Algeria
Sales Algiers REDUCOM Sarl Tel. +213 21 8214-91
16, rue des Frères Zaghnoune Fax +213 21 8222-84
Bellevue http://www.reducom-dz.com
16200 El Harrach Alger info@reducom-dz.com
Argentina
Assembly Buenos Aires SEW EURODRIVE ARGENTINA S.A. Tel. +54 3327 4572-84
Sales Ruta Panamericana Km 37.5, Lote 35 Fax +54 3327 4572-21
(B1619IEA) Centro Industrial Garín http://www.sew-eurodrive.com.ar
Prov. de Buenos Aires sewar@sew-eurodrive.com.ar
Australia
Assembly Melbourne SEW-EURODRIVE PTY. LTD. Tel. +61 3 9933-1000
Sales 27 Beverage Drive Fax +61 3 9933-1003
Service Tullamarine, Victoria 3043 http://www.sew-eurodrive.com.au
enquires@sew-eurodrive.com.au
Sydney SEW-EURODRIVE PTY. LTD. Tel. +61 2 9725-9900
9, Sleigh Place, Wetherill Park Fax +61 2 9725-9905
New South Wales, 2164 enquires@sew-eurodrive.com.au
Austria
Assembly Vienna SEW-EURODRIVE Ges.m.b.H. Tel. +43 1 617 55 00-0
Sales Richard-Strauss-Straße 24 Fax +43 1 617 55 00-30
Service 1230 Wien http://www.sew-eurodrive.at
sew@sew-eurodrive.at
Bangladesh
Sales Bangladesh SEW-EURODRIVE INDIA PRIVATE LIMITED Tel. +88 01729 097309
345 DIT Road salesdhaka@seweurodrivebangladesh.com
East Rampura
Dhaka-1219, Bangladesh
Belarus
Sales Minsk Foreign unitary production enterprise SEW- Tel. +375 17 298 47 56 / 298 47 58
EURODRIVE Fax +375 17 298 47 54
RybalkoStr. 26 http://www.sew.by
220033 Minsk sales@sew.by
Belgium
Assembly Brussels SEW-EURODRIVE n.v./s.a. Tel. +32 16 386-311
Sales Researchpark Haasrode 1060 Fax +32 16 386-336
Service Evenementenlaan 7 http://www.sew-eurodrive.be
3001 Leuven info@sew-eurodrive.be
Service Competence Industrial SEW-EURODRIVE n.v./s.a. Tel. +32 84 219-878
Center Gears Rue de Parc Industriel, 31 Fax +32 84 219-879
6900 Marche-en-Famenne http://www.sew-eurodrive.be
service-IG@sew-eurodrive.be
Brazil
Production São Paulo SEW-EURODRIVE Brasil Ltda. Tel. +55 19 3835-8000
Sales Estrada Municipal José Rubim, 205 – Rodovia sew@sew.com.br
Service Santos Dumont Km 49
Indaiatuba – 13347-510 – SP
Assembly Rio Claro SEW-EURODRIVE Brasil Ltda. Tel. +55 19 3522-3100
Sales Rodovia Washington Luiz, Km 172 Fax +55 19 3524-6653
Service Condomínio Industrial Conpark montadora.rc@sew.com.br
22760253/EN – 08/2016
Caixa Postal: 327

13501-600 – Rio Claro / SP
Joinville SEW-EURODRIVE Brasil Ltda. Tel. +55 47 3027-6886
Rua Dona Francisca, 12.346 – Pirabeiraba Fax +55 47 3027-6888
89239-270 – Joinville / SC filial.sc@sew.com.br
Bulgaria
Sales Sofia BEVER-DRIVE GmbH Tel. +359 2 9151160
Bogdanovetz Str.1 Fax +359 2 9151166
1606 Sofia bever@bever.bg

Address list
11
Cameroon
Sales Douala SEW-EURODRIVE S.A.R.L. Tel. +237 233 39 02 10
Ancienne Route Bonabéri Fax +237 233 39 02 10
P.O. Box info@sew-eurodrive-cm
B.P 8674
Douala-Cameroun
Canada
Assembly Toronto SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 905 791-1553
Sales 210 Walker Drive Fax +1 905 791-2999
Service Bramalea, ON L6T 3W1 http://www.sew-eurodrive.ca
l.watson@sew-eurodrive.ca
Vancouver SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 604 946-5535
Tilbury Industrial Park Fax +1 604 946-2513
7188 Honeyman Street b.wake@sew-eurodrive.ca
Delta, BC V4G 1G1
Montreal SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 514 367-1124
2555 Rue Leger Fax +1 514 367-3677
Lasalle, PQ H8N 2V9 a.peluso@sew-eurodrive.ca
Chile
Assembly Santiago de SEW-EURODRIVE CHILE LTDA Tel. +56 2 2757 7000
Sales Chile Las Encinas 1295 Fax +56 2 2757 7001
Service Parque Industrial Valle Grande http://www.sew-eurodrive.cl
LAMPA ventas@sew-eurodrive.cl
Santiago de Chile
P.O. Box
Casilla 23 Correo Quilicura - Santiago - Chile
China
Production Tianjin SEW-EURODRIVE (Tianjin) Co., Ltd. Tel. +86 22 25322612
Assembly No. 78, 13th Avenue, TEDA Fax +86 22 25323273
Sales Tianjin 300457 http://www.sew-eurodrive.cn
Service info@sew-eurodrive.cn
Assembly Suzhou SEW-EURODRIVE (Suzhou) Co., Ltd. Tel. +86 512 62581781
Sales 333, Suhong Middle Road Fax +86 512 62581783
Service Suzhou Industrial Park suzhou@sew-eurodrive.cn
Jiangsu Province, 215021
Guangzhou SEW-EURODRIVE (Guangzhou) Co., Ltd. Tel. +86 20 82267890
No. 9, JunDa Road Fax +86 20 82267922
East Section of GETDD guangzhou@sew-eurodrive.cn
Guangzhou 510530
Shenyang SEW-EURODRIVE (Shenyang) Co., Ltd. Tel. +86 24 25382538
10A-2, 6th Road Fax +86 24 25382580
Shenyang Economic Technological Develop- shenyang@sew-eurodrive.cn
ment Area
Shenyang, 110141
Taiyuan SEW-EURODRIVE (Taiyuan) Co,. Ltd. Tel. +86-351-7117520
No.3, HuaZhang Street, Fax +86-351-7117522
TaiYuan Economic & Technical Development taiyuan@sew-eurodrive.cn
Zone
ShanXi, 030032
Wuhan SEW-EURODRIVE (Wuhan) Co., Ltd. Tel. +86 27 84478388
10A-2, 6th Road Fax +86 27 84478389
No. 59, the 4th Quanli Road, WEDA wuhan@sew-eurodrive.cn
430056 Wuhan
Xi'An SEW-EURODRIVE (Xi'An) Co., Ltd. Tel. +86 29 68686262
No. 12 Jinye 2nd Road Fax +86 29 68686311
Xi'An High-Technology Industrial Development xian@sew-eurodrive.cn
22760253/EN – 08/2016
Zone
Xi'An 710065
Sales Hong Kong SEW-EURODRIVE LTD. Tel. +852 36902200
Service Unit No. 801-806, 8th Floor Fax +852 36902211
Hong Leong Industrial Complex contact@sew-eurodrive.hk
No. 4, Wang Kwong Road
Kowloon, Hong Kong

Address list
11
Colombia
Assembly Bogota SEW-EURODRIVE COLOMBIA LTDA. Tel. +57 1 54750-50
Sales Calle 17 No. 132-18 Fax +57 1 54750-44
Service Interior 2 Bodega 6, Manzana B http://www.sew-eurodrive.com.co
Santafé de Bogotá sew@sew-eurodrive.com.co
Croatia
Sales Zagreb KOMPEKS d. o. o. Tel. +385 1 4613-158
Service Zeleni dol 10 Fax +385 1 4613-158
10 000 Zagreb kompeks@inet.hr
Czech Republic
Assembly Hostivice SEW-EURODRIVE CZ s.r.o. Tel. +420 255 709 601
Sales Floriánova 2459 Fax +420 235 350 613
Service 253 01 Hostivice http://www.sew-eurodrive.cz
sew@sew-eurodrive.cz
Drive Service +420 800 739 739 (800 SEW SEW) Service
Hotline / 24 Tel. +420 255 709 632
Hour Service Fax +420 235 358 218
servis@sew-eurodrive.cz
Denmark
Assembly Copenhagen SEW-EURODRIVEA/S Tel. +45 43 95 8500
Sales Geminivej 28-30 Fax +45 43 9585-09
Service 2670 Greve http://www.sew-eurodrive.dk
sew@sew-eurodrive.dk
Egypt
Sales Cairo Copam Egypt Tel. +202 44812673 / 79 (7 lines)
Service for Engineering & Agencies Fax +202 44812685
Building 10, Block 13005, First Industrial Zone, http://www.copam-egypt.com
Obour City Cairo copam@copam-egypt.com
Estonia
Sales Tallin ALAS-KUUL AS Tel. +372 6593230
Reti tee 4 Fax +372 6593231
75301 Peetri küla, Rae vald, Harjumaa http://www.alas-kuul.ee
veiko.soots@alas-kuul.ee
Finland
Assembly Hollola SEW-EURODRIVE OY Tel. +358 201 589-300
Sales Vesimäentie 4 Fax +358 3 780-6211
Service 15860 Hollola http://www.sew-eurodrive.fi
sew@sew.fi
Service Hollola SEW-EURODRIVE OY Tel. +358 201 589-300
Keskikankaantie 21 Fax +358 3 780-6211
15860 Hollola http://www.sew-eurodrive.fi
sew@sew.fi
Production Karkkila SEW Industrial Gears Oy Tel. +358 201 589-300
Assembly Santasalonkatu 6, PL 8 Fax +358 201 589-310
03620 Karkkila, 03601 Karkkila http://www.sew-eurodrive.fi
sew@sew.fi
France
Production Hagenau SEW-USOCOME Tel. +33 3 88 73 67 00
Sales 48-54 route de Soufflenheim Fax +33 3 88 73 66 00
Service B. P. 20185 http://www.usocome.com
67506 Haguenau Cedex sew@usocome.com
Production Forbach SEW-USOCOME Tel. +33 3 87 29 38 00
Zone industrielle
22760253/EN – 08/2016
Technopôle Forbach Sud

B. P. 30269
57604 Forbach Cedex
Brumath SEW-USOCOME Tel. +33 3 88 37 48 00
1 Rue de Bruxelles
67670 Mommenheim Cedex
Assembly Bordeaux SEW-USOCOME Tel. +33 5 57 26 39 00
Sales Parc d'activités de Magellan Fax +33 5 57 26 39 09
Service 62 avenue de Magellan – B. P. 182
33607 Pessac Cedex

Address list
11
France
Lyon SEW-USOCOME Tel. +33 4 74 99 60 00
75 rue Antoine Condorcet Fax +33 4 74 99 60 15
38090 Vaulx-Milieu
Nantes SEW-USOCOME Tel. +33 2 40 78 42 00
Parc d’activités de la forêt Fax +33 2 40 78 42 20
4 rue des Fontenelles
44140 Le Bignon
Paris SEW-USOCOME Tel. +33 1 64 42 40 80
Zone industrielle Fax +33 1 64 42 40 88
2 rue Denis Papin
77390 Verneuil I'Étang
Gabon
Sales Libreville SEW-EURODRIVE SARL Tel. +241 03 28 81 55
183, Rue 5.033.C, Lalala à droite +241 06 54 81 33
P.O. Box 15682 http://www.sew-eurodrive.cm
Libreville sew@sew-eurodrive.cm
Germany
Headquarters Bruchsal SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-0
Production Ernst-Blickle-Straße 42 Fax +49 7251 75-1970
Sales 76646 Bruchsal http://www.sew-eurodrive.de
P.O. Box sew@sew-eurodrive.de
Postfach 3023 – D-76642 Bruchsal
Production / Industrial Bruchsal SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-0
Gears Christian-Pähr-Str. 10 Fax +49 7251 75-2970
76646 Bruchsal
Production Graben SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-0
Ernst-Blickle-Straße 1 Fax +49 7251-2970
76676 Graben-Neudorf
P.O. Box
Postfach 1220 – D-76671 Graben-Neudorf
Östringen SEW-EURODRIVE GmbH & Co KG, Werk Tel. +49 7253 9254-0
Östringen Fax +49 7253 9254-90
Franz-Gurk-Straße 2 oestringen@sew-eurodrive.de
76684 Östringen
Service Competence Mechanics / SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-1710
Center Mechatronics Ernst-Blickle-Straße 1 Fax +49 7251 75-1711
76676 Graben-Neudorf scc-mechanik@sew-eurodrive.de
Electronics SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-1780
Ernst-Blickle-Straße 42 Fax +49 7251 75-1769
76646 Bruchsal scc-elektronik@sew-eurodrive.de
Drive Technology North SEW-EURODRIVE GmbH & Co KG Tel. +49 5137 8798-30
Center Alte Ricklinger Straße 40-42 Fax +49 5137 8798-55
30823 Garbsen (Hannover) dtc-nord@sew-eurodrive.de
East SEW-EURODRIVE GmbH & Co KG Tel. +49 3764 7606-0
Dänkritzer Weg 1 Fax +49 3764 7606-30
08393 Meerane (Zwickau) dtc-ost@sew-eurodrive.de
South SEW-EURODRIVE GmbH & Co KG Tel. +49 89 909552-10
Domagkstraße 5 Fax +49 89 909552-50
85551 Kirchheim (München) dtc-sued@sew-eurodrive.de
West SEW-EURODRIVE GmbH & Co KG Tel. +49 2173 8507-30
Siemensstraße 1 Fax +49 2173 8507-55
40764 Langenfeld (Düsseldorf) dtc-west@sew-eurodrive.de
Drive Center Berlin SEW-EURODRIVE GmbH & Co KG Tel. +49 306331131-30
Alexander-Meißner-Straße 44 Fax +49 306331131-36
12526 Berlin dc-berlin@sew-eurodrive.de
22760253/EN – 08/2016
Ludwigshafen SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75 3759

c/o BASF SE Fax +49 7251 75 503759
Gebäude W130 Raum 101 dc-ludwigshafen@sew-eurodrive.de
67056 Ludwigshafen
Saarland SEW-EURODRIVE GmbH & Co KG Tel. +49 6831 48946 10
Gottlieb-Daimler-Straße 4 Fax +49 6831 48946 13
66773 Schwalbach Saar – Hülzweiler dc-saarland@sew-eurodrive.de
Ulm SEW-EURODRIVE GmbH & Co KG Tel. +49 7348 9885-0
Dieselstraße 18 Fax +49 7348 9885-90
89160 Dornstadt dc-ulm@sew-eurodrive.de

Address list
11
Germany
Würzburg SEW-EURODRIVE GmbH & Co KG Tel. +49 931 27886-60
Nürnbergerstraße 118 Fax +49 931 27886-66
97076 Würzburg-Lengfeld dc-wuerzburg@sew-eurodrive.de
Drive Service Hotline / 24 Hour Service 0 800 SEWHELP
0 800 7394357
Great Britain
Assembly Normanton SEW-EURODRIVE Ltd. Tel. +44 1924 893-855
Sales DeVilliers Way Fax +44 1924 893-702
Service Trident Park http://www.sew-eurodrive.co.uk
Normanton info@sew-eurodrive.co.uk
West Yorkshire
WF6 1GX
Drive Service Hotline / 24 Hour Service Tel. 01924 896911
Greece
Sales Athens Christ. Boznos & Son S.A. Tel. +30 2 1042 251-34
12, K. Mavromichali Street Fax +30 2 1042 251-59
P.O. Box 80136 http://www.boznos.gr
18545 Piraeus info@boznos.gr
Hungary
Sales Budapest SEW-EURODRIVE Kft. Tel. +36 1 437 06-58
Service Csillaghegyí út 13. Fax +36 1 437 06-50
1037 Budapest http://www.sew-eurodrive.hu
office@sew-eurodrive.hu
Iceland
Sales Reykjavik Varma & Vélaverk ehf. Tel. +354 585 1070
Knarrarvogi 4 Fax +354 585)1071
104 Reykjavík http://www.varmaverk.is
vov@vov.is
India
Registered Office Vadodara SEW-EURODRIVE India Private Limited Tel. +91 265 3045200
Assembly Plot No. 4, GIDC Fax +91 265 3045300
Sales POR Ramangamdi • Vadodara - 391 243 http://www.seweurodriveindia.com
Service Gujarat salesvadodara@seweurodriveindia.com
Assembly Chennai SEW-EURODRIVE India Private Limited Tel. +91 44 37188888
Sales Plot No. K3/1, Sipcot Industrial Park Phase II Fax +91 44 37188811
Service Mambakkam Village saleschennai@seweurodriveindia.com
Sriperumbudur - 602105
Kancheepuram Dist, Tamil Nadu
Pune SEW-EURODRIVE India Private Limited Tel. +91 21 35 628700
Plant: Plot No. D236/1, Fax +91 21 35 628715
Chakan Industrial Area Phase- II, salespune@seweurodriveindia.com
Warale, Tal- Khed,
Pune-410501, Maharashtra
Indonesia
Sales Medan PT. Serumpun Indah Lestari Tel. +62 61 687 1221
Jl.Pulau Solor no. 8, Kawasan Industri Medan Fax +62 61 6871429 / +62 61 6871458 / +62
II 61 30008041
Medan 20252 sil@serumpunindah.com
serumpunindah@yahoo.com
http://www.serumpunindah.com
Jakarta PT. Cahaya Sukses Abadi Tel. +62 21 65310599
Komplek Rukan Puri Mutiara Blok A no 99, Fax +62 21 65310600
22760253/EN – 08/2016
Sunter csajkt@cbn.net.id
Jakarta 14350
Jakarta PT. Agrindo Putra Lestari Tel. +62 21 2921-8899
JL.Pantai Indah Selatan, Komplek Sentra In- Fax +62 21 2921-8988
dustri Terpadu, Pantai indah Kapuk Tahap III, aplindo@indosat.net.id
Blok E No. 27 http://www.aplindo.com
Jakarta 14470

Address list
11
Indonesia
Surabaya PT. TRIAGRI JAYA ABADI Tel. +62 31 5990128
Jl. Sukosemolo No. 63, Galaxi Bumi Permai Fax +62 31 5962666
G6 No. 11 sales@triagri.co.id
Surabaya 60111 http://www.triagri.co.id
Surabaya CV. Multi Mas Tel. +62 31 5458589
Jl. Raden Saleh 43A Kav. 18 Fax +62 31 5317220
Surabaya 60174 sianhwa@sby.centrin.net.id
http://www.cvmultimas.com
Ireland
Sales Dublin Alperton Engineering Ltd. Tel. +353 1 830-6277
Service 48 Moyle Road Fax +353 1 830-6458
Dublin Industrial Estate http://www.alperton.ie
Glasnevin, Dublin 11 info@alperton.ie
Israel
Sales Tel Aviv Liraz Handasa Ltd. Tel. +972 3 5599511
Ahofer Str 34B / 228 Fax +972 3 5599512
58858 Holon http://www.liraz-handasa.co.il
office@liraz-handasa.co.il
Italy
Assembly Milan SEW-EURODRIVE di R. Blickle & Co.s.a.s. Tel. +39 02 96 980229
Sales Via Bernini,14 Fax +39 02 96 980 999
Service 20020 Solaro (Milano) http://www.sew-eurodrive.it
milano@sew-eurodrive.it
Ivory Coast
Sales Abidjan SEW-EURODRIVE SARL Tel. +225 21 21 81 05
Ivory Coast Fax +225 21 25 30 47
Rue des Pêcheurs, Zone 3 info@sew-eurodrive.ci
26 BP 916 Abidjan 26 http://www.sew-eurodrive.ci
Japan
Assembly Iwata SEW-EURODRIVE JAPAN CO., LTD Tel. +81 538 373811
Sales 250-1, Shimoman-no, Fax +81 538 373814
Service Iwata http://www.sew-eurodrive.co.jp
Shizuoka 438-0818 sewjapan@sew-eurodrive.co.jp
hamamatsu@sew-eurodrive.co.jp
Kazakhstan
Sales Almaty SEW-EURODRIVE LLP Tel. +7 (727) 350 5156
291-291A, Tole bi street Fax +7 (727) 350 5156
050031, Almaty http://www.sew-eurodrive.kz
sew@sew-eurodrive.kz
Tashkent SEW-EURODRIVE LLP Tel. +998 71 2359411

Representative office in Uzbekistan Fax +998 71 2359412
96A, Sharaf Rashidov street, http://www.sew-eurodrive.uz
Tashkent, 100084 sew@sew-eurodrive.uz
Ulaanbaatar IM Trading LLC Tel. +976-77109997
Narny zam street 62 Fax +976-77109997
Sukhbaatar district, imt@imt.mn
Ulaanbaatar 14230
Kenya
Sales Nairobi SEW-EURODRIVE Pty Ltd Tel. +254 791 398840
Transnational Plaza, 5th Floor http://www.sew-eurodrive.co.tz
Mama Ngina Street info@sew.co.tz
22760253/EN – 08/2016
P.O. Box 8998-00100

Nairobi
Latvia
Sales Riga SIA Alas-Kuul Tel. +371 6 7139253
Katlakalna 11C Fax +371 6 7139386
1073 Riga http://www.alas-kuul.lv
info@alas-kuul.com

Address list
11
Lebanon
Sales (Lebanon) Beirut Gabriel Acar & Fils sarl Tel. +961 1 510 532
B. P. 80484 Fax +961 1 494 971
Bourj Hammoud, Beirut ssacar@inco.com.lb
Sales (Jordan, Kuwait , Beirut Middle East Drives S.A.L. (offshore) Tel. +961 1 494 786
Saudi Arabia, Syria) Sin El Fil. Fax +961 1 494 971
B. P. 55-378 http://www.medrives.com
Beirut info@medrives.com
Lithuania
Sales Alytus UAB Irseva Tel. +370 315 79204
Statybininku 106C Fax +370 315 56175
63431 Alytus http://www.irseva.lt
irmantas@irseva.lt
Luxembourg
representation: Belgium
Macedonia
Sales Skopje Boznos DOOEL Tel. +389 23256553
Dime Anicin 2A/7A Fax +389 23256554
1000 Skopje http://www.boznos.mk
Malaysia
Assembly Johor SEW-EURODRIVE SDN BHD Tel. +60 7 3549409
Sales No. 95, Jalan Seroja 39, Taman Johor Jaya Fax +60 7 3541404
Service 81000 Johor Bahru, Johor sales@sew-eurodrive.com.my
West Malaysia
Mexiko
Assembly Quéretaro SEW-EURODRIVE MEXICO S.A. de C.V. Tel. +52 442 1030-300
Sales SEM-981118-M93 Fax +52 442 1030-301
Service Tequisquiapan No. 102 http://www.sew-eurodrive.com.mx
Parque Industrial Quéretaro scmexico@seweurodrive.com.mx
C.P. 76220
Querétaro, México
Sales Puebla SEW-EURODRIVE MEXICO S.A. de C.V. Tel. +52 (222) 221 248
Service Calzada Zavaleta No. 3922 Piso 2 Local 6 http://www.sew-eurodrive.com.mx
Col. Santa Cruz Buenavista scmexico@seweurodrive.com.mx
C.P. 72154
Puebla, México
Mongolia
Technical Office Ulaanbaatar IM Trading LLC Tel. +976-77109997
Narny zam street 62 Tel. +976-99070395
Union building, Suite A-403-1 Fax +976-77109997
Sukhbaatar district, http://imt.mn/
Ulaanbaatar 14230 imt@imt.mn
Morocco
Sales Bouskoura SEW-EURODRIVE Morocco Tel. +212 522 88 85 00
Service Parc Industriel CFCIM, Lot 55 and 59 Fax +212 522 88 84 50
Bouskoura http://www.sew-eurodrive.ma
sew@sew-eurodrive.ma
Namibia
Sales Swakopmund DB Mining & Industrial Services Tel. +264 64 462 738
Einstein Street Fax +264 64 462 734
Strauss Industrial Park anton@dbminingnam.com
Unit1
22760253/EN – 08/2016
Swakopmund
Netherlands
Assembly Rotterdam SEW-EURODRIVE B.V. Tel. +31 10 4463-700
Sales Industrieweg 175 Fax +31 10 4155-552
Service 3044 AS Rotterdam Service: 0800-SEWHELP
Postbus 10085 http://www.sew-eurodrive.nl
3004 AB Rotterdam info@sew-eurodrive.nl

Address list
11
New Zealand
Assembly Auckland SEW-EURODRIVE NEW ZEALAND LTD. Tel. +64 9 2745627
Sales P.O. Box 58-428 Fax +64 9 2740165
Service 82 Greenmount drive http://www.sew-eurodrive.co.nz
East Tamaki Auckland sales@sew-eurodrive.co.nz
Christchurch SEW-EURODRIVE NEW ZEALAND LTD. Tel. +64 3 384-6251
30 Lodestar Avenue, Wigram Fax +64 3 384-6455
Christchurch sales@sew-eurodrive.co.nz
Nigeria
Sales Lagos Greenpeg Nig. Ltd Tel. +234-701-821-9200-1
Plot 296A, Adeyemo Akapo Str. Omole GRA http://www.greenpegltd.com
Ikeja Lagos-Nigeria bolaji.adekunle@greenpegltd.com
Norway
Assembly Moss SEW-EURODRIVE A/S Tel. +47 69 24 10 20
Sales Solgaard skog 71 Fax +47 69 24 10 40
Service 1599 Moss http://www.sew-eurodrive.no
sew@sew-eurodrive.no
Pakistan
Sales Karachi Industrial Power Drives Tel. +92 21 452 9369
Al-Fatah Chamber A/3, 1st Floor Central Com- Fax +92-21-454 7365
mercial Area, seweurodrive@cyber.net.pk
Sultan Ahmed Shah Road, Block 7/8,
Karachi
Paraguay
Sales Fernando de la SEW-EURODRIVE PARAGUAY S.R.L Tel. +595 991 519695
Mora De la Victoria 112, Esquina nueva Asunción Fax +595 21 3285539
Departamento Central sewpy@sew-eurodrive.com.py
Fernando de la Mora, Barrio Bernardino
Peru
Assembly Lima SEW EURODRIVE DEL PERU S.A.C. Tel. +51 1 3495280
Sales Los Calderos, 120-124 Fax +51 1 3493002
Service Urbanizacion Industrial Vulcano, ATE, Lima http://www.sew-eurodrive.com.pe
sewperu@sew-eurodrive.com.pe
Philippines
Sales Makati P.T. Cerna Corporation Tel. +63 2 519 6214
4137 Ponte St., Brgy. Sta. Cruz Fax +63 2 890 2802
Makati City 1205 mech_drive_sys@ptcerna.com
http://www.ptcerna.com
Poland
Assembly Łódź SEW-EURODRIVE Polska Sp.z.o.o. Tel. +48 42 293 00 00
Sales ul. Techniczna 5 Fax +48 42 293 00 49
Service 92-518 Łódź http://www.sew-eurodrive.pl
sew@sew-eurodrive.pl
Service Tel. +48 42 293 0030 24 Hour Service
Fax +48 42 293 0043 Tel. +48 602 739 739 (+48 602 SEW SEW)
serwis@sew-eurodrive.pl
Portugal
Assembly Coimbra SEW-EURODRIVE, LDA. Tel. +351 231 20 9670
Sales Av. da Fonte Nova, n.º 86 Fax +351 231 20 3685
Service 3050-379 Mealhada http://www.sew-eurodrive.pt
infosew@sew-eurodrive.pt
22760253/EN – 08/2016
Romania
Sales Bucharest Sialco Trading SRL Tel. +40 21 230-1328
Service str. Brazilia nr. 36 Fax +40 21 230-7170
011783 Bucuresti sialco@sialco.ro
Russia
Assembly St. Petersburg ЗАО «СЕВ-ЕВРОДРАЙФ» Tel. +7 812 3332522 / +7 812 5357142
Sales а. я. 36 Fax +7 812 3332523
Service 195220 Санкт-Петербург http://www.sew-eurodrive.ru
sew@sew-eurodrive.ru

Address list
11
Sambia
representation: South Africa
Senegal
Sales Dakar SENEMECA Tel. +221 338 494 770
Mécanique Générale Fax +221 338 494 771
Km 8, Route de Rufisque http://www.senemeca.com
B.P. 3251, Dakar senemeca@senemeca.sn
Serbia
Sales Belgrade DIPAR d.o.o. Tel. +381 11 347 3244 / +381 11 288 0393
Ustanicka 128a Fax +381 11 347 1337
PC Košum, IV floor office@dipar.rs
11000 Beograd
Singapore
Assembly Singapore SEW-EURODRIVE PTE. LTD. Tel. +65 68621701
Sales No 9, Tuas Drive 2 Fax +65 68612827
Service Jurong Industrial Estate http://www.sew-eurodrive.com.sg
Singapore 638644 sewsingapore@sew-eurodrive.com
Slovakia
Sales Bratislava SEW-Eurodrive SK s.r.o. Tel.+421 2 33595 202, 217, 201
Rybničná 40 Fax +421 2 33595 200
831 06 Bratislava http://www.sew-eurodrive.sk
sew@sew-eurodrive.sk
Košice SEW-Eurodrive SK s.r.o. Tel. +421 55 671 2245
Slovenská ulica 26 Fax +421 55 671 2254
040 01 Košice Mobile +421 907 671 976
sew@sew-eurodrive.sk
Slovenia
Sales Celje Pakman - Pogonska Tehnika d.o.o. Tel. +386 3 490 83-20
Service UI. XIV. divizije 14 Fax +386 3 490 83-21
3000 Celje pakman@siol.net
South Africa
Assembly Johannesburg SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 11 248-7000
Sales Eurodrive House Fax +27 11 248-7289
Service Cnr. Adcock Ingram and Aerodrome Roads http://www.sew.co.za
Aeroton Ext. 2 info@sew.co.za
Johannesburg 2013
P.O.Box 90004
Bertsham 2013
Cape Town SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 21 552-9820
Rainbow Park Fax +27 21 552-9830
Cnr. Racecourse & Omuramba Road Telex 576 062
Montague Gardens bgriffiths@sew.co.za
Cape Town
P.O.Box 36556
Chempet 7442
Durban SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 31 902 3815
48 Prospecton Road Fax +27 31 902 3826
Isipingo cdejager@sew.co.za
Durban
P.O. Box 10433, Ashwood 3605
Nelspruit SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 13 752-8007
7 Christie Crescent Fax +27 13 752-8008
Vintonia robermeyer@sew.co.za
P.O.Box 1942
22760253/EN – 08/2016
Nelspruit 1200
South Korea
Assembly Ansan SEW-EURODRIVE KOREA CO., LTD. Tel. +82 31 492-8051
Sales 7, Dangjaengi-ro, Fax +82 31 492-8056
Service Danwon-gu, http://www.sew-eurodrive.kr
Ansan-si, Gyeonggi-do, Zip 425-839 master.korea@sew-eurodrive.com

Address list
11
South Korea
Busan SEW-EURODRIVE KOREA CO., LTD. Tel. +82 51 832-0204
28, Noksansandan 262-ro 50beon-gil, Fax +82 51 832-0230
Gangseo-gu,
Busan, Zip 618-820
Spain
Assembly Bilbao SEW-EURODRIVE ESPAÑA, S.L. Tel. +34 94 43184-70
Sales Parque Tecnológico, Edificio, 302 Fax +34 94 43184-71
Service 48170 Zamudio (Vizcaya) http://www.sew-eurodrive.es
sew.spain@sew-eurodrive.es
Sri Lanka
Sales Colombo SM International (Pte) Ltd Tel. +94 1 2584887
254, Galle Raod Fax +94 1 2582981
Colombo 4, Sri Lanka
Swaziland
Sales Manzini C G Trading Co. (Pty) Ltd Tel. +268 2 518 6343
PO Box 2960 Fax +268 2 518 5033
Manzini M200 engineering@cgtrading.co.sz
Sweden
Assembly Jönköping SEW-EURODRIVE AB Tel. +46 36 34 42 00
Sales Gnejsvägen 6-8 Fax +46 36 34 42 80
Service 553 03 Jönköping http://www.sew-eurodrive.se
Box 3100 S-550 03 Jönköping jonkoping@sew.se
Switzerland
Assembly Basel Alfred lmhof A.G. Tel. +41 61 417 1717
Sales Jurastrasse 10 Fax +41 61 417 1700
Service 4142 Münchenstein bei Basel http://www.imhof-sew.ch
info@imhof-sew.ch
Taiwan
Sales Taipei Ting Shou Trading Co., Ltd. Tel. +886 2 27383535
6F-3, No. 267, Sec. 2 Fax +886 2 27368268
Tung Huw S. Road Telex 27 245
Taipei sewtwn@ms63.hinet.net
http://www.tingshou.com.tw
Nan Tou Ting Shou Trading Co., Ltd. Tel. +886 49 255353
No. 55 Kung Yeh N. Road Fax +886 49 257878
Industrial District sewtwn@ms63.hinet.net
Nan Tou 540 http://www.tingshou.com.tw
Tanzania
Sales Daressalam SEW-EURODRIVE PTY LIMITED TANZANIA Tel. +255 0 22 277 5780
Plot 52, Regent Estate Fax +255 0 22 277 5788
PO Box 106274 http://www.sew-eurodrive.co.tz
Dar Es Salaam info@sew.co.tz
Thailand
Assembly Chonburi SEW-EURODRIVE (Thailand) Ltd. Tel. +66 38 454281
Sales 700/456, Moo.7, Donhuaroh Fax +66 38 454288
Service Muang sewthailand@sew-eurodrive.com
Chonburi 20000
Tunisia
Sales Tunis T. M.S. Technic Marketing Service Tel. +216 79 40 88 77
Zone Industrielle Mghira 2 Fax +216 79 40 88 66
22760253/EN – 08/2016
Lot No. 39 http://www.tms.com.tn

2082 Fouchana tms@tms.com.tn
Turkey
Assembly Kocaeli-Gebze SEW-EURODRİVE Hareket Tel. +90 262 9991000 04
Sales Sistemleri San. Ve TIC. Ltd. Sti Fax +90 262 9991009
Service Gebze Organize Sanayi Böl. 400 Sok No. 401 http://www.sew-eurodrive.com.tr
41480 Gebze Kocaeli sew@sew-eurodrive.com.tr

Address list
11
Ukraine
Assembly Dnipropetrovsk ООО «СЕВ-Евродрайв» Tel. +380 56 370 3211
Sales ул. Рабочая, 23-B, офис 409 Fax +380 56 372 2078
Service 49008 Днепропетровск http://www.sew-eurodrive.ua
sew@sew-eurodrive.ua
Uruguay
Assembly Montevideo SEW-EURODRIVE Uruguay, S. A. Tel. +598 2 21181-89
Sales Jose Serrato 3569 Esqina Corumbe Fax +598 2 21181-90
CP 12000 Montevideo sewuy@sew-eurodrive.com.uy
USA
Production Southeast SEW-EURODRIVE INC. Tel. +1 864 439-7537
Assembly Region 1295 Old Spartanburg Highway Fax Sales +1 864 439-7830
Sales P.O. Box 518 Fax Production +1 864 439-9948
Service Lyman, S.C. 29365 Fax Assembly +1 864 439-0566
Fax Confidential/HR +1 864 949-5557
http://www.seweurodrive.com
cslyman@seweurodrive.com
Assembly Northeast SEW-EURODRIVE INC. Tel. +1 856 467-2277
Sales Region Pureland Ind. Complex Fax +1 856 845-3179
Service 2107 High Hill Road, P.O. Box 481 csbridgeport@seweurodrive.com
Bridgeport, New Jersey 08014
Midwest SEW-EURODRIVE INC. Tel. +1 937 335-0036
Region 2001 West Main Street Fax +1 937 332-0038
Troy, Ohio 45373 cstroy@seweurodrive.com
Southwest SEW-EURODRIVE INC. Tel. +1 214 330-4824
Region 3950 Platinum Way Fax +1 214 330-4724
Dallas, Texas 75237 csdallas@seweurodrive.com
Western SEW-EURODRIVE INC. Tel. +1 510 487-3560
Region 30599 San Antonio St. Fax +1 510 487-6433
Hayward, CA 94544 cshayward@seweurodrive.com
Wellford SEW-EURODRIVE INC. IGLogistics@seweurodrive.com
148/150 Finch Rd.
Wellford, S.C. 29385
Additional addresses for service provided on request!
Uzbekistan
Technical Office Tashkent SEW-EURODRIVE LLP Tel. +998 71 2359411
Representative office in Uzbekistan Fax +998 71 2359412
96A, Sharaf Rashidov street, http://www.sew-eurodrive.uz
Tashkent, 100084 sew@sew-eurodrive.uz
Vietnam
Sales Ho Chi Minh Nam Trung Co., Ltd Tel. +84 8 8301026
City Huế - South Vietnam / Construction Materials Fax +84 8 8392223
250 Binh Duong Avenue, Thu Dau Mot Town, khanh-nguyen@namtrung.com.vn
Binh Duong Province http://www.namtrung.com.vn
HCM office: 91 Tran Minh Quyen Street
District 10, Ho Chi Minh City
Hanoi MICO LTD Tel. +84 4 39386666
Quảng Trị - North Vietnam / All sectors except Fax +84 4 3938 6888
Construction Materials nam_ph@micogroup.com.vn
8th Floor, Ocean Park Building, 01 Dao Duy http://www.micogroup.com.vn
Anh St, Ha Noi, Viet Nam
22760253/EN – 08/2016

Index
Index
Icons BUR.............................................................. 206
Connecting ..................................................... 80
/DUB (Diagnostic Unit Brake) ............................ 149
Control cabinet ............................................. 177
/Hx ....................................................................... 98
Motor wiring space ....................................... 176
/LF ....................................................................... 45
Brake malfunctions ............................................ 196
/V forced cooling fan............................................ 92
Brake rectifier combinations .............................. 174
A Brake replacement
AB.., AD.., AM.., AK.., AC.., AS plug connectors 77 DR..250 – 315, DRN250 – 315 .................... 145
Add-on encoders ................................................. 94 DR..90 – 225, DRN90 – 225 ........................ 144
AG7. .................................................................... 94 DR.71 – 80, DRN80 ..................................... 143
AH7. .................................................................... 94 Brakemotor inspection
Air filter /LF .......................................................... 45 DR.71 – 315, DRN80 – 315 ......................... 129
Ambient conditions .............................................. 61 Brakemotor structure
Hazardous radiation ....................................... 61 DR..160 – 315, DRN132M – 315 ................. 128
Ambient temperature ........................................... 61 DR..71 – 80, DRN80 .................................... 126
Anti-condensation heating /Hx ............................ 98 DR..90 – 132, DRN90 – 132S ...................... 127
AS7...................................................................... 94 Braking torques ................................................. 166
Auxiliary terminals, arrangement ....................... 214 Braking work...................................................... 166
Built-in encoder ................................................. 204
B Built-in encoders.................................................. 95
Backstop............................................................ 161 C
BE05 – 2............................................................ 132
Bearing Cable gland
Reinforced ............................................ 100, 106 NPT ................................................................ 39
Bearing lubrication............................................. 105 Changing the blocking direction ........................ 161
Brake Changing the brake disk carrier
BE05 – 2....................................................... 132 BE05 – 122................................................... 138
BE05 – 20..................................................... 133 Changing the brake spring
BE120........................................................... 134 BE05 – 122................................................... 140
BE122........................................................... 135 Changing the braking torque
BE30............................................................. 134 BE05 – 122................................................... 139
BE32............................................................. 135 Changing the magnet body
BE60............................................................. 134 BE05 – 122................................................... 141
BE62............................................................. 135 Condensation drain holes.................................... 32
Braking torques ............................................ 166 Connecting diagnostic unit .................................. 84
Braking work................................................. 166 Connecting diagnostic unit /DUE....................... 153
Working air gap ............................................ 166 Connecting the motor .......................................... 62
Brake connection................................................. 80 AB.., AD.., AM.., AK.., AC.., AS plug connectors
77
22760253/EN – 08/16
Brake control ............................................... 50, 174

IS plug connector ........................................... 72
BG ................................................................ 206
KC1 terminal strip........................................... 79
BGE.............................................................. 206
KCC terminal strip .......................................... 78
BMP3.1......................................................... 210
Terminal box....................................... 63, 64, 65
BSG.............................................................. 206
via plug connector .......................................... 72
BSR .............................................................. 208

Index
via terminal board........................................... 63 EI7. ................................................................. 95

via terminal strip ............................................. 78 ES7................................................................. 94
Connection Technical data .............................................. 182
Cable ............................................................ 104 Encoder connection............................................. 97
Encoder .......................................................... 97 Encoder mounting adapter .......................... 36, 113
Variants .......................................................... 27 Equipment, optional............................................. 87
Copyright notice .................................................... 8 ES7...................................................................... 94
Customer service .............................................. 198 Exclusion of liability ............................................... 8
D Extended storage ................................................ 30
F
Delta connection
R13............................................................... 199 Forced cooling fan
R72............................................................... 200 Wiring diagram ............................................. 211
Design Forced cooling fan /V .......................................... 92
DR..315, DRN315 .................................. 21, 123 Frequency inverter operation .............................. 51
Motor ...................................................... 21, 123 Functional safety ............................................... 191
Designated use ................................................... 12 G
Diagnostic unit /DUB ........................................... 84
Diagnostic unit /DUE ......................................... 152 Gases .................................................................. 61
Disassembly General safety notes ........................................... 10
Diagnostic unit /DUE .................................... 151 Grounding............................................................ 54
Drive components, installation ............................ 33 at the terminal box.......................................... 53
DRK single-phase motor NF................................................................... 53
S1 operation ................................................. 192 H
DRK.. ................................................................... 59
Hazard symbols
DRK... single-phase motor
Meaning............................................................ 7
Wiring diagram ............................................. 213
Hollow shaft rotary encoder................................. 37
Drying
HR/HF manual brake release, retrofitting .... 43, 146
Motor .............................................................. 30
Dusts ................................................................... 61 I
E Improving the grounding...................................... 54
Inspection .......................................................... 102
EG7. .................................................................... 94
/DUB for function monitoring ........................ 149
EH7. .................................................................... 94
/DUB for wear monitoring ............................. 150
EI7 ..................................................................... 204
DUB for function and wear monitoring ......... 150
EI7. ...................................................................... 95
Inspection intervals............................................ 104
Electrical connection ........................................... 15
Installation ..................................................... 15, 32
Electrical installation ............................................ 49
Electrical......................................................... 49
Embedded safety notes......................................... 7
In damp locations or outdoors ........................ 32
EMC..................................................................... 54
Mechanical ..................................................... 29
22760253/EN – 08/16
Encoder ......................................................... 27, 94

Tolerances...................................................... 33
AG7. ............................................................... 94
XH.A encoder mounting adapter .................... 37
AH7. ............................................................... 94
Installation altitude............................................... 61
AS7................................................................. 94
Installation notes
EG7. ............................................................... 94
Encoder .......................................................... 97
EH7. ............................................................... 94

Index
Installation regulations......................................... 49 TH......................................................... 202, 203

Installation tolerances.......................................... 33 Motor protection device ....................................... 50
Installation, conditions ......................................... 29 Motor structure .................................................... 17
Insulation resistance............................................ 30 DR..160 – 180, DRN132M – 180 ........... 18, 120
Insulation, reinforced ........................................... 51 DR..200 – 225, DRN200 – 225 .............. 19, 121
Intervals for inspection and maintenance .......... 104 DR..250 – 280, DRN250 – 280 .............. 20, 122
IS plug connector ................................................ 72 DR.71 – 132 ........................................... 17, 119
Isolation transformer............................................ 30 Mounting
K Measuring nipple ............................................ 46
Mounting adapter .................................. 34, 36, 113
KC1 terminal strip ................................................ 79 Measuring nipple ............................................ 46
KCC terminal strip ............................................... 78 XH.A ............................................................. 117
KTY84-130 .......................................................... 89 XV................................................................. 115
L XV.A ............................................................. 112
Mounting XH.A .................................................... 37
Low-speed motors ............................................... 58
Low-voltage equipment ....................................... 49 N
Lubricant table ................................................... 180 Nameplate ........................................................... 22
Lubrication ......................................................... 105 Notes
M Designation in the documentation .................... 6
Meaning of the hazard symbols ....................... 7
Maintenance ...................................................... 102
Maintenance intervals ....................................... 104 O
Malfunctions ...................................................... 193 Operating currents............................................. 167
Malfunctions when operating with a frequency in- Operation with frequency inverter ....................... 51
verter ............................................................ 197
Options ................................................................ 26
Measuring nipple mounting adapter .................... 46
Electrical......................................................... 87
Mechanical installation ........................................ 29
Mechanical ..................................................... 43
Motor
Other applicable documentation............................ 8
Connect via terminal board ............................ 63
Connecting the terminal strip.......................... 78 P
Connecting via plug connector ....................... 72 Plug connector .................................................... 72
Connection ..................................................... 62 AB.., AD.., AM.., AK.., AC.., AS...................... 77
Drying ............................................................. 30 IS .................................................................... 72
Extended storage ........................................... 30 ISU ................................................................. 72
Installation ...................................................... 32 Preliminary work for motor and brake maintenance .
Motor design 107
DR..315, DRN315 .................................. 21, 123 Product names ...................................................... 8
Motor designation ................................................ 25 PT100 .................................................................. 90
Motor feet PT100 temperature detection .............................. 90
Retrofitting / modifying motor feet .................. 40 PT1000 ................................................................ 91
22760253/EN – 08/16
Motor inspection PT1000 temperature detection ............................ 91

DR..71 – 315, DRN80 – 315 ........................ 124 Pulse voltages ..................................................... 51
Motor malfunctions ............................................ 194 R
Motor protection ........................................ 202, 203
TF ......................................................... 202, 203 Reinforced bearings .................................. 100, 106
Relubrication ..................................................... 105

Index
Relubrication device .......................................... 105 Serial number ...................................................... 24

Relubrication intervals ....................................... 106 Setting the working air gap
Removing rotary encoder .................. 107, 108, 109 BE05 – 122................................................... 136
EG7. and AG7. ..................................... 108, 109 Signal words in safety notes.................................. 6
ES7. and AS7............................................... 107 Single-phase motor ............................................. 59
Removing the absolute encoder................ 112, 115 Special design ..................................................... 29
Removing the encoder ..... 107, 108, 109, 110, 112, Special features
115, 117 Low-speed motors.......................................... 58
EG7. and AG7. ..................................... 108, 109 Switching operation ........................................ 58
EH7. and AH7. ............................................. 110 Torque motors ................................................ 58
ES7. and AS7............................................... 107 Star connection
EV.., AV.., and XV.. .............................. 112, 115 R13............................................................... 199
EV.., AV.., and XV.A..................................... 112 R76............................................................... 201
Removing the hollow shaft encoder .................. 117 Startup ................................................................. 99
Removing the incremental encoder........... 112, 115 Status message evaluation unit ........................ 160
EV.., AV.., and XV.. ...................................... 115 Storage, extended ............................................... 30
EV.., AV.., and XV.A..................................... 112 Structure
Removing the rotary encoder ............................ 110 Brakemotor................................... 126, 127, 128
EH7. and AH7. ............................................. 110 DR..160 – 315, DRN132M – 315 with BE .... 128
Removing the special encoder .................. 112, 115 DR..160 – 180, DRN132M – 180 ........... 18, 120
Resistance measurement of the brake...... 170, 173 DR..200 – 225, DRN200 – 225 .............. 19, 121
Resistors............................................................ 170 DR..250 – 280, DRN250 – 280 .............. 20, 122
Retrofitting the HR/HF manual brake release .... 43, DR..71 – 80, DRN80 with BE ....................... 126
146
DR..90 – 132, DRN90 – 132S with BE......... 127
Rights to claim under limited warranty .................. 8
DR.71 – 132 ........................................... 17, 119
Rolling bearing .................................................. 178
DUB.............................................................. 148
RS ..................................................................... 161
Motor ............ 17, 18, 19, 20, 119, 120, 121, 122
S Switch contacts ................................................... 99
Switching operation ............................................. 58
Safety characteristics ........................................ 191
Safety cover ........................................................ 47 T
Safety notes
Target group ........................................................ 12
Designated use .............................................. 12
Technical data ................................................... 164
Designation in the documentation .................... 6
ASI absolute encoder ........................... 184, 189
Electrical connection ...................................... 15
Incremental rotary encoders with plug-in shaft....
General information........................................ 10 182, 188
Installation ...................................................... 15 Incremental rotary encoders with solid shaft 187
Meaning of the hazard symbols ....................... 7 Incremental rotary encoders with spread shaft ...
Operation........................................................ 16 182, 188
Preliminary information................................... 10 SSI absolute encoder ................................... 183
22760253/EN – 08/16
Structure of embedded..................................... 7 Temperature sensor KTY84-130 ......................... 89

Structure of the section-related ........................ 6 Terminal arrangement ....................................... 214
Transport ........................................................ 14 Terminal board .................................................... 63
Safety, functional ............................................... 191 Terminal box
Second shaft end ................................................ 47 Turning ........................................................... 38
Section-related safety notes .................................. 6 Terminal box positions ...................................... 214

Index
Terminal strip....................................................... 78 U

KC1 ................................................................ 79
UWU51A switched-mode power supply .............. 93
KCC................................................................ 78
TF ........................................................ 87, 202, 203 V
TF temperature sensor ........................................ 87 Vapors ................................................................. 61
TH........................................................ 88, 202, 203 Visual feedback ................................................... 95
TH winding thermostats....................................... 88
Torque motors ..................................................... 58
W
Trademarks ........................................................... 8 Waste disposal .................................................. 198
Transport ............................................................. 14 Wear .................................................................. 104
Type designation ................................................. 25 Wiring diagram
Bearing ........................................................... 28 BG ................................................................ 206
Connection variants........................................ 27 BGE.............................................................. 206
Encoder .......................................................... 27 BMP3.1......................................................... 210
Mechanical mount-on components ................ 26 R13 delta connection............................ 199, 200
Other additional features ................................ 28 R13 star connection ..................................... 199
Output types;Output types.............................. 26 R76 star connection ..................................... 201
Temperature detection ................................... 26 Wiring diagrams ................................................ 199
Temperature sensor and temperature detection . BS24............................................................. 206
26 BSG.............................................................. 206
Ventilation....................................................... 28 BSR .............................................................. 208
Type designation DR.. TF ......................................................... 202, 203
Condition monitoring ...................................... 28 TH......................................................... 202, 203
Types Working air gap ................................................. 166
Overview ........................................................ 26
22760253/EN – 08/16

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Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
Gear Units, R..7, F..7, K..7, S..7 Series, A6.B01
SPIROPLAN® W
Edition 05/2004
11226811 / EN Operating Instructions
SEW-EURODRIVE – Driving the world
Contents
1 Important Notes................................................................................................. 4
2 Safety Notes ...................................................................................................... 6
3 Gear Unit Structure ........................................................................................... 9
3.1 Basic structure of helical gear units .......................................................... 9
3.2 Basicstructure of parallel shaft helical gear units.................................... 10
3.3 Basic structure of helical-bevel gear units .............................................. 11
3.4 Basic structure of helical-worm gear units .............................................. 12
3.5 Basic structure of SPIROPLAN® gear units ............................................ 13
3.6 Nameplate, unit designation ................................................................... 14
4 Mechanical Installation................................................................................... 15
4.1 Required tools / aids ............................................................................... 15
4.2 Prerequisites for assembly...................................................................... 15
4.3 Installing the gear unit............................................................................. 16
4.4 Gear unit with solid shaft......................................................................... 19
4.5 Torque arms for mounted gear units....................................................... 21
4.6 Mounted gear unit with keyway or splined hollow shaft .......................... 23
4.7 Mounted gear units with shrink disc........................................................ 27
4.8 Mounted gear units with TorqLOC® ........................................................ 30
4.9 AM adapter coupling ............................................................................... 36
4.10 AQ adapter coupling ............................................................................... 38
4.11 AD input shaft assembly ......................................................................... 40
5 Startup.............................................................................................................. 44
5.1 Startup of helical-worm and SPIROPLAN® W gear units........................ 44
5.2 Startup of helical, parallel shaft helical and helical-bevel gear units....... 44
6 Inspection and Maintenance .......................................................................... 45
6.1 Inspection and maintenance intervals..................................................... 45
6.2 Lubricant change intervals ...................................................................... 45
6.3 Inspection and maintenance of the gear unit .......................................... 46
6.4 Inspection / maintenance of AM / AQA adapters .................................... 47
6.5 Inspection / maintenance of AD adapters ............................................... 47
7 Malfunctions .................................................................................................... 48
7.1 Gear unit malfunctions ............................................................................ 48
7.2 AM / AQA / AL adapter malfunctions ...................................................... 48
7.3 AD input shaft assembly malfunctions .................................................... 49
8 Mounting Positions......................................................................................... 50
8.1 General information on mounting positions ............................................ 50
8.2 Key to the mounting position sheets ....................................................... 51
8.3 Mounting positions for R helical gearmotors........................................... 52
8.4 Mounting positions of RX helical gearmotors.......................................... 55
8.5 Mounting positions for parallel shaft helical gearmotors ......................... 57
8.6 Mounting positions for helical-bevel gearmotors..................................... 60
8.7 Mounting positions for helical-worm gearmotors .................................... 65
8.8 Mounting positions for SPIROPLAN® W gearmotors.............................. 71
9 Lubricants........................................................................................................ 74
9.1 Lubricant table ........................................................................................ 74
9.2 Lubricant fill quantities ............................................................................ 77
10 Appendix.......................................................................................................... 82
10.1 Index of changes..................................................................................... 82
11 Index................................................................................................................. 83
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 3
Important Notes
1
1 Important Notes
Operating instructions
Safety and Always follow the safety and warning instructions in this publication!
warning
instructions
Electrical hazard
Possible consequences: Severe or fatal injuries.
Hazard
Possible consequences: Severe or fatal injuries.
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the drive and the environment.
Tips and useful information.
You must adhere to the operating instructions to ensure:

• Trouble-free operation
• Fulfillment of any rights to claim under guarantee
Consequently, read the operating instructions before you start working with the gear
unit!
The operating instructions contain important information about servicing. Therefore,
keep the operating instructions close to the gear unit.
• Adjust the lubricant fill volume and position of the breather valve accordingly in the
event of a change of mounting position (see Sec. "Lubricants" and "Mounting
Positions").
• Follow the instructions in Sec. "Mechanical installation" / "Installing the gear unit"!
4 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W
Important Notes
1
Waste disposal Please follow the latest instructions: Dispose of the following materials in accordance
with the regulations in force:
• Steel scrap:
– Housing parts
– Gears
– Shafts
– Anti-friction bearing
– Gray-cast iron (if there is no special collection)
• Parts of the worm gears are made of non-ferrous metals. Dispose of the worm gears
as appropriate.
• Collect waste oil and dispose of it correctly.
Safety Notes
2
2 Safety Notes
Preface The following safety notes are primarily concerned with the use of gear units. If using
gearmotors, please also refer to the safety notes for motors in the relevant operating
instructions.
Please also consider the supplementary safety notes in the individual sections of
these operating instructions.
General During and after operation, gearmotors, gear units and motors have:
information • Live parts
• Moving parts
• Hot surfaces (may be the case)
Only qualified personnel may carry out the following work:
• Transportation
• Putting into storage
• Installation / assembly
• Connection
• Startup
• Maintenance
• Servicing
The following information and documents must be observed during these processes:
• Relevant operating instructions and wiring diagrams
• Warning and safety signs on the gear unit / gearmotor
• System-specific regulations and requirements
• National / regional regulations governing safety and the prevention of accidents
Serious injuries and property damage may result from:
• Improper use
• Incorrect installation or operation
• Unauthorized removal of necessary protection covers or the housing
Designated use Gearmotors / gear units from SEW are intended for industrial systems. They correspond
to the applicable standards and regulations.
Technical data and information about the permitted conditions can be found on the
nameplate and in the documentation.
It is essential that you follow all the instructions!
Safety Notes
2
Transportation Inspect the shipment for any damage that may have occurred in transit as soon
as you receive the delivery. Inform the shipping company immediately. It may be
that you are not permitted to startup the drive due to the damage.
Tighten installed eyebolts. The eyebolts are only designed for the weight of the
gearmotor / gear unit. Do not attach any additional loads.
The installed lifting eyebolts comply with DIN 580. The loads and regulations specified
in this standard must always be observed. If two eyebolts are available, use both of them
for transport. In this case, the tension force vector of the slings must not exceed a 45°
angle in accordance with DIN 580.
Use suitable, sufficiently rated handling equipment if necessary. Remove any
transportation fixtures prior to startup.
Extended stor- Gear units of the "extended storage" type have:

age of gear units • An oil fill suitable for the mounting position so the unit is ready to run (mineral oil CLP
and synthetic oil CLP HC). You should still check the oil level before startup (see Sec.
"Inspection / Maintenance" / "Inspection and maintenance of the gear unit").
• A higher oil level in some cases (synthetic oil CLP PG / food grade oil). Correct the
oil level before startup (see Sec. "Inspection / Maintenance" / "Inspection and
maintenance of the gear unit").
Comply with the storage conditions specified in the following table for extended storage:
Climate zone Packaging1) Storage location Storage time
Up to three years with regular
Packed in containers, with
checks on the packaging and
desiccant and moisture With roof, protected against rain and snow, no
moisture indicator (relative
Temperate indicator sealed in the plas- shock loads.
atmospheric humidity
(Europe, USA, tic wrap.
< 50 %).
Canada, China
and Russia, With roof, enclosed at constant temperature and Two years or more given reg-
excluding tropi- atmospheric humidity (5 °C < ϑ < 60 °C, < 50 % ular inspections. Check for
cal zones) relative atmospheric humidity). cleanliness and mechanical
Open
No sudden temperature fluctuations and con- damage as part of the inspec-
trolled ventilation with filter (free from dirt and tion. Check corrosion
dust). No aggressive vapors and no shock loads. protection.
Packed in containers, with
desiccant and moisture Up to three years with regular
indicator sealed in the plas- checks on the packaging and
tic wrap. With roof, protected against rain, no shock loads. moisture indicator (relative
Tropical (Asia, Protected against insect atmospheric humidity
Africa, Central damage and mildew by < 50 %).
and South Amer- chemical treatment.
ica, Australia,
New Zealand With roof, enclosed at constant temperature and
Two years or more given reg-
excluding temper- atmospheric humidity (5 °C < ϑ < 60 °C, < 50 %
ular inspections. Check for
ate zones) relative atmospheric humidity).
cleanliness and mechanical
Open No sudden temperature fluctuations and con-
damage as part of the inspec-
trolled ventilation with filter (free from dirt and
tion. Check corrosion
dust). No aggressive vapors and no shock loads.
protection.
Protection against insect damage.
1) Packaging must be performed by an experienced company using the packaging materials that have been expressly specified for the
particular application.
Safety Notes
2
Installation / Observe the instructions in the sections "Installation" and "Assembly/Removal"!

assembly
Startup / Check that the direction of rotation is correct in decoupled status. Listen out for unusual
operation grinding noises as the shaft rotates.
Secure the shaft keys for test mode without drive components. Do not render monitoring
and protection equipment inoperative even for test mode.
Switch off the gearmotor if in doubt whenever changes occur in relation to normal
operation (e.g. increased temperature, noise, vibration). Determine the cause; contact
SEW-EURODRIVE if necessary.
Inspection / Follow the instructions in the section "Inspection and Maintenance"!

maintenance
Gear Unit Structure
Basic structure of helical gear units
3
3 Gear Unit Structure
The following figures are block diagrams. Their purpose is only to make it easier to
assign components to the spare parts lists. Discrepancies may occur depending on the
gear unit size and version!
3.1 Basic structure of helical gear units
03438AXX
Figure 1: Basic structure of helical gear units
Key
1 Pinion 19 Key 42 Anti-friction bearing 507 Shim ring
2 Gear 20 Breather valve 43 Key 508 Shim ring
3 Pinion shaft 22 Gearcase 45 Anti-friction bearing 515 Shim ring
4 Gear 24 Lifting eyebolt 47 Circlip 516 Shim ring
5 Pinion shaft 25 Anti-friction bearing 59 Screw plug 517 Shim ring
6 Gear 30 Anti-friction bearing 88 Circlip 521 Shim ring
7 Output shaft 31 Key 100 Gearcase cover 522 Shim ring
8 Key 32 Spacer 101 Hex head bolt 523 Shim ring
9 Oil seal 34 Anti-friction bearing 102 Gasket
11 Anti-friction bearing 37 Anti-friction bearing 131 Closing cap
12 Circlip 39 Circlip 181 Closing cap
17 Spacer 41 Circlip 506 Shim ring
Gear Unit Structure
3 Basicstructure of parallel shaft helical gear units
3.2 Basicstructure of parallel shaft helical gear units
2 45 20
59
43 22
515 1
516 42 3
517
181 41
161
4 30
32
59
31
5
506 37
507 39 183
508
131 165
160
19
102
94 521 88
93 25 522 100
92 523
91
101
7
59
17
9 11 6
81
14
16
05676AXX
Figure 2: Basic structure of parallel shaft helical gear units
Key
1 Pinion 22 Gearcase 91 Circlip 506 Shim ring
2 Gear 25 Anti-friction bearing 92 Washer 507 Shim ring
3 Pinion shaft 30 Anti-friction bearing 93 Lock washer 508 Shim ring
4 Gear 31 Key 94 Hex head bolt 515 Shim ring
5 Pinion shaft 32 Spacer 100 Gearcase cover 516 Shim ring
6 Gear 37 Anti-friction bearing 101 Hex head bolt 517 Shim ring
7 Hollow shaft 39 Circlip 102 Gasket 521 Shim ring
9 Oil seal 41 Circlip 131 Closing cap 522 Shim ring
11 Anti-friction bearing 42 Anti-friction bearing 160 Closing plug 523 Shim ring
14 Hex head bolt 43 Key 161 Closing cap
16 Output flange 45 Anti-friction bearing 165 Closing plug
17 Spacer 59 Screw plug 181 Closing cap
19 Key 81 O-ring 183 Oil seal
20 Breather valve 88 Circlip
Gear Unit Structure
Basic structure of helical-bevel gear units
3
3.3 Basic structure of helical-bevel gear units
100 102
20
536
3 43 537 533 59
534 22
538
535
45 2
114
101 113
42 119 59
(116)
523 89 59
522 88
521
25
1
84
19
7 59
8
6 59
17
83
11
12
9 161
132
133
31 542
30 543
135 544
4
5
131 37
506
507
137 508
39
05675AXX
Figure 3: Basic structure of helical-bevel gear units
Key
1 Pinion 25 Anti-friction bearing 102 Adhesive and sealing 522 Shim ring
compound
2 Gear 30 Anti-friction bearing 113 Slotted round nut 523 Shim ring
3 Pinion shaft 31 Key 114 Multi-tang washer 533 Shim ring
4 Gear 37 Anti-friction bearing 116 Thread lock 534 Shim ring
5 Pinion shaft 39 Circlip 119 Spacer 535 Shim ring
6 Gear 42 Anti-friction bearing 131 Closing cap 536 Shim ring
7 Output shaft 43 Key 132 Circlip 537 Shim ring
8 Key 45 Anti-friction bearing 133 Spacer 538 Shim ring
9 Oil seal 59 Screw plug 135 Nilos ring 542 Shim ring
11 Anti-friction bearing 83 Nilos ring 161 Closing cap 543 Shim ring
12 Circlip 84 Nilos ring 506 Shim ring 544 Shim ring
17 Spacer 88 Circlip 507 Shim ring
19 Key 89 Closing cap 508 Shim ring
20 Breather valve 100 Gearcase cover 521 Shim ring
22 Gearcase 101 Hex head bolt 521 Shim ring
Gear Unit Structure
3 Basic structure of helical-worm gear units
3.4 Basic structure of helical-worm gear units
59
101 20
100
131
39 506
137
507
37 102
22
5
43 30 2 61 59
19
89
88 59
523
25 522
521
6
11
520
12 519
518
9
50884AXX
Figure 4: Basic structure of helical-worm gear units
Key
1 Pinion 20 Breather valve 88 Circlip 518 Shim ring
2 Gear 22 Gearcase 89 Closing cap 519 Shim ring
5 Worm 25 Anti-friction bearing 100 Gearcase cover 520 Shim ring
6 Worm gear wheel 30 Anti-friction bearing 101 Hex head bolt 521 Shim ring
7 Output shaft 37 Anti-friction bearing 102 Rubber seal 522 Shim ring
9 Oil seal 39 Circlip 131 Closing cap 523 Shim ring
11 Anti-friction bearing 43 Key 137 Spacer
12 Circlip 59 Screw plug 506 Shim ring
19 Key 61 Circlip 507 Shim ring
Gear Unit Structure
Basic structure of SPIROPLAN® gear units
3
3.5 Basic structure of SPIROPLAN® gear units

100 101
102 65 66 143
71 68
72
1
22
89
88
521
522
523
25
19 250
251
17
8
7
11
518
519
520
12
9
05674AXX
Figure 5: Basic structure of SPIROPLAN® gear units
Key
1 Pinion 19 Key 88 Circlip 251 Circlip
6 Gear 22 Gearcase 89 Closing cap 518 Shim ring
7 Output shaft 25 Anti-friction bearing 100 Gearcase cover 519 Shim ring
8 Key 65 Oil seal 101 Hex head bolt 520 Shim ring
9 Oil seal 66 Anti-friction bearing 102 Gasket 521 Shim ring
11 Anti-friction bearing 71 Spacer 132 Circlip 522 Shim ring
12 Circlip 72 Circlip 183 Oil seal 523 Shim ring
17 Spacer 143 Spacer 250 Circlip
Gear Unit Structure
3 Nameplate, unit designation
3.6 Nameplate, unit designation

Sample nameplate
06687ADE
Figure 6: Sample nameplate
fb = Service factor
FRa max [N] = Maximum overhung load on the output side
FRe max [N] = Maximum overhung load on the input side (with input shaft assembly AD)
i = Gear unit reduction ratio
IM = Mounting position
IP.. = Enclosure
ne max [1/min] = Maximum input speed
na [1/min] = Output speed
Me max [Nm] = Maximum input torque
Ma [Nm] = Output torque
MR [Nm] = Overload torque when using an AR adapter
MRS [Nm] = Locking torque of the backstop
Unit designation
Example: Helical gear unit, category II2GD
RF 47 / A / II2GD
Explosion-proof design to directive 94/9/EC
For direct motor mounting
Gear unit size
Helical gear unit series (flange mounted)
Example: Serial number

3229561201. 0001. 03
Year number end digits of the year of manufacture (2-digit)
Part number (4-digit)
Order number (10 digits)
Mechanical Installation
Required tools / aids
4
4 Mechanical Installation
4.1 Required tools / aids
• Set of spanners
• Torque wrench for:
– Shrink discs
– AQH motor adapter
– Input shaft assembly with centering shoulder
• Mounting device
• Shims and distance rings if necessary
• Fixing devices for input and output elements
• Lubricant (e.g. NOCO® Fluid)
• Bolt adhesive (for input shaft assembly with centering shoulder), e.g. Loctite® 243
• Standard parts are not part of the delivery
Installation
tolerances
Shaft end Flanges
Diameter tolerance in accordance with DIN 748 Centering shoulder tolerance in accordance with
• ISO k6 for solid shafts with ∅ ≤ 50 mm DIN 42948
• ISO m6 for solid shafts with ∅ > 50 mm • ISO j6 with b1 ≤ 230 mm
• ISO H7 for hollow shafts • ISO h6 with b1> 230 mm
• Center bore in accordance with DIN 332, shape
DR
4.2 Prerequisites for assembly

Check that the following conditions have been met:
• The data on the nameplate of the gearmotor matches the voltage supply system.
• The drive has not been damaged during transportation or storage.
• Ensure that the following requirements have been met:
– For standard gear units:
Ambient temperature according to the lubricant table in Sec. "Lubricants" (see
standard).
The drive must not be assembled in the following ambient conditions:
– Potentially explosive atmosphere
– Oil
– Acids
– Gas
– Vapors
– Radiation
– For special versions:
The drive configured in accordance with the ambient conditions.
– For helical-worm / SPIROPLAN® W gear units:
No large external mass moments of inertia which could exert a retrodriving load
on the gear unit.
[At η’ (retrodriving) = 2 – 1/η < 0.5 self-locking]
4 Installing the gear unit
• You must clean the output shafts and flange surfaces thoroughly to ensure they are
free of anti-corrosion agents, contamination or similar. Use a commercially available
solvent. Do not let the solvent come into contact with the sealing lips of the oil seals
– danger of damage to the material!
• When the drive is installed in abrasive ambient conditions, protect the output end oil
seals against wear.
4.3 Installing the gear unit

The gear unit or gearmotor is only allowed to be installed in the specified mounting
position. SPIROPLAN® gear units are not dependent on the mounting position.
The support structure must have the following characteristics:
• Level
• Vibration damping
• Torsionally rigid
Maximum permitted flatness error for foot and flange mounting (approximate values with
reference to DIN ISO 1101):
• Gear unit size ≤ 67: max. 0.4 mm
• Gear unit size 77 ... 107: max. 0.5 mm
Do not tighten the housing legs and mounting flanges against one another and ensure
that you comply with the permitted overhung and axial loads!
Secure the gearmotors with bolts of quality 8.8.
Secure the following gearmotors with bolts of quality 10.9:
• RF37, R37F with flange ∅ 120 mm
The oil checking and drain screws and the breather valves must be freely
accessible!
At the same time, also check that the oil fill is as specified for the mounting position (see
Sec. "Lubricants" / "Lubricant fill quantities" or refer to the information on the nameplate).
The gear units are filled with the required oil volume at the factory. There may be slight
deviations at the oil level plug as a result of the mounting position, which are permitted
within the manufacturing tolerances.
Installing the gear unit
4
Adjust the lubricant fill volumes and the position of the breather valve accordingly
in the event of a change of mounting position.
Please contact our SEW customer service if you change the mounting position of K gear
units to M5 or M6 or between M5 and M6.
Please contact our SEW customer service if you change the mounting position of size
S47 S97 S gear units to mounting position M2.
Use plastic inserts (2 ... 3 mm thick) if there is a risk of electrochemical corrosion
between the gear unit and the driven machine. The material used must have an electri-
cal bleeder resistor < 109 Ω. Electrochemical corrosion can occur between various
metals, for example, cast iron and high-grade steel. Also install the bolts with plastic
washers! Ground the housing additionally – use the grounding bolts on the motor.
Installation in Drives are supplied in corrosion-resistant versions for use in damp areas or in the open
damp locations or air. Repair any damage to the paint work (e.g. on the breather valve).
in the open When mounting the motors onto AM, AQ, AR, AT adapters, seal the flange areas with a
suitable sealing compound, e.g. Loctite® 574.
4 Installing the gear unit
Gear unit venting No breather plug is required for the following gear units:
• R07 in mounting positions M1, M2, M3, M5 and M6
• R17, R27 and F27 in mounting positions M1, M3, M5 and M6
• SPIROPLAN® W gear units
SEW-EURODRIVE supplies all other gear units with the breather valve installed and
activated according to the particular mounting position.
Exceptions:
1. SEW supplies the following gear units with a screw plug on the vent hole provided:
• Gear units for extended storage
• Pivoted mounting positions, if possible
• Gear units for mounting on a slant
The breather valve is located in the motor terminal box. Before startup, you must re-
place the highest screw plug with the breather valve supplied.
2. SEW supplies a breather valve in a plastic bag for gear head units requiring venting
on the input end.
3. Enclosed gear units are supplied without a breather valve.
Activating the As a rule, the breather valve is already activated at the factory. If the breather valve has
breather valve not been activated, you must remove the transport fixture from the breather valve before
starting up the gear unit!
1. Breather valve with 2. Remove the transport fixture 3. Breather valve activated
transport fixture
02053BXX 02054BXX 02055BXX
Painting the gear If you paint or respray the drive, ensure that you cover the breather valve and oil seals
unit carefully. Remove the strips of tape after completing the painting work.
Gear unit with solid shaft
4
4.4 Gear unit with solid shaft

Installing input The following figure shows a mounting device for installing couplings or hubs on gear
and output unit or motor shaft ends. It may be possible to dispense with the thrust bearing on the
elements mounting device.
1) Gear shaft end

2) Thrust bearing
3) Coupling hub
03371BXX
Avoid impermissibly high overhung loads: Install the gear or chain sprocket according
to figure B.
1 = Hub
A = Unfavorable
B = Correct
03369BXX
• Only use a mounting device for installing input and output elements. Use the center
bore and the thread on the shaft end for positioning.
• Never drive belt pulleys, couplings, pinions, etc. onto the shaft end by hitting
them with a hammer This will damage the bearings, housing and the shaft!
• In the case of belt pulleys, make sure the belt is tensioned correctly in accor-
dance with the manufacturer's instructions.
• Power transmission elements should be balanced after fitting and must not give rise
to any impermissible radial or axial forces (see the "Gearmotor" or "Explosion-Proof
Drives" catalogs for permitted values).
Note:
Assembly is easier if you first apply lubricant to the output element or heat it up briefly
(to 80 ... 100 °C).
4 Gear unit with solid shaft
Installing Couplings must be mounted and balanced according to the information provided by the
couplings coupling manufacturer:
a) Maximum and minimum clearance
b) Axial misalignment
c) Angular misalignment
a) b) c)
03356AXX
Figure 7: Clearance and misalignment for coupling installation
Input and output elements such as belt pulleys, couplings, etc. must be protected
against contact!
Torque arms for mounted gear units
4
4.5 Torque arms for mounted gear units

Do not place torque arms under strain during installation!
Parallel shaft
helical gear units
01029BXX
Figure 8: Torque arm for parallel shaft helical
gear units
Helical-bevel gear • Bush with bearings on both ends → (1).

units • Install connection end B as a mirror image of A.
01030CXX
Figure 9: Torque arm for helical-bevel gear units
Gear unit Bolts Tightening torque
KA37 4 × M10 × 25 – 8.8 48 Nm
KA47 4 × M10 × 30 – 8.8 48 Nm
KA67 4 × M12 × 35 – 8.8 86 Nm
KA77 4 × M16 × 40 – 8.8 210 Nm
KA87 4 × M16 × 45 – 8.8 210 Nm
KA97 4 × M20 × 50 – 8.8 410 Nm
KA107 4 × M24 × 60 – 8.8 710 Nm
KA127 4 × M36 × 130 – 8.8 2500 Nm
KA157 4 × M36 × 130 – 8.8 2500 Nm
4 Torque arms for mounted gear units
Helical-worm • Bush with bearings on both ends → (1).

gear units
01031CXX
Figure 10: Torque arm for helical-worm gear units
SA37 M6 × 16 – 8.8 11 Nm
SA47 M8 × 20 – 8.8 25 Nm
SA57 M8 × 20 – 8.8 25 Nm
SA67 M12 × 25 – 8.8 86 Nm
SA77 M12 × 35 – 8.8 86 Nm
SA87 M16 × 35 – 8.8 210 Nm
SA97 M16 × 35 – 8.8 210 Nm
SPIROPLAN® W • Bush with bearings on both ends → (1)

gear units
45°
(1)
02050CXX
Figure 11: Torque arm for SPIROPLAN® W gear units
WA10 M6 × 16 11 Nm
WA20 M6 × 16 11 Nm
WA30 M6 × 16 11 Nm
Mounted gear unit with keyway or splined hollow shaft
4
4.6 Mounted gear unit with keyway or splined hollow shaft
For the configuration of customer shafts, please also refer to the design notes in the
Gearmotors catalog!
Installation notes 1. Apply NOCO® fluid.
®
O
C
O I
N U
L
F
®
O
C
O I
N U
L
F
02042BXX
2. Distribute the NOCO® fluid carefully.
02043AXX
3. Install the shaft and secure it axially

(mounting is facilitated by using a mounting device)
3A: Mounting with standard scope of delivery
1
2 1 Short retaining bolt
3 (standard scope of delivery)
4 2 Lock washer
A 3
4
Washer
Circlip
6 Customer shaft
6
03361BXX
4 Mounted gear unit with keyway or splined hollow shaft
3B: Assembly with SEW-EURODRIVE assembly/disassembly kit (→ page 26)

– Customer's shaft with contact shoulder
1 1 Retaining bolt
2 2 Lock washer
3
4 3 Washer
B 4
6
Circlip
Customer's shaft with contact
shoulder
6
03362BXX
3C: Assembly with SEW-EURODRIVE assembly/disassembly kit (→ page 26)

– Customer's shaft without contact shoulder
1 1 Retaining bolt
23 2 Lock washer
4 3 Washer
5 4 Circlip
5 Spacer
C 6 Customer's shaft without
contact shoulder
6
03363AXX
4. Tighten the retaining bolt to the appropriate torque (see table).

Bolt Tightening torque
[Nm]
M5 5
M6 8
M10/12 20
M16 40
M20 80
M24 200
03364AXX
Note:
To avoid contact corrosion, we recommend that the customer's shaft should additionally
be recessed between the two contact surfaces!
Mounted gear unit with keyway or splined hollow shaft
4
Removal notes This description is only applicable when the gear unit was assembled using the installa-
tion/removal kit from SEW-EURODRIVE(→ page 26) (see the previous description,
point 3B or 3C).
1. Loosen the retaining bolt [1].
2. Remove parts 2 to 4 and, if fitted, spacer 5.
1
2 1 Retaining bolt
3 2 Lock washer
4
5 3 Washer
4 Circlip
5 Spacer
6 Customer shaft
03366AXX
3. Insert the forcing washer [8] and the fixed nut [7] from the SEW-EURODRIVE instal-
lation/removal kit between the customer's shaft [6] and the circlip [4].
4. Re-insert the circlip [4].
5. Screw the retaining bolt [1] back in. Now you can force the gear unit off the shaft by
tightening the bolt.
1
1 Retaining bolt
4 4 Circlip
7 6 Customer shaft
8
7 Fixed nut
8 Forcing washer
03367AXX
4 Mounted gear unit with keyway or splined hollow shaft
SEW The SEW-EURODRIVE installation/removal kit can be ordered under the following part
installation/remo number.
val kit
8 7
03394AXX
Figure 12: SEW-EURODRIVE installation/removal kit
1 Retaining bolt
7 Fixed nut for disassembly
8 Forcing washer
Type DH7 M1) C4 C5 C6 U-0.5 T -0.5 D3-0.5 L4 Part number of

[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] installa-
tion/removal kit
WA..10 16 M5 5 5 12 4.5 18 15.7 50 643 712 5
WA..20 18 M6 5 6 13.5 5.5 20.5 17.7 25 643,682 X
WA..20, WA..30, SA..37 20 M6 5 6 15.5 5.5 22.5 19.7 25 643 683 8
FA..27, SA..47 25 M10 5 10 20 7.5 28 24.7 35 643 684 6
FA..37, KA..37, SA..47, SA..57 30 M10 5 10 25 7.5 33 29.7 35 643 685 4
FA..47, KA..47, SA..57 35 M12 5 12 29 9.5 38 34.7 45 643 686 2
FA..57, KA..57, FA..67, KA..67, SA..67 40 M16 5 12 34 11.5 41.9 39.7 50 643 687 0
SA..67 45 M16 5 12 38.5 13.5 48.5 44.7 50 643 688 9
FA..77, KA..77, SA..77 50 M16 5 12 43.5 13.5 53.5 49.7 50 643 689 7
FA..87, KA..87, SA..77, SA..87 60 M20 5 16 56 17.5 64 59.7 60 643 690 0
FA..97, KA..97, SA..87, SA..97 70 M20 5 16 65.5 19.5 74.5 69.7 60 643 691 9
FA..107, KA..107, SA..97 90 M24 5 20 80 24.5 95 89.7 70 643 692 7
FA..127, KA..127 100 M24 5 20 89 27.5 106 99.7 70 643 693 5
FA..157, KA..157 120 M24 5 20 107 31 127 119.7 70 643 694 3
1) Retaining bolt
The SEW assembly kit for mounting the customer shaft is a recommendation from SEW-EURODRIVE.
You must always check whether this design can compensate the axial loads. In particular applications (e.g.
mounting mixer shafts), a different design may have to be used to secure the shaft axially. In these cases,
customers can use their own devices. However, you must ensure that these designs do not cause potential
sources of combustion according to DIN EN 13463 (for example, impact sparks).
Mounted gear units with shrink disc
4
4.7 Mounted gear units with shrink disc

Installation notes • Do not tighten the locking bolts unless the shaft is installed - the hollow shaft could
become deformed!
1. Loosen the locking bolts by a few turns 2. Carefully degrease the hollow shaft hole
(do not unscrew them completely!). and the input shaft.
A B
51092AXX 51093AXX
3. Hollow shaft/input shaft after degreasing 4. Apply NOCO® fluid to the input shaft1) in
the area of the bushing.
51094AXX 51095AXX
1) It is essential to make sure that the clamping area of the shrink disk is free from
grease!
For this reason, never apply NOCO® fluid directly to the bushing as the paste may
be able to get into the clamping area of the shrink disk when the input shaft is put
on.
4 Mounted gear units with shrink disc
5. Install the input shaft, making sure that the locking collars of the shrink disk are in-
stalled in parallel to each other2). For gear unit housing with a shaft collar, mount
the shrink disc to the stop on the shaft collar. For gear unit housing without a
shaft collar, mount the shrink disk with a clearance of 1 to 2 mm from the gear
unit housing. Tighten the locking bolts with the torque wrench by working round
several times from one bolt to the next (not in diametrically opposite sequence) until
the bolts cannot be tightened any more. See the following table for tightening
torques.
1-2mm s>1mm
51096AXX
2)After
installation
• There must be a gap s > 1 mm between the locking collars
• Grease the outside of the hollow shaft in the area of the shrink disk to prevent corro-
sion.
Gear unit type Bolt Nm max.1)
SH37 M5 5
KH37...77 FH37...77 SH47...77 M6 12
KH87/97 FH87/97 SH87/97 M8 30
KH107 FH107 M10 59 60°
KH127/157 FH127 M12 100
KH167 M16 250
KH187 M20 470
1) Maximum tightening angle per cycle
Mounted gear units with shrink disc
4
Notes on 1. Unscrew the locking bolts evenly one after the other. Each locking bolt may only be
removing the unscrewed by about one quarter turn in the initial cycle. This is in order to avoid tilting
shrink disk and jamming the locking collars. Do not fully unscrew the locking bolts!
2. Remove the shaft or pull the hub off the shaft. (You must first remove any rust that
may have formed between the hub and the end of the shaft.)
3. Pull the shrink disk off the hub.
Caution!
Risk of injury if the shrink disk is not removed correctly!
Cleaning and There is no need to strip down and re-grease disassembled shrink disks before they are
lubricating the screwed back on.
shrink disk The shrink disk only needs to be cleaned and re-greased if it is contaminated.
Use one of the following solid lubricants for the tapered surfaces.
Lubricant (Mo S2) Sold as
Molykote 321 (lube coat) Spray
Molykote spray (powder spray) Spray
Molykote G Rapid Spray or paste
Aemasol MO 19P Spray or paste
Aemasol DIO-sétral 57 N (lube coat) Spray
Grease the locking bolts with a multipurpose grease such as Molykote BR 2 or similar.
4 Mounted gear units with TorqLOC®
4.8 Mounted gear units with TorqLOC®

1. Clean the inside of the hollow shaft and the customer shaft. Ensure that all traces of
grease or oil are removed.
2. Install the split ring and the bushing on the customer shaft.
52089AXX
3. Apply NOCO® fluid to the bushing and distribute it carefully.
O
C
®
O D
N UI
L
F
52090AXX
4. Push the gear unit onto the customer shaft.
52091AXX
Mounted gear units with TorqLOC®
4
5. Preassemble the torque arm (do not tighten the bolts).
K...
F...
S...
52092AXX
6. Push the busing onto the gear unit up to the stop.
52093AXX
7. Tighten all the retaining bolts for the torque arm.
52094AXX
8. Secure the bushing with the split ring. Tighten the split ring on the bushing using the
appropriate torque as specified in the following table.
52095AXX
Type Torque [Nm]

KT/FT ST Nickel plated Stainless steel
- 37 18 7.5
37 47 18 7.5
47 57 18 7.5
57, 67 67 35 18
77 77 35 18
87 87 35 18
97 97 35 18
9. Slide the shrink disk onto the hollow shaft. Ensure that all bolts have been loosened.
52096AXX
4
10.Push the counter bushing onto the customer shaft and into the hollow shaft or shrink
disk right into the seat.
52097AXX
11.Tap lightly on the flange of the counter bushing to ensure that the socket is fitted se-
curely in the hollow shaft.
52098AXX
12.Ensure that the customer shaft is fitted in the counter bushing.
53478AXX
13.Tighten the bolts of the shrink disk by hand and ensure that the end rings of the shrink
disc are parallel.
52100AXX
14.Tighten the locking bolts by working round several times from one bolt to the next
(not in diametrically opposite sequence). See the table for tightening torques.
After installation, the remaining gap between the outer rings of the shrink
discs must be > 0 mm.
> 0mm
52101AXX
Type Nickel plated Stainless steel

KT/FT ST Torque [Nm]
- 37 4.1 6.8
37 47 10 6.8
47 57 12 6.8
57, 67 67 12 15
77 77 30 30
87 87 30 50
97 97 30 50
4
15.The distance between the counter bushing and the hollow shaft end and between the
split ring and the clamping ring must not exceed the following values. The following
table lists the maximum and minimum gap width.
52102AXX
Type Distance [mm]

KT/FT ST a min. a max.
- 37 3.3 5.6
37 47 3.3 5.6
47 57 5.0 7.6
57, 67 67 5.0 7.6
77 77 5.0 7.6
87 87 5.8 8.6
97 97 5.8 8.6
4 AM adapter coupling
4.9 AM adapter coupling

IEC adapter AM63
225 / NEMA
04469CXX
adapter AM56
365
1 = Motor shaft
1. Clean the motor shaft and flange surfaces of the motor and adapter.
2. Remove the key from the motor shaft and replace it with the supplied key (484) (not
AM63 and AM250).
3. Heat the coupling half (479) to approx. 80 – 100 °C, push the coupling half onto the
motor shaft.
Until stop at motor shaft shoulder (position to point A except for AM25 / AM280 and
NEMA).
4. Secure key and coupling half using grub screw (481) and tightening torque TA on mo-
tor shaft according to the table.
5. Check point A.
6. Seal the contact surfaces between the adapter and motor using a suitable sealing
compound.
7. Mount the motor on the adapter. When doing this, make sure the coupling dogs of
the adapter shaft engage in the plastic spider.
IEC AM 63 / 71 80 / 90 100 / 112 132 160 / 180 200 225 250 / 280
A 24.5 31.5 41.5 54 76 78.5 93.5 139
TA 1.5 1.5 4.8 4.8 10 17 17 17
Thread M4 M4 M6 M6 M8 M10 M10 M10
NEMA AM 56 143 / 145 182 / 184 213 / 215 254 / 256 284 / 286 324 / 326 364 / 365
A 46 43 55 63.5 78.5 85.5 107 107
TA 1.5 1.5 4.8 4.8 10 17 17 17
Thread M4 M4 M6 M6 M8 M10 M10 M10
AM adapter coupling
4
To avoid contact corrosion, we recommend applying NOCO® fluid to the motor shaft
before mounting the coupling half.
When installing a motor onto the adapter, you must use an anaerobic fluid seal to
ensure that moisture cannot penetrate the adapter.
Permitted loads
The load data specified in the following table must not be exceeded when a motor
is mounted.
Fq
51102AXX
Adapter type Fq1) [N]

IEC NEMA x1) [mm] IEC adapter NEMA adapter
AM63/71 AM56 77 530 410
AM80/90 AM143/145 113 420 380
AM100/112 AM182/184 144 2000 1760
AM132 2) AM213/2152) 1600 1250
186
AM132.. AM213/215 4700 3690
AM160/180 AM254/286 251 4600 4340
AM200/225 AM324 - AM365 297 5600 5250
AM250/280 - 390 11200 -
1) The maximum permitted weight of the attached motor Fqmax must be reduced proportionally as the dis-
tance between the adapter flange and the middle of the motor (x) increases. When this distance is redu-
ced, the maximum permitted weight Fqmax cannot be increased.
2) Diameter of the adapter drive flange: 160 mm
4 AQ adapter coupling
Adapter AM with Check the direction of rotation of the drive before installation and startup. Please inform
backstop AM../RS the SEW-EURODRIVE customer service if the direction of rotation is incorrect.
The backstop is maintenance-free in operation, and does not require any further main-
tenance work.
The backstops have a minimum lift-off speed depending on the size (→ following table).
If the minimum lift-off speeds are violated, the backstops are subject to wear, and the
resulting friction causes the temperature to increase.
Maximum locking torque of backstop Minimum lift-off speed
Type
[Nm] [1/min]
AM80/90/RS,
90 640
AM143/145/RS
AM100/112/RS,
340 600
AM182/184/RS
AM132/RS,
700 550
AM213/215/RS
AM160/180/RS,
1200 630
AM254/286/RS
AM200/225/RS,
1450 430
AM324-365/RS
In rated operation, the lift-off speeds must not drop below the minimum values.
The lift-off speeds are only permitted to drop below the minimum values during
start-up or braking.
4.10 AQ adapter coupling
AQA AQH
479
479
1 Motor shaft
2 Setscrew
1
3 Bolt
1
AQA = With keyway
AQH = Without keyway
2 3
A A
53512AXX
1. Clean the motor shaft and flange surfaces of the motor and adapter.
2. Type AQH: Unscrew the bolts of the coupling half (479) and loosen the conical
connection.
3. Heat the coupling half (80 °C – 100 °C) and push it onto the motor shaft.
Type AQA / AQH: Up to clearance "A" (see table).
4. Type AQH: Tighten the bolts on the coupling half in diametrically opposite sequence
AQ adapter coupling
4
(work round several times tightening the bolts evenly one after the other) until all
bolts reach the tightening torque TA specified in the table.
Type AQA: Use a setscrew to secure the coupling half (see table).
5. Check the position of the coupling half (clearance "A", see table).
Install motor onto the adapter making sure that the dogs of the two coupling halves
engage in each other. The force that must be applied when joining the two coupling
halves is dissipated after final assembly, so there is no risk of any axial load being
applied to adjacent bearings.
Only for AQA, not permitted for AQH: To avoid contact corrosion, we recommend
applying NOCO® fluid to the motor shaft before mounting the coupling half.
When installing a motor onto the adapter, you must use an anaerobic fluid seal to
ensure that moisture cannot penetrate the adapter.
Setting dimen-
sions, tightening Type Coupling size Clearance "A" Bolts DIN 912 Tightening torque TA
torques [mm] [Nm]
AQA AQH AQA AQH
AQA /AQH 80 /1/2/3 44,5
AQA /AQH 100 /1/2 39
19/24 M5 M4 2 3
AQA /AQH 100 /3/4 53
AQA /AQH 115 /1/2 62
AQA /AQH 115 /3 62
24/28 M5 M5 2 6
AQA /AQH 140 /1/2 62
AQA /AQH 140 /3 74,5
28/38 M8 M5 10 6
AQA /AQH 190 /1/2 76,5
AQA /AQH 190 /3 38/45 100 M8 M6 10 10
4 AD input shaft assembly
4.11 AD input shaft assembly

Please refer to Sec. "Installing input and output shafts" for information on mounting of
input elements.
Cover with motor Mounting the motor and adjusting the motor mounting platform.
mounting plat-
form AD../P
1 Motor mounting platform

2 Stud bolt (only AD6/P / AD7/P)
3 Support (only AD6/P / AD7/P)
4 Nut
5 Threaded column
03519BXX
1. Set the motor mounting platform to the required mounting position by evenly tighten-
ing the adjusting nuts. It may be necessary to remove the lifting eyebolt from helical
gear units in order to achieve the lowest adjustment position. Touch up any damage
to the paint work.
2. Align the motor on the motor mounting platform (shaft ends must be in alignment)
and secure it.
3. Mount the input elements on the input shaft end and the motor shaft. Line them up
with one another. Correct the motor position again if necessary.
4. Put on traction elements (V-belt, chain, etc.) and apply a preload by evenly adjusting
the motor mounting platform. Do not stress the motor mounting platform and the
columns against one another when doing this.
5. Tighten the threaded columns using the nuts which are not used for adjustment.
Only AD6/P and Unscrew the nuts on the stud bolts before adjustment to allow the stud bolts to move
AD7/P: axially in the support without restriction. Do not tighten the nuts until the final adjustment
position has been achieved. Do not adjust the motor mounting platform using the
support.
AD input shaft assembly
4
Type with center- Mounting applications on the input shaft assembly with centering shoulder.
ing shoulder 1. Retaining bolts of a suitable length must be used to secure the application. The
AD../ZR length l of the new bolts is calculated as follows:
l= t+a
t = Screw-in depth (see table)
a = Thickness of the application
s = Retaining thread (see table)
02725CXX
Round down the calculated bolt length to the next smaller standard length.
2. Remove the retaining bolts from the centering shoulder.
3. Clean the contact surface and the centering shoulder.
4. Clean the threads of the new bolts and apply a bolt locking compound (e.g. Loctite
243) to the first few threads.
5. Position the application against the centering shoulder and tighten the retaining bolts
to the specified tightening torque TA (see table).
Tightening torque
Screw-in depth Retaining thread
Type TA for connection bolts in strength class 8.8
t [mm] s
[Nm]
AD2/ZR 25,5 M8 25
AD3/ZR 31,5 M10 48
AD4/ZR 36 M12 86
AD5/ZR 44 M12 86
AD6/ZR 48,5 M16 210
AD7/ZR 49 M20 410
AD8/ZR 42 M12 86
4 AD input shaft assembly
Permitted loads
The load values specified in the following table must not be exceeded.
Fq
53513AXX
x1) Fq1)
Type
[mm] [N]
AD2/ZR 193 330
AD3/ZR 274 1400
AD4/ZR2) 1120
361
AD4/ZR 3300
AD5/ZR 487 3200
AD6/ZR 567 3900
AD7/ZR 663 10000
AD8/ZR 516 4300
1) Maximum load values for connection bolts in strength class 8.8. The maximum permitted weight of the
attached motor Fqmax must be reduced proportionally as the distance between the adapter flange and the
middle of the motor (x) increases When this distance is reduced, the Fqmax cannot be increased.
2) Diameter of the adapter output flange: 160 mm
AD input shaft assembly
4
Cover with back- Check the direction of rotation of the drive before installation and startup. Please inform
stop AD../RS the SEW-EURODRIVE customer service if the direction of rotation is incorrect.
The backstop is maintenance-free in operation, and does not require any further main-
tenance work.
The backstops have a minimum lift-off speed depending on the size (→ following table).
If the minimum lift-off speeds are violated, the backstops are subject to wear, and the
resulting friction causes the temperature to increase.
Maximum locking torque of backstop Minimum lift-off speed
Type
[Nm] [1/min]
AD2/RS 90 640
AD3/RS 340 600
AD4/RS 700 550
AD5/RS 1200 630
AD6/RS 1450 430
AD7/RS 1450 430
AD8/RS 2860 430
In rated operation, the lift-off speeds must not drop below the minimum values.
The lift-off speeds are only permitted to drop below the minimum values during
start-up or braking.
I Startup
5 Startup of helical-worm and SPIROPLAN® W gear units
0
5 Startup
Prior to startup check that the oil level is as specified for the mounting position.
The oil checking and drain screws and the breather valves must be freely acces-
sible.
5.1 Startup of helical-worm and SPIROPLAN® W gear units
Note: The direction of rotation of the output shaft in series S..7 helical-worm gear units
has been changed from CW to CCW; this is different from the S..2 series. Change
direction of rotation: Swap over two motor feeder cables.
Run-in period SPIROPLAN® and helical-worm gear units require a run-in period of at least 24 hours
before reaching their maximum efficiency. A separate run-in period applies for each
direction of rotation if the gear unit is operated in both directions of rotation. The table
shows the average power reduction during the run-in period.
No. of Worm Spiroplan®

starts Power reduction i range Power reduction i range
1 start ca. 12 % ca. 50...280 ca. 15 % approx. 40 ... 75
2 start ca. 6 % ca. 20...75 ca. 10 % ca. 20...30
3 start ca. 3 % ca. 20...90 ca. 8 % ca. 15
4 start - - ca. 8 % ca. 10
5 start ca. 3 % ca. 6...25 ca. 5 % ca. 8
6 start ca. 2 % ca. 7...25 - -
5.2 Startup of helical, parallel shaft helical and helical-bevel gear units
No special startup instructions are required for helical, parallel shaft helical and helical-
bevel gear units providing the gear units have been installed in accordance with Sec.
"Mechanical Installation".
Inspection and Maintenance
Inspection and maintenance intervals
6
6 Inspection and Maintenance

6.1 Inspection and maintenance intervals
Frequency What to do?

• Every 3000 machine hours, at least every 6 • Check oil and oil level.
months. • Check the seals visually for leakage.
• For gear units with a torque arm: Check the
rubber buffer and change it, if necessary
• Depending on the operating conditions (see chart • Change mineral oil.
below), every 3 years at the latest.
• Replace anti-friction bearing grease (recom-
• According to oil temperature.
mendation).
• Replace oil seal (do not install it in the same
track).
• Depending on the operating conditions (see chart • Change synthetic oil
below), every 5 years at the latest.
• Replace anti-friction bearing grease (recom-
• According to oil temperature.
mendation).
• Replace oil seal (do not install it in the same
track).
• Gear unitsR07, R17, R27, F27 and Spiroplan® are have lubrication for life and are therefore mainte-
nance-free
• Varying (depending on external factors). • Touch up or renew the surface/anticorrosion
coating.
6.2 Lubricant change intervals
30000
[h]
25000
[3]
20000
15000
[4]
[1]
10000
[5]
5000
0
70 80 90 100 110 115 120
[2] [°C]
53232AXX
Figure 13: Oil change intervals for standard gear units under normal environmental conditions
[1] Operating hours [3] CLP PG

[2] Sustained oil bath temperature [4] CLP HC / HCE
• Average value per oil type at 70 °C [5] CLP / HLP / E Oil
Oil
6 Inspection and maintenance of the gear unit
6.3 Inspection and maintenance of the gear unit

Do not intermix synthetic lubricants and do not mix synthetic and mineral lubricants
together!
The standard lubricant is mineral oil (except for Spiroplan® gear units).
The position of the oil level and oil drain plug and the breather valve depends on
the mounting position. Refer to the diagrams of the mounting positions.
Checking the oil 1. De-energize the gearmotor and secure it to prevent it from being switched on
level inadvertently!
Wait until the gear unit has cooled off – Danger of burns!
2. Refer to Sec. "Installing the gear unit" when changing the mounting position!
3. For gear units with an oil level plug: Remove the oil level plug, check the fill level and
correct it if necessary. Screw the oil level plug back in.
Checking the oil 1. De-energize the gearmotor and secure it to prevent it from being switched on
inadvertently!
2. Remove a little oil from the oil drain plug.
3. Check the oil consistency.
– Viscosity
– If you can see that the oil is heavily contaminated, we recommend that you
change the oil even if this is outside the service intervals specified in "Inspection
and maintenance periods".
4. For gear units with an oil level plug: Remove the oil level plug, check the fill level and
correct it if necessary. Screw the oil level plug back in.
Changing the oil Only change the oil when the gear unit is at operating temperature.
De-energize the gearmotor and secure it to prevent it from being switched back
on inadvertently!
Wait until the gear unit cools down - Danger of burns!
Note: The gear unit must still be warm otherwise the high viscosity of excessively
cold oil will make it harder to drain the oil correctly.
With oil drain plug / 1. Place a container underneath the oil drain plug
oil level screw 2. Remove the oil level plug, breather plug/breather valve and oil drain plug.
3. Drain all the oil.
4. Screw in the oil drain plug.
5. Pour in new oil of the same type through the vent hole (if changing the oil type, please
first contact our customer service). Do not mix synthetic lubricants.
– Pour in the volume of oil in accordance with the mounting position (see Sec. "Lu-
bricant fill quantities") or as specified on the nameplate.
– Check at the oil level plug.
6. Screw the oil level plug back in
7. Screw in the breather plug/breather valve.
Inspection / maintenance of AM / AQA adapters
6
Without oil drain 1. Remove cover plate.

plug / oil level plug 2. Drain the oil through the cover plate opening.
3. Pour in new oil of the same type through the vent hole (if changing the oil type, please
first contact our customer service). Do not mix synthetic lubricants.
– Pour in the volume of oil in accordance with the mounting position (see Sec. "Lu-
bricant fill quantities") or as specified on the nameplate.
4. Check the oil level (→ Sec. "Check oil level for gear units with oil level plug")
5. Attach cover plate (observe the tightening torque and series → Sec. "Check the oil
level for gear units without an oil level plug")
Changing the oil 1. De-energize the gearmotor and secure it to prevent it from being switched on
seal inadvertently!
2. When changing the oil seal, ensure that there is a sufficient grease reservoir between
the dust lip and protective lip, depending on the type of gear unit.
3. If you use double oil seals, the space has to be filled one-third with grease.
6.4 Inspection / maintenance of AM / AQA adapters

• Every 3000 machine hours, at least every 6 months • Check torsional play
• Visually check the elastic annular gear
• Check the adapter visually for leakage
• After 25000 - 30000 machine hours • Renew the anti-friction bearing grease
• Replace oil seal (do not install it in the
same track)
• Change the elastic annular gear.
6.5 Inspection / maintenance of AD adapters

• Every 3000 machine hours, at least every 6 months • Check running noise for possible bearing
damage
• Check the adapter visually for leakage
• After 25000 - 30000 machine hours • Renew the anti-friction bearing grease
• Change the oil seal
Malfunctions
7 Gear unit malfunctions
7 Malfunctions
Customer service
Please have the following information to hand if you require the assistance of our
customer service:
• Data from the nameplate (complete)
• Nature and extent of the fault
• Time and peripheral circumstances of the fault
• Presumed cause
7.1 Gear unit malfunctions

Problem Possible cause Remedy
Unusual, regular running A Meshing/grinding noise: Bearing damage. A Check the oil (see Sec. "Inspection and Mainte-
noise B Knocking noise: Irregularity in the gearing nance"), change bearings
B Contact customer service
Unusual, irregular running Foreign bodies in the oil • Check the oil (see Sec. "Inspection and Mainte-
noise nance")
• Stop the drive, contact customer service
Oilleaking1) A Rubber seal on the gear cover plate leak- A Tighten the bolts on the gear cover plate and
• From the gear cover ing observe the gear unit. Oil still leaking: Contact cus-
plate B Seal defective tomer service
• From the motor flange C Gear unit not vented B Contact customer service
• From the motor oil seal C Vent the gear unit (see Sec. "Mounting Positions")
• From the gear unit
flange
• From the output end oil
seal
Oil leaking from breather A Too much oil A Correct the oil level (see Sec. "Inspection and
valve B Drive operated in incorrect mounting posi- Maintenance")
tion B Mount the breather valve correctly (see Sec.
C Frequent cold starts (oil foams) and/or "Mounting Positions") and correct the oil level (see
high oil level "Lubricants")
Output shaft does not turn Connection between shaft and hub in gear unit Send in the gear unit/gearmotor for repair
although the motor is run- interrupted
ning or the input shaft is
rotated
1) Short-term oil/grease leakage at the oil seal is possible in the run-in phase (24 hours running time).
7.2 AM / AQA / AL adapter malfunctions

Unusual, regular running Meshing/grinding noise: Bearing damage Contact SEW-EURODRIVE customer service
noise
Oil leaking Seal defective Contact SEW-EURODRIVE customer service
Output shaft does not turn Connection between shaft and hub in gear Send the gear unit to SEW-EURODRIVE for repair.
although the motor is run- unit interrupted
ning or the input shaft is
rotated
Change in running noise A Annular gear wear, short-term torque A Change the annular gear
and / or vibrations occur transfer through metal contact B Tighten the bolts
B Bolts to secure hub axially are loose.
Premature wear in annular A Contact with aggressive fluids / oil; ozone Contact SEW-EURODRIVE customer service
gear influence; too high ambient temperatures
etc, which can cause a change in the
physical properties of the annular gear.
B Impermissibly high ambient/contact tem-
perature for the annular gear; maximum
permitted temperature –20 °C to +80 °C.
C Overload
Malfunctions
AD input shaft assembly malfunctions
7
7.3 AD input shaft assembly malfunctions

Unusual, regular running Meshing/grinding noise: Bearing damage. Contact SEW-EURODRIVE customer service
noise
Oil leaking Seal defective Contact SEW-EURODRIVE customer service
Output shaft does not turn Connection between shaft and hub in gear Send the gear unit to SEW-EURODRIVE for repair.
although the input shaft is unit or cover interrupted
rotated.
Mounting Positions
8 M1 … M6 General information on mounting positions
8 Mounting Positions
8.1 General information on mounting positions
Mounting position designation
SEW differentiates between six mounting positions M1 ... M6 for gear units. The following figure shows the
spatial orientation of the gearmotor in mounting positions M1 ... M6.
M6 M6
M1 M1
M2 M2
M5 M5
M4 M4
R..
M3 M3
M6
M6 M1
M2
M2
M1
M5
M5 M4
M4
F..
M3 M3
M6
M1
M1 M6
M2 M2
M5
M5
M4
K..
M4 W..
S.. M3
M3
03203AXX
Figure 14: Depiction of mounting positions M1 ... M6
Mounting Positions
Key to the mounting position sheets M1 … M6 8
8.2 Key to the mounting position sheets
SPIROPLAN® gearmotors do not depend on any particular mounting position. However,

mounting positions M1 to M6 are also shown for SPIROPLAN® gearmotors to assist you
in working with this documentation.
Important: SPIROPLAN® gearmotors cannot be equipped with breather valves, oil

level plugs or drain plugs.
Symbols used The following table shows the symbols used in the mounting position sheets and what
they mean:
Symbol Meaning
Breather valve
Oil level plug
Oil drain plug
Churning losses Increased churning losses may arise in some mounting positions. Contact
SEW-EURODRIVE in case of the following combinations:
Input speed
Mounting position Gear unit type Gear unit size
[1/min]
97 ... 107 > 2500
M2, M4 R
> 107 >1500
97 ... 107 > 2500
F
> 107 > 1500
M2, M3, M4, M5, M6 77 ... 107 > 2500
K
> 107 > 1500
S 77 ... 97 > 2500
Mounting Positions
8 M1 … M6 Mounting positions for R helical gearmotors
8.3 Mounting positions for R helical gearmotors

R07-R167
* → page 51
Mounting Positions
Mounting positions for R helical gearmotors M1 … M6
8
RF07-RF167
* → page 51
Mounting Positions
8 M1 … M6 Mounting positions for R helical gearmotors
R07F-R87F
* → page 51
Important: See the information in the "Gearmotors" catalog, section "Project Planning for Gear Units/Overhung and
axial loads."
Mounting Positions
Mounting positions of RX helical gearmotors M1 … M6 8
8.4 Mounting positions of RX helical gearmotors

RX57-RX107
* → page 51
Mounting Positions
8 M1 … M6 Mounting positions of RX helical gearmotors
RXF57 - RXF107
* → page 51
Mounting Positions
Mounting positions for parallel shaft helical gearmotors M1 … M6 8
8.5 Mounting positions for parallel shaft helical gearmotors

F/FA..B/FH27B-157B, FV27B-107B
* → page 51
Mounting Positions
8 M1 … M6 Mounting positions for parallel shaft helical gearmotors
FF/FAF/FHF/FAZ/FHZ27-157, FVF/FVZ27-107
* → page 51
Mounting Positions
Mounting positions for parallel shaft helical gearmotors M1 … M6 8
FA/FH27-157, FV27-107, FT37-97
* → page 51
Mounting Positions
8 M1 … M6 Mounting positions for helical-bevel gearmotors
8.6 Mounting positions for helical-bevel gearmotors

K/KA..B/KH37B-157B, KV37B-107B
* → page 51
axial loads."
Mounting Positions
Mounting positions for helical-bevel gearmotors M1 … M6 8
K167-187, KH167B-187B
* → page 51
axial loads."
Mounting Positions
KF/KAF/KHF/KAZ/KHZ37-157, KVF/KVZ37-107
* → page 51
Mounting Positions
Mounting positions for helical-bevel gearmotors M1 … M6 8
KA/KH37-157, KV37-107, KT37-97
* → page 51
Mounting Positions
KH167-187
* → page 51
Mounting Positions
Mounting positions for helical-worm gearmotors M1 … M6 8
8.7 Mounting positions for helical-worm gearmotors

S37
axial loads."
Mounting Positions
8 M1 … M6 Mounting positions for helical-worm gearmotors
S47 - S97
* → page 51
axial loads."
Mounting Positions
SF/SAF/SHF37
Mounting Positions
SF/SAF/SHF/SAZ/SHZ47-97
* → page 51
Mounting Positions
SA/SH/ST37
Mounting Positions
SA/SH/ST47-97
* → page 51
Mounting Positions
Mounting positions for SPIROPLAN® W gearmotors M1 … M6 8
8.8 Mounting positions for SPIROPLAN® W gearmotors

W10-30
Mounting Positions
8 M1 … M6 Mounting positions for SPIROPLAN® W gearmotors
WF/WAF10-30
Mounting Positions
Mounting positions for SPIROPLAN® W gearmotors M1 … M6 8
WA10-30
Lubricants
9 Lubricant table
9 Lubricants
General Unless a special arrangement is made, SEW-EURODRIVE supplies the drives with a
information lubricant fill adapted for the specific gear unit and mounting position. The decisive factor
is the mounting position (M1 ... M6, → Sec. "Mounting Positions and Important Order
Information") specified when ordering the drive. You must adapt the lubricant fill to any
subsequent changes made to the mounting position (→ Lubricant fill quantities).
9.1 Lubricant table

The lubricant table on the following page shows the permitted lubricants for
SEW-EURODRIVE gear units. Please note the following key to the lubricant table.
Key to the Abbreviations used, meaning of shading and notes:
lubricant table CLP = Mineral oil
CLP PG = Polyglycol (W gear units, conforms to USDA-H1)
CLP HC = Synthetic hydrocarbons
E = Ester oil (water pollution danger category WGK 1)
HCE = Synthetic hydrocarbons + ester oil (USDA-H1 certification)
HLP = Hydraulic oil
= Synthetic lubricant (= synthetic anti-friction bearing grease)
= Mineral lubricant (= mineral-based anti-friction bearing grease)
1) Helical-worm gear units with PG oil: Please contact SEW
2) Special lubricant for Spiroplan® gear units only
3) Recommendation: Select SEW fB ≥ 1.2
4) Pay attention to critical starting behavior at low temperatures!
5) Low-viscosity grease
6) Ambient temperature
Lubricant for the food industry (food grade oil)
Biodegradable oil (lubricant for use in agriculture, forestry and water resources)
Oil
Oil
Lubricants
Lubricant table
9
Anti-friction The anti-friction bearings in gear units and motors are given a factory-fill with the
bearing greases greases listed below. SEW-EURODRIVE recommends regreasing anti-friction bearings
with a grease fill at the same time as changing the oil.
Ambient temperature Manufacturer Type
Anti-friction bearing in -20 °C ... +60 °C Mobil Mobilux EP 2
gear unit -40 °C ... +80 °C Mobil Mobiltemp SHC 100
-20 °C ... +80 °C Esso Unirex EQ3
Anti-friction bearing in -20 °C ... +60 °C Shell Alvania RL3
motor +80 °C ... +100 °C Klüber Barrierta L55/2
-45 °C ... -25 °C Shell Aero Shell Grease 16
Special greases for anti-friction bearings in gear units:
-30 °C ... +40 °C Aral Eural Grease EP 2
-20 °C ... +40 °C Aral Aralube BAB EP2

Oil
The following grease quantities are required:

• For fast-running bearings (motor and gear unit input end): Fill the cavities between
the rolling elements one third full with grease.
• For slow-running bearings (in gear units and at gear unit output end): Fill the cavities
between the rolling elements two thirds full with grease.
9
76
6)
Oil ISO,NLGI Mobil®
°C -50 0 +50 +100 DIN (ISO)
Standard Mobilgear Shell Omala Klüberoil Aral Degol BP Energol Tribol Optigear Renolin
R... -10 +40 CLP(CC) VG 220 Meropa 220
630 220 GEM 1-220 BG 220 GR-XP 220 1100/220 BM 220 CLP 220
Lubricant table
Mobil Shell Tivela Klübersynth Aral Degol BP Enersyn Tribol Synlube Optiflex A
-25 +80 CLP PG VG 220
Glygoyle 30 S 220 GH 6-220 GS 220 SG-XP 220 800/220 CLP 220 220
4) Mobil Shell Omala Klübersynth Aral Degol Tribol Pinnacle Optigear Syn- Renolin Unisyn
-40 +80 VG 220 thetic A 220
SHC 630 HD 220 EG 4-220 PAS 220 1510/220 EP 220 CLP 220
K...(HK...) CLP HC
4) -40 +40 Mobil Shell Omala Klübersynth Pinnacle
VG 150
SHC 629 HD 150 EG 4-150 EP 150
Lubricants
-20 CLP (CC) VG 150 Mobilgear Shell Omala Klüberoil Aral Degol BP Energol Tribol Optigear Renolin
+25 Meropa 150
VG 100 627 100 GEM 1-150 BG 100 GR-XP 100 1100/100 BM 100 CLP 150
Lubricant table
-30 +10
VG 68-46 Mobil Shell Tellus Klüberoil Aral Degol Tribol Rando EP Optigear Renolin
F... HLP (HM)
VG 32 D.T.E. 13M T 32 GEM 1-68 BG 46 1100/68 Ashless 46 32 B 46 HVI
4) Mobil Klüber-Summit Cetus
-40 +10 CLP HC VG 32
SHC 624 HySyn FG-32 PAO 46
4) -40 -20
VG 22 Mobil Shell Tellus Isoflex BP Energol Rando
HLP (HM)
VG 15 D.T.E. 11M T 15 MT 30 ROT HLP-HM 15 HDZ 15
Standard Mobilgear Shell Omala Klüberoil Aral Degol BP Energol Tribol Optigear Renolin
0 +40 CLP (CC) VG 680 Meropa 680
636 680 GEM 1-680 BG 680 GR-XP 680 1100/680 BM 680 CLP 680
1) Shell Tivela Klübersynth BP Enersyn Tribol Synlube
-20 +60 CLP PG VG 680
S 680 GH 6-680 SG-XP 680 800/680 CLP 680
S...(HS...) 4) Mobil Shell Omala Klübersynth Pinnacle
-30 +80 VG 460
SHC 634 HD 460 EG 4-460 EP 460
CLP HC
4) Mobil Shell Omala Klübersynth Pinnacle
-40 +10 VG 150
SHC 629 HD 150 EG 4-150 EP 150
VG 150 Mobilgear
Shell Omala Klüberoil Aral Degol BP Energol Tribol Optigear Renolin
-20 +10 CLP (CC) Meropa 100
VG 100 627 100 GEM 1-150 BG 100 GR-XP 100 1100/100 BM 100 CLP 150
1) Mobil Shell Tivela Klübersynth Tribol Synlube Optiflex A
-25 +20 CLP PG VG 220
Glygoyle 30 S 220 GH 6-220 800/220 CLP 220 220
4) Mobil Klüber-Summit Cetus
-40 0 CLP HC VG 32 HySyn FG-32
SHC 624 PAO 46
4) Shell Cassida Klüberoil Aral Eural Optileb
-30 +40 HCE VG 460
R...,K...(HK...), Fluid GL 460 4UH1-460 N Gear 460 GT 460
F...,S...(HS...) -20 +40
Klüberbio Aral Degol Optisynt
E VG 460
Oil CA2-460 BAB 460 BS 460
Standard 2) Klüber SEW
W...(HW...) -20 +40 SEW PG VG 460
HT-460-5
4) -40 +10 API GL5
SAE 75W90 Mobilube SHC
(~VG 100) 75 W90-LS
-20 +40
3) Klübersynth
CLP PG VG 460
UH1 6-460
Glygoyle Shell Tivela Klübersynth Multifak
R32 -25 +60 00 GL 00
Grease 00 GE 46-1200 6833 EP 00
DIN 51 818
R302 Standard Mobilux Shell Alvania Aralub BP Energrease Multifak Longtime Renolin
5) 000 - 0
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W
-15 +40 EP 004 GL 00 MFL 00 LS-EP 00 EP 000 PD 00 SF 7 - 041
01 805 892
Lubricants
Lubricant fill quantities
9
9.2 Lubricant fill quantities

The specified fill quantities are recommended values. The precise values vary depend-
ing on the number of stages and gear ratio. When filling, it is essential to check the oil
level plug since it indicates the precise oil capacity.
The following tables show guide values for lubricant fill quantities in relation to the
mounting position M1 ... M6.
Helical (R) gear
units Gear unit Fill quantity in liters
type 1) 1)
R.., R..F M1 M2 M3 M4 M5 M6
R07/R07F 0.12 0.20 0.20 0.20 0.20 0.20
R17/R17F 0.25 0.55 0.35 0.55 0.35 0.35
R27/R27F 0.25/0.40 0.70 0.50 0.70 0.50 0.50
R37/R37F 0.30/0.95 0.85 0.95 1.05 0.75 0.95
R47/R47F 0.70/1.50 1.60 1.50 1.65 1.50 1.50
R57/R57F 0.80/1.70 1.90 1.70 2.10 1.70 1.70
R67/R67F 1.10/2.30 2.60/3.50 2.80 3.20 1.80 2.00
R77/R77F 1.20/3.00 3.80/4.10 3.60 4.10 2.50 3.40
R87/R87F 2.30/6.0 6.7/8.2 7.2 7.7 6.3 6.5
R97 4.60/9.8 11.7/14.0 11.7 13.4 11.3 11.7
R107 6.0/13.7 16.3 16.9 19.2 13.2 15.9
R137 10.0/25.0 28.0 29.5 31.5 25.0 25.0
R147 15.4/40.0 46.5 48.0 52.0 39.5 41.0
R167 27.0/70.0 82.0 78.0 88.0 66.0 69.0
Gear unit Fill quantity in liters
type
RF.. / RM.. M11) M21) M3 M4 M5 M6
RF07 0.12 0.20 0.20 0.20 0.20 0.20
RF17 0.25 0.55 0.35 0.55 0.35 0.35
RF27 0.25/0.40 0.70 0.50 0.70 0.50 0.50
RF37 0.35/0.95 0.90 0.95 1.05 0.75 0.95
RF47 0.65/1.50 1.60 1.50 1.65 1.50 1.50
RF/RM57 0.80/1.70 1.80 1.70 2.00 1.70 1.70
RF/RM67 1.20/2.50 2.70/3.60 2.70 2.60 1.90 2.10
RF/RM77 1.20/2.60 3.80/4.10 3.30 4.10 2.40 3.00
RF/RM87 2.40/6.0 6.8/7.9 7.1 7.7 6.3 6.4
RF/RM97 5.1/10.2 11.9/14.0 11.2 14.0 11.2 11.8
RF/RM107 6.3/14.9 15.9 17.0 19.2 13.1 15.9
RF/RM137 9.5/25.0 27.0 29.0 32.5 25.0 25.0
RF/RM147 16.4/42.0 47.0 48.0 52.0 42.0 42.0
RF/RM167 26.0/70.0 82.0 78.0 88.0 65.0 71.0
1) The output end gear unit of multi-stage gear units must be filled with the larger oil volume.
Lubricants
9 Lubricant fill quantities
Helical (RX) gear

units Gear unit Fill quantity in liters
type
RX.. M1 M2 M3 M4 M5 M6
RX57 0.60 0.80 1.30 1.30 0.90 0.90
RX67 0.80 0.80 1.70 1.90 1.10 1.10
RX77 1.10 1.50 2.60 2.70 1.60 1.60
RX87 1.70 2.50 4.80 4.80 2.90 2.90
RX97 2.10 3.40 7.4 7.0 4.80 4.80
RX107 3.90 5.6 11.6 11.9 7.7 7.7
type
RXF.. M1 M2 M3 M4 M5 M6
RXF57 0.50 0.80 1.10 1.10 0.70 0.70
RXF67 0.70 0.80 1.50 1.40 1.00 1.00
RXF77 0.90 1.30 2.40 2.00 1.60 1.60
RXF87 1.60 1.95 4.90 3.95 2.90 2.90
RXF97 2.10 3.70 7.1 6.3 4.80 4.80
RXF107 3.10 5.7 11.2 9.3 7.2 7.2
Parallel shaft
helical (F) gear
units
F.., FA..B, FH..B, FV..B:
type M1 M2 M3 M4 M5 M6
F..27 0.60 0.80 0.65 0.70 0.60 0.60
F..37 0.95 1.25 0.70 1.25 1.00 1.10
F..47 1.50 1.80 1.10 1.90 1.50 1.70
F..57 2.60 3.50 2.10 3.50 2.80 2.90
F..67 2.70 3.80 1.90 3.80 2.90 3.20
F..77 5.9 7.3 4.30 8.0 6.0 6.3
F..87 10.8 13.0 7.7 13.8 10.8 11.0
F..97 18.5 22.5 12.6 25.2 18.5 20.0
F..107 24.5 32.0 19.5 37.5 27.0 27.0
F..127 40.5 54.5 34.0 61.0 46.3 47.0
F..157 69.0 104.0 63.0 105.0 86.0 78.0
FF..:
FF27 0.60 0.80 0.65 0.70 0.60 0.60
FF37 1.00 1.25 0.70 1.30 1.00 1.10
FF47 1.60 1.85 1.10 1.90 1.50 1.70
FF57 2.80 3.50 2.10 3.70 2.90 3.00
FF67 2.70 3.80 1.90 3.80 2.90 3.20
FF77 5.9 7.3 4.30 8.1 6.0 6.3
FF87 10.8 13.2 7.8 14.1 11.0 11.2
FF97 19.0 22.5 12.6 25.6 18.9 20.5
FF107 25.5 32.0 19.5 38.5 27.5 28.0
FF127 41.5 55.5 34.0 63.0 46.3 49.0
FF157 72.0 105.0 64.0 106.0 87.0 79.0
Lubricants
9
FA.., FH.., FV.., FAF.., FHF.., FVF.., FAZ.., FHZ.., FVZ..:

F..27 0.60 0.80 0.65 0.70 0.60 0.60
F..37 0.95 1.25 0.70 1.25 1.00 1.10
F..47 1.50 1.80 1.10 1.90 1.50 1.70
F..57 2.70 3.50 2.10 3.40 2.90 3.00
F..67 2.70 3.80 1.90 3.80 2.90 3.20
F..77 5.9 7.3 4.30 8.0 6.0 6.3
F..87 10.8 13.0 7.7 13.8 10.8 11.0
F..97 18.5 22.5 12.6 25.2 18.5 20.0
F..107 24.5 32.0 19.5 37.5 27.0 27.0
F..127 39.0 54.5 34.0 61.0 45.0 46.5
F..157 68.0 103.0 62.0 104.0 85.0 77.0
Helical-bevel (K)
gear units
K.., KA..B, KH..B, KV..B:
K..37 0.50 1.00 1.00 1.25 0.95 0.95
K..47 0.80 1.30 1.50 2.00 1.60 1.60
K..57 1.20 2.30 2.50 2.80 2.60 2.40
K..67 1.10 2.40 2.60 3.45 2.60 2.60
K..77 2.20 4.10 4.40 5.8 4.20 4.40
K..87 3.70 8.0 8.7 10.9 8.0 8.0
K..97 7.0 14.0 15.7 20.0 15.7 15.5
K..107 10.0 21.0 25.5 33.5 24.0 24.0
K..127 21.0 41.5 44.0 54.0 40.0 41.0
K..157 31.0 62.0 65.0 90.0 58.0 62.0
K..167 33.0 95.0 105.0 123.0 85.0 84.0
K..187 53.0 152.0 167.0 200 143.0 143.0
KF..:
KF37 0.50 1.10 1.10 1.50 1.00 1.00
KF47 0.80 1.30 1.70 2.20 1.60 1.60
KF57 1.30 2.30 2.70 3.15 2.90 2.70
KF67 1.10 2.40 2.80 3.70 2.70 2.70
KF77 2.10 4.10 4.40 5.9 4.50 4.50
KF87 3.70 8.2 9.0 11.9 8.4 8.4
KF97 7.0 14.7 17.3 21.5 15.7 16.5
KF107 10.0 21.8 25.8 35.1 25.2 25.2
KF127 21.0 41.5 46.0 55.0 41.0 41.0
KF157 31.0 66.0 69.0 92.0 62.0 62.0
Lubricants
9 Lubricant fill quantities
KA.., KH.., KV.., KAF.., KHF.., KVF.., KAZ.., KHZ.., KVZ..:

K..37 0.50 1.00 1.00 1.40 1.00 1.00
K..47 0.80 1.30 1.60 2.15 1.60 1.60
K..57 1.30 2.30 2.70 3.15 2.90 2.70
K..67 1.10 2.40 2.70 3.70 2.60 2.60
K..77 2.10 4.10 4.60 5.9 4.40 4.40
K..87 3.70 8.2 8.8 11.1 8.0 8.0
K..97 7.0 14.7 15.7 20.0 15.7 15.7
K..107 10.0 20.5 24.0 32.4 24.0 24.0
K..127 21.0 41.5 43.0 52.0 40.0 40.0
K..157 31.0 66.0 67.0 87.0 62.0 62.0
KH167 33.0 95.0 105.0 123.0 85.0 84.0
KH187 53.0 152.0 167.0 200 143.0 143.0
Spiroplan® (W) The fill quantity of Spiroplan® gear units does not vary, irrespective of their mounting
gear units position:
Gear unit
Fill quantity in liters, regardless of mounting position
type
W..10 0.16
W..20 0.26
W..30 0.50
Helical-worm (S)
gear units
S..:
type M1 M2 M31) M4 M5 M6
S37 0.25 0.40 0.50 0.55 0.40 0.40
S47 0.35 0.80 0.70/0.90 1.00 0.80 0.80
S57 .50 1.20 1.00/1.20 1.45 1.30 1.30
S67 1.00 2.00 2.20/3.10 3.10 2.60 2.60
S77 1.90 4.20 3.70/5.4 5.9 4.40 4.40
S87 3.30 8.1 6.9/10.4 11.3 8.4 8.4
S97 6.8 15.0 13.4/18.0 21.8 17.0 17.0
1) The larger gear unit of multi-stage gear units must be filled with the larger oil volume.
SF..:
SF37 0.25 0.40 0.50 0.55 0.40 0.40
SF47 0.40 0.90 0.90/1.05 1.05 1.00 1.00
SF57 0.50 1.20 1.00/1.50 1.55 1.40 1.40
SF67 1.00 2.20 2.30/3.00 3.20 2.70 2.70
SF77 1.90 4.10 3.90/5.8 6.5 4.90 4.90
SF87 3.80 8.0 7.1/10.1 12.0 9.1 9.1
SF97 7.4 15.0 13.8/18.8 22.6 18.0 18.0
Lubricants
9
SA.., SH.., SAF.., SHF.., SAZ.., SHZ..:

S..37 0.25 0.40 0.50 0.50 0.40 0.40
S..47 0.40 0.80 0.70/0.90 1.00 0.80 0.80
S..57 0.50 1.10 1.00/1.50 1.50 1.20 1.20
S..67 1.00 2.00 1.80/2.60 2.90 2.50 2.50
S..77 1.80 3.90 3.60/5.0 5.8 4.50 4.50
S..87 3.80 7.4 6.0/8.7 10.8 8.0 8.0
S..97 7.0 14.0 11.4/16.0 20.5 15.7 15.7
Appendix
10
10 Appendix
10.1 Index of changes
The following additions and changes have been made compared to the previous edition
of the "Explosion-Proof Gear Units R..7, F..7, K..7, S..7, SPIROPLAN® W" (publication
number: 1055520x, edition 11/2002) operating instructions:
General additions and corrections.
Mechanical • Installing the gear unit: Data on flatness error

installation • Installing torque arms for mounted gear units: Data on retaining bolts
• Mounted gear units with shrink disks: Information on assembly / removal has been
added
• Mounted gear units with TorqLOC®
• AM adapter coupling: Point A
Inspection and • Lubricant change intervals
maintenance
11
11 Index 1
A Input and output elements, installation 19
Inspection intervals 45
2
AD inspection / maintenance 47
AD, mounting on the input shaft assembly 40 Inspection of AD adapter 47
Adapter coupling 36 Inspection of AM / AQA adapters 47 3
Adjusting the mounting position 17 Installation tolerances 15
AM with backstop 38 Installing couplings 20 4
Anti-friction bearing greases 75 Installing input and output elements 19
AQ, installing the coupling adapter 38 Installing the AM coupling adapter 36 5
AQA, maintenance / inspection 47 Installing the AQ coupling adapter 38
Installing the gear unit 16
B 6
Backstop RS 38 K
Breather valve 18 K gear units, lubricant fill quantities 79 7
Keyway 23
C
Centering shoulder AD../ZR 41 L 8
Change the oil seal 47 Lubricant change intervals 45
Check oil 46 Lubricant fill quantities 77 9
Check oil level 46 Lubricant fill quantities for helical gear units 77, 78
Churning losses 51 Lubricant fill quantities for helical-bevel gear units 79 10
Couplings, installation 20 Lubricant fill quantities for helical-worm gear units 80
Cover with backstop AD../RS 43 Lubricant fill quantities for parallel shaft helical gear units
78 11
Cover with motor mounting platform AD../P 40
Lubricant fill quantities for Spiroplan® gear units 80
Customer service 48
Lubricant table 74, 76
D Lubricants 74
Damp locations 17 13
Designated use 6
M
Maintenance / inspection 47
E Maintenance intervals 45 14
Extended storage 7 Maintenance of AD adapter 47
F Maintenance of AM / AQA adapters 47 15

Malfunctions 48
F gear units, lubricant fill quantities 78
AD input shaft assembly 49
Flatness error 16 AM / AQA / AL adapters 48
16
Gear units 48
G
Mechanical installation 15 17
Gear unit inspection 46
Motor mounting platform 40
Gear unit maintenance 46
Mounted gear units 23, 27, 30 18
Gear unit structure 9
Mounting on the input shaft assembly AD 40
Gear unit venting 18
Mounting position designation 50
19
H Mounting positions
Helical gear units, lubricant fill quantities 77, 78 Helical gear units 52, 55
helical gear units, structure 9
Helical-bevel gear units 60 20
Helical-worm gear units 65
Helical-bevel gear units, lubricant fill quantities 79 Parallel shaft helical gear units 57
Helical-bevel gear units, structure 11 Spiroplan® gear units 71 21
Helical-worm gear unit, structure 12 Mounting torque arms 21
Helical-worm gear units, lubricant fill quantities 80
N 22
I Nameplate 14
IEC adapter 36 NEMA adapter 36
Operating Instructions – Gear Units, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 83
11
O
Oil change 46
Open air 17
P
Painting gear units 18
Parallel shaft helical gear unit, structure 10
Parallel shaft helical gear units, lubricant fill quantities 78
R
R gear units, lubricant fill quantities 77
RS backstop 43
RX gear units, lubricant fill quantities 78
S
S gear units, lubricant fill quantities 80
Safety notes 6
Serial number 14
Shrink disk 27
Solid shaft 19
Spiroplan® gear units, lubricant fill quantities 80
Spiroplan® W gear units, structure 13
Splined hollow shaft 23
Startup 44
Helical, parallel shaft helical and helical-bevel gear
units 44
Helical-worm and Spiroplan® W gear units 44
Structure
Helical gear units 9
Helical-bevel gear units 11
Helical-worm gear unit 12
Parallel shaft helical gear unit 10
Spiroplan® gear units 13
T
TorqLOC® 30
Torque arm for helical-bevel gear units 21
Torque arm for helical-worm gear units 22
Torque arm for Spiroplan® W gear units 22
Torque arms for parallel shaft helical gear units 21
Torque arms, mounting 21
Transportation 7
U
Unit designation 14
W
W gear units, lubricant fill quantities 80
Waste disposal 5
84 Operating instructions – Gear Units, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W
Address List
Address List
Germany
Headquarters Bruchsal SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-0
Production Ernst-Blickle-Straße 42 Fax +49 7251 75-1970
Sales D-76646 Bruchsal http://www.sew-eurodrive.de
P.O. Box sew@sew-eurodrive.de
Postfach 3023 · D-76642 Bruchsal
Service Central SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-1710
Competence Center Gear units / Ernst-Blickle-Straße 1 Fax +49 7251 75-1711
Motors D-76676 Graben-Neudorf sc-mitte-gm@sew-eurodrive.de
Central SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-1780
Electronics Ernst-Blickle-Straße 42 Fax +49 7251 75-1769
D-76646 Bruchsal sc-mitte-e@sew-eurodrive.de
North SEW-EURODRIVE GmbH & Co KG Tel. +49 5137 8798-30
Alte Ricklinger Straße 40-42 Fax +49 5137 8798-55
D-30823 Garbsen (near Hannover) sc-nord@sew-eurodrive.de
East SEW-EURODRIVE GmbH & Co KG Tel. +49 3764 7606-0
Dänkritzer Weg 1 Fax +49 3764 7606-30
D-08393 Meerane (near Zwickau) sc-ost@sew-eurodrive.de
South SEW-EURODRIVE GmbH & Co KG Tel. +49 89 909552-10
Domagkstraße 5 Fax +49 89 909552-50
D-85551 Kirchheim (near München) sc-sued@sew-eurodrive.de
West SEW-EURODRIVE GmbH & Co KG Tel. +49 2173 8507-30
Siemensstraße 1 Fax +49 2173 8507-55
D-40764 Langenfeld (near Düsseldorf) sc-west@sew-eurodrive.de
Drive Service Hotline / 24 Hour Service +49 180 5 SEWHELP
+49 180 5 7394357
Additional addresses for service in Germany provided on request!
France
Production Haguenau SEW-USOCOME Tel. +33 3 88 73 67 00
Sales 48-54, route de Soufflenheim Fax +33 3 88 73 66 00
Service B. P. 20185 http://www.usocome.com
F-67506 Haguenau Cedex sew@usocome.com
Assembly Bordeaux SEW-USOCOME Tel. +33 5 57 26 39 00
Sales Parc d’activités de Magellan Fax +33 5 57 26 39 09
Service 62, avenue de Magellan - B. P. 182
F-33607 Pessac Cedex
Lyon SEW-USOCOME Tel. +33 4 72 15 37 00
Parc d’Affaires Roosevelt Fax +33 4 72 15 37 15
Rue Jacques Tati
F-69120 Vaulx en Velin
Paris SEW-USOCOME Tel. +33 1 64 42 40 80
Zone industrielle Fax +33 1 64 42 40 88
2, rue Denis Papin
F-77390 Verneuil I’Etang
Additional addresses for service in France provided on request!
Algeria
Sales Alger Réducom Tel. +213 21 8222-84
16, rue des Frères Zaghnoun Fax +213 21 8222-84
Bellevue El-Harrach
16200 Alger
Argentina
Assembly Buenos Aires SEW EURODRIVE ARGENTINA S.A. Tel. +54 3327 4572-84
Sales Centro Industrial Garin, Lote 35 Fax +54 3327 4572-21
Service Ruta Panamericana Km 37,5 sewar@sew-eurodrive.com.ar
1619 Garin
08/2004 85
Address List
Australia
Assembly Melbourne SEW-EURODRIVE PTY. LTD. Tel. +61 3 9933-1000
Sales 27 Beverage Drive Fax +61 3 9933-1003
Service Tullamarine, Victoria 3043 http://www.sew-eurodrive.com.au
enquires@sew-eurodrive.com.au
Sydney SEW-EURODRIVE PTY. LTD. Tel. +61 2 9725-9900
9, Sleigh Place, Wetherill Park Fax +61 2 9725-9905
New South Wales, 2164 enquires@sew-eurodrive.com.au
Austria
Assembly Wien SEW-EURODRIVE Ges.m.b.H. Tel. +43 1 617 55 00-0
Sales Richard-Strauss-Strasse 24 Fax +43 1 617 55 00-30
Service A-1230 Wien http://sew-eurodrive.at
sew@sew-eurodrive.at
Belgium
Assembly Brüssel CARON-VECTOR S.A. Tel. +32 10 231-311
Sales Avenue Eiffel 5 Fax +32 10 231-336
Service B-1300 Wavre http://www.caron-vector.be
info@caron-vector.be
Brazil
Production Sao Paulo SEW-EURODRIVE Brasil Ltda. Tel. +55 11 6489-9133
Sales Avenida Amâncio Gaiolli, 50 Fax +55 11 6480-3328
Service Caixa Postal: 201-07111-970 http://www.sew.com.br
Guarulhos/SP - Cep.: 07251-250 sew@sew.com.br
Additional addresses for service in Brazil provided on request!
Bulgaria
Sales Sofia BEVER-DRIVE GMBH Tel. +359 2 9532565
Bogdanovetz Str.1 Fax +359 2 9549345
BG-1606 Sofia bever@mbox.infotel.bg
Cameroon
Sales Douala Electro-Services Tel. +237 4322-99
Rue Drouot Akwa Fax +237 4277-03
B.P. 2024
Douala
Canada
Assembly Toronto SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 905 791-1553
Sales 210 Walker Drive Fax +1 905 791-2999
Service Bramalea, Ontario L6T3W1 http://www.sew-eurodrive.ca
l.reynolds@sew-eurodrive.ca
Vancouver SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 604 946-5535
7188 Honeyman Street Fax +1 604 946-2513
Delta. B.C. V4G 1 E2 b.wake@sew-eurodrive.ca
Montreal SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 514 367-1124
2555 Rue Leger Street Fax +1 514 367-3677
LaSalle, Quebec H8N 2V9 a.peluso@sew-eurodrive.ca
Additional addresses for service in Canada provided on request!
Chile
Assembly Santiago de SEW-EURODRIVE CHILE LTDA. Tel. +56 2 75770-00
Sales Chile Las Encinas 1295 Fax +56 2 75770-01
Service Parque Industrial Valle Grande sewsales@entelchile.net
LAMPA
RCH-Santiago de Chile
P.O. Box
Casilla 23 Correo Quilicura - Santiago - Chile
China
Production Tianjin SEW-EURODRIVE (Tianjin) Co., Ltd. Tel. +86 22 25322612
Assembly No. 46, 7th Avenue, TEDA Fax +86 22 25322611
Sales Tianjin 300457 victor.zhang@sew-eurodrive.cn
Service http://www.sew.com.cn
86 08/2004
Address List
China
Assembly Suzhou SEW-EURODRIVE (Suzhou) Co., Ltd. Tel. +86 512 62581781
Sales 333, Suhong Middle Road Fax +86 512 62581783
Service Suzhou Industrial Park suzhou@sew.com.cn
Jiangsu Province, 215021
P. R. China
Colombia
Assembly Bogotá SEW-EURODRIVE COLOMBIA LTDA. Tel. +57 1 54750-50
Sales Calle 22 No. 132-60 Fax +57 1 54750-44
Service Bodega 6, Manzana B sewcol@andinet.com
Santafé de Bogotá
Croatia
Sales Zagreb KOMPEKS d. o. o. Tel. +385 1 4613-158
Service PIT Erdödy 4 II Fax +385 1 4613-158
HR 10 000 Zagreb kompeks@net.hr
Czech Republic
Sales Praha SEW-EURODRIVE CZ S.R.O. Tel. +420 220121234 + 220121236
Business Centrum Praha Fax +420 220121237
Luná 591 http://www.sew-eurodrive.cz
CZ-16000 Praha 6 - Vokovice sew@sew-eurodrive.cz
Denmark
Assembly Kopenhagen SEW-EURODRIVEA/S Tel. +45 43 9585-00
Sales Geminivej 28-30, P.O. Box 100 Fax +45 43 9585-09
Service DK-2670 Greve http://www.sew-eurodrive.dk
sew@sew-eurodrive.dk
Estonia
Sales Tallin ALAS-KUUL AS Tel. +372 6593230
Paldiski mnt.125 Fax +372 6593231
EE 0006 Tallin veiko.soots@alas-kuul.ee
Finland
Assembly Lahti SEW-EURODRIVE OY Tel. +358 3 589-300
Sales Vesimäentie 4 Fax +358 3 7806-211
Service FIN-15860 Hollola 2 http://www.sew-eurodrive.fi
sew@sew-eurodrive.fi
Gabon
Sales Libreville Electro-Services Tel. +241 7340-11
B.P. 1889 Fax +241 7340-12
Libreville
Great Britain
Assembly Normanton SEW-EURODRIVE Ltd. Tel. +44 1924 893-855
Sales Beckbridge Industrial Estate Fax +44 1924 893-702
Service P.O. Box No.1 http://www.sew-eurodrive.co.uk
GB-Normanton, West- Yorkshire WF6 1QR info@sew-eurodrive.co.uk
Greece
Sales Athen Christ. Boznos & Son S.A. Tel. +30 2 1042 251-34
Service 12, Mavromichali Street Fax +30 2 1042 251-59
P.O. Box 80136, GR-18545 Piraeus http://www.boznos.gr
info@boznos.gr
Hong Kong
Assembly Hong Kong SEW-EURODRIVE LTD. Tel. +852 2 7960477 + 79604654
Sales Unit No. 801-806, 8th Floor Fax +852 2 7959129
Service Hong Leong Industrial Complex sew@sewhk.com
No. 4, Wang Kwong Road
Kowloon, Hong Kong
08/2004 87
Address List
Hungary
Sales Budapest SEW-EURODRIVE Kft. Tel. +36 1 437 06-58
Service H-1037 Budapest Fax +36 1 437 06-50
Kunigunda u. 18 office@sew-eurodrive.hu
India
Assembly Baroda SEW-EURODRIVE India Pvt. Ltd. Tel. +91 265 2831021
Sales Plot No. 4, Gidc Fax +91 265 2831087
Service Por Ramangamdi · Baroda - 391 243 mdoffice@seweurodriveindia.com
Gujarat
Technical Offices Bangalore SEW-EURODRIVE India Private Limited Tel. +91 80 22266565
308, Prestige Centre Point Fax +91 80 22266569
7, Edward Road sewbangalore@sify.com
Bangalore
Mumbai SEW-EURODRIVE India Private Limited Tel. +91 22 28348440
312 A, 3rd Floor, Acme Plaza Fax +91 22 28217858
Andheri Kurla Road, Andheri (E) sewmumbai@vsnl.net
Mumbai
Ireland
Sales Dublin Alperton Engineering Ltd. Tel. +353 1 830-6277
Service 48 Moyle Road Fax +353 1 830-6458
Dublin Industrial Estate
Glasnevin, Dublin 11
Israel
Sales Tel-Aviv Liraz Handasa Ltd. Tel. +972 3 5599511
Ahofer Str 34B / 228 Fax +972 3 5599512
58858 Holon lirazhandasa@barak-online.net
Italy
Assembly Milano SEW-EURODRIVE di R. Blickle & Co.s.a.s. Tel. +39 2 96 9801
Sales Via Bernini,14 Fax +39 2 96 799781
Service I-20020 Solaro (Milano) sewit@sew-eurodrive.it
Ivory Coast
Sales Abidjan SICA Tel. +225 2579-44
Ste industrielle et commerciale pour l’Afrique Fax +225 2584-36
165, Bld de Marseille
B.P. 2323, Abidjan 08
Japan
Assembly Toyoda-cho SEW-EURODRIVE JAPAN CO., LTD Tel. +81 538 373811
Sales 250-1, Shimoman-no, Fax +81 538 373814
Service Toyoda-cho, Iwata gun sewjapan@sew-eurodrive.co.jp
Shizuoka prefecture, 438-0818
Korea
Assembly Ansan-City SEW-EURODRIVE KOREA CO., LTD. Tel. +82 31 492-8051
Sales B 601-4, Banweol Industrial Estate Fax +82 31 492-8056
Service Unit 1048-4, Shingil-Dong master@sew-korea.co.kr
Ansan 425-120
Latvia
Sales Riga SIA Alas-Kuul Tel. +371 7139386
Katlakalna 11C Fax +371 7139386
LV-1073 Riga info@alas-kuul.ee
Lebanon
Sales Beirut Gabriel Acar & Fils sarl Tel. +961 1 4947-86
B. P. 80484 +961 1 4982-72
Bourj Hammoud, Beirut +961 3 2745-39
Fax +961 1 4949-71
gacar@beirut.com
88 08/2004
Address List
Lithuania
Sales Alytus UAB Irseva Tel. +370 315 79204
Merkines g. 2A Fax +370 315 79688
LT-4580 Alytus irmantas.irseva@one.lt
Luxembourg
Assembly Brüssel CARON-VECTOR S.A. Tel. +32 10 231-311
Sales Avenue Eiffel 5 Fax +32 10 231-336
Service B-1300 Wavre http://www.caron-vector.be
info@caron-vector.be
Malaysia
Assembly Johore SEW-EURODRIVE SDN BHD Tel. +60 7 3549409
Sales No. 95, Jalan Seroja 39, Taman Johor Jaya Fax +60 7 3541404
Service 81000 Johor Bahru, Johor kchtan@pd.jaring.my
West Malaysia
Morocco
Sales Casablanca S. R. M. Tel. +212 2 6186-69 + 6186-70 + 6186-
Société de Réalisations Mécaniques 71
5, rue Emir Abdelkader Fax +212 2 6215-88
05 Casablanca srm@marocnet.net.ma
Netherlands
Assembly Rotterdam VECTOR Aandrijftechniek B.V. Tel. +31 10 4463-700
Sales Industrieweg 175 Fax +31 10 4155-552
Service NL-3044 AS Rotterdam http://www.vector.nu
Postbus 10085 info@vector.nu
NL-3004 AB Rotterdam
New Zealand
Assembly Auckland SEW-EURODRIVE NEW ZEALAND LTD. Tel. +64 9 2745627
Sales P.O. Box 58-428 Fax +64 9 2740165
Service 82 Greenmount drive sales@sew-eurodrive.co.nz
East Tamaki Auckland
Christchurch SEW-EURODRIVE NEW ZEALAND LTD. Tel. +64 3 384-6251
10 Settlers Crescent, Ferrymead Fax +64 3 384-6455
Christchurch sales@sew-eurodrive.co.nz
Norway
Assembly Moss SEW-EURODRIVE A/S Tel. +47 69 241-020
Sales Solgaard skog 71 Fax +47 69 241-040
Service N-1599 Moss sew@sew-eurodrive.no
Peru
Assembly Lima SEW DEL PERU MOTORES REDUCTORES Tel. +51 1 3495280
Sales S.A.C. Fax +51 1 3493002
Service Los Calderos, 120-124 sewperu@sew-eurodrive.com.pe
Urbanizacion Industrial Vulcano, ATE, Lima
Poland
Assembly Lodz SEW-EURODRIVE Polska Sp.z.o.o. Tel. +48 42 67710-90
Sales ul. Techniczna 5 Fax +48 42 67710-99
Service PL-92-518 Lodz http://www.sew-eurodrive.pl
sew@sew-eurodrive.pl
Portugal
Assembly Coimbra SEW-EURODRIVE, LDA. Tel. +351 231 20 9670
Sales Apartado 15 Fax +351 231 20 3685
Service P-3050-901 Mealhada http://www.sew-eurodrive.pt
infosew@sew-eurodrive.pt
Romania
Sales Bucuresti Sialco Trading SRL Tel. +40 21 230-1328
Service str. Madrid nr.4 Fax +40 21 230-7170
011785 Bucuresti sialco@sialco.ro
08/2004 89
Address List
Russia
Sales St. Petersburg ZAO SEW-EURODRIVE Tel. +7 812 5357142 +812 5350430
P.O. Box 263 Fax +7 812 5352287
RUS-195220 St. Petersburg http://www.sew-eurodrive.ru
sew@sew-eurodrive.ru
Senegal
Sales Dakar SENEMECA Tel. +221 849 47-70
Mécanique Générale Fax +221 849 47-71
Km 8, Route de Rufisque senemeca@sentoo.sn
B.P. 3251, Dakar
Serbia and Montenegro

Sales Beograd DIPAR d.o.o. Tel. +381 11 3046677
Kajmakcalanska 54 Fax +381 11 3809380
SCG-11000 Beograd dipar@yubc.net
Singapore
Assembly Singapore SEW-EURODRIVE PTE. LTD. Tel. +65 68621701 ... 1705
Sales No 9, Tuas Drive 2 Fax +65 68612827
Service Jurong Industrial Estate sales@sew-eurodrive.com.sg
Singapore 638644
Slovakia
Sales Sered SEW-Eurodrive SK s.r.o. Tel. +421 31 7891311
Trnavska 920 Fax +421 31 7891312
SK-926 01 Sered sew@sew-eurodrive.sk
Slovenia
Sales Celje Pakman - Pogonska Tehnika d.o.o. Tel. +386 3 490 83-20
Service UI. XIV. divizije 14 Fax +386 3 490 83-21
SLO – 3000 Celje pakman@siol.net
South Africa
Assembly Johannesburg SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 11 248-7000
Sales Eurodrive House Fax +27 11 494-3104
Service Cnr. Adcock Ingram and Aerodrome Roads dross@sew.co.za
Aeroton Ext. 2
Johannesburg 2013
P.O.Box 90004
Bertsham 2013
Capetown SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 21 552-9820
Rainbow Park Fax +27 21 552-9830
Cnr. Racecourse & Omuramba Road Telex 576 062
Montague Gardens dswanepoel@sew.co.za
Cape Town
P.O.Box 36556
Chempet 7442
Cape Town
Durban SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 31 700-3451
2 Monaceo Place Fax +27 31 700-3847
Pinetown dtait@sew.co.za
Durban
P.O. Box 10433, Ashwood 3605
Spain
Assembly Bilbao SEW-EURODRIVE ESPAÑA, S.L. Tel. +34 9 4431 84-70
Sales Parque Tecnológico, Edificio, 302 Fax +34 9 4431 84-71
Service E-48170 Zamudio (Vizcaya) sew.spain@sew-eurodrive.es
Sweden
Assembly Jönköping SEW-EURODRIVE AB Tel. +46 36 3442-00
Sales Gnejsvägen 6-8 Fax +46 36 3442-80
Service S-55303 Jönköping http://www.sew-eurodrive.se
Box 3100 S-55003 Jönköping info@sew-eurodrive.se
90 08/2004
Address List
Switzerland
Assembly Basel Alfred lmhof A.G. Tel. +41 61 41717-17
Sales Jurastrasse 10 Fax +41 61 41717-00
Service CH-4142 Münchenstein bei Basel http://www.imhof-sew.ch
info@imhof-sew.ch
Thailand
Assembly Chon Buri SEW-EURODRIVE (Thailand) Ltd. Tel. +66 38 454281
Sales Bangpakong Industrial Park 2 Fax +66 38 454288
Service 700/456, Moo.7, Tambol Donhuaroh sewthailand@sew-eurodrive.co.th
Muang District
Chon Buri 20000
Tunisia
Sales Tunis T. M.S. Technic Marketing Service Tel. +216 1 4340-64 + 1 4320-29
7, rue Ibn EI Heithem Fax +216 1 4329-76
Z.I. SMMT
2014 Mégrine Erriadh
Turkey
Assembly Istanbul SEW-EURODRIVE Tel. +90 216 4419163 + 216 4419164 +
Sales Hareket Sistemleri Sirketi 216 3838014
Service Bagdat Cad. Koruma Cikmazi No. 3 Fax +90 216 3055867
TR-34846 Maltepe ISTANBUL sew@sew-eurodrive.com.tr
USA
Production Greenville SEW-EURODRIVE INC. Tel. +1 864 439-7537
Assembly 1295 Old Spartanburg Highway Fax Sales +1 864 439-7830
Sales P.O. Box 518 Fax Manuf. +1 864 439-9948
Service Lyman, S.C. 29365 Fax Ass. +1 864 439-0566
Telex 805 550
http://www.seweurodrive.com
cslyman@seweurodrive.com
Assembly San Francisco SEW-EURODRIVE INC. Tel. +1 510 487-3560
Sales 30599 San Antonio St. Fax +1 510 487-6381
Service Hayward, California 94544-7101 cshayward@seweurodrive.com
Philadelphia/PA SEW-EURODRIVE INC. Tel. +1 856 467-2277
Pureland Ind. Complex Fax +1 856 845-3179
2107 High Hill Road, P.O. Box 481 csbridgeport@seweurodrive.com
Bridgeport, New Jersey 08014
Dayton SEW-EURODRIVE INC. Tel. +1 937 335-0036
2001 West Main Street Fax +1 937 440-3799
Troy, Ohio 45373 cstroy@seweurodrive.com
Dallas SEW-EURODRIVE INC. Tel. +1 214 330-4824
3950 Platinum Way Fax +1 214 330-4724
Dallas, Texas 75237 csdallas@seweurodrive.com
Additional addresses for service in the USA provided on request!
Venezuela
Assembly Valencia SEW-EURODRIVE Venezuela S.A. Tel. +58 241 832-9804
Sales Av. Norte Sur No. 3, Galpon 84-319 Fax +58 241 838-6275
Service Zona Industrial Municipal Norte sewventas@cantv.net
Valencia, Estado Carabobo sewfinanzas@cantv.net
08/2004 91
Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
How we’re driving the world
With people who With comprehensive With uncompromising

think fast and With a worldwide With drives and controls knowledge in virtually quality that reduces the
develop the service network that is that automatically every branch of cost and complexity of
future with you. always close at hand. improve your productivity. industry today. daily operations.
SEW-EURODRIVE
Driving the world
With a global presence With innovative With online information

that offers responsive technology that solves and software updates, via
and reliable solutions. tomorrow’s problems the Internet, available
Anywhere. today. around the clock.
SEW-EURODRIVE GmbH & Co KG

P.O. Box 3023 · D-76642 Bruchsal / Germany
Phone +49 7251 75-0 · Fax +49 7251 75-1970
sew@sew-eurodrive.com
www.sew-eurodrive.com
THERMO SCIENTIFIC Proline Safety Pull Switch
Interruptor de Cordón de Seguridad Proline de Thermo Scientific
SPS-2D
COPYRIGHT 1999 BY THERMO SCIENTIFIC
THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF THERMO SCIENTIFIC. IT

MAY NOT BE COPIED OR REPRODUCED IN ANY WAY WITHOUT THE EXPRESS WRITTEN
CONSENT OF THERMO SCIENTIFIC.. THIS DOCUMENT ALSO IS AN UNPUBLISHED WORK
OF THERMO SCIENTIFIC. THERMO SCIENTIFIC. INTENDS TO AND IS MAINTAINING THE
WORK AS CONFIDENTIAL INFORMATION. THERMO SCIENTIFIC. ALSO MAY SEEK TO
PROTECT THIS WORK AS AN UNPUBLISHED COPYRIGHT. IN THE EVENT OF EITHER
INADVERTENT OR DELIBERATE PUBLICATION, THERMO SCIENTIFIC. INTENDS TO
ENFORCE ITS RIGHTS TO THIS WORK UNDER THE COPYRIGHT LAWS AS A PUBLISHED
WORK. THOSE HAVING ACCESS TO THIS WORK MAY NOT COPY, USE OR DISCLOSE THE
INFORMATION IN THIS WORK UNLESS EXPRESSLY AUTHORIZED BY THERMO
SCIENTIFIC..
EL PRESENTE DOCUMENTO ES CONFIDENCIAL Y ES PROPIEDAD DE THERMO

SCIENTIFIC. NO PUEDE SER COPIADO O REPRODUCIDO EN NINGUNA DE SUS FORMAS
SIN EL CONSENTIMIENTO EXPRESO Y ESCRITO DE THERMO SCIENTIFIC. ASIMISMO,
ESTE DOCUMENTO ES UN TRABAJO NO PUBLICADO DE THERMO SCIENTIFIC. THERMO
SCIENTIFIC. DESEA MANTENER Y ESTA MANTENIENDO EL TRABAJO COMO
INFORMACION CONFIDENCIAL. THERMO SCIENTIFIC, ADEMAS, PUEDE INTENTAR
PROTEGER ESTE TRABAJO COMO UN DERECHO DE AUTOR NO PUBLICADO. EN CASO DE
PUBLICACION INVOLUNTARIA O DELIBERADA, THERMO SCIENTIFIC EJERCERA SUS
DERECHOS EN CUANTO A ESTE TRABAJO BAJO LAS LEYES DE DERECHO DE AUTOR
COMO UN TRABAJO PUBLICADO. QUIENES TENGAN ACCESO A ESTE TRABAJO NO
PUEDEN COPIAR, USAR O DIVULGAR LA INFORMACION CONTENIDA EN EL MISMO, A
MENOS QUE THERMO RAMSEY LO AUTORICE EXPRESAMENTE.
FAILURE TO OBSERVE THIS MANUAL WILL CAUSE

VERY SERIOUS PERSONAL INJURY OR DEATH
EL NO CUMPLIMIENTO DE ESTE MANUAL PROVOCARA LESIONES PERSONALES MUY
SERIAS O LA MUERTE
1.0 INSPECTION
Inspect the package for external damage before opening, as often times the carrier can be
held responsible for shipping damages. After unpacking, inspect the unit for damage.
INSPECCION
Inspeccione el embalaje para verificar daños externos antes de abrirlo, ya que a menudo el
transportista es el responsable de los daños de envío. Después de desempacar,
inspeccionar la unidad para verificar que no haya daños.
2.0 SPECIFICATIONS
2.1 Temperature Range: -13° to 176° F (-25° to 80° C)
2.2 NEMA 4 enclosure (NEMA 4X Optional) , CSA
2.3 Lock angle: 20°
2.4 Two conduit openings, threaded 3/4" -14 NPT or optional metric 20 x 1.50
2.5 Adjustable angle actuator in 22-1/2° increments
2.6 Recommended spacing between switches: 150ft when using supported cable, aircraft,
.094 dia 7x7 strand with orange vinyl cover part # 003676
or in type and color suitable for environment.
2.7 Switch, positive break, 2 sets of SPDT
REC 4095 REV D Page 1 Part # 059675

ESPECIFICACIONES
2.1 Rango de Temperatura : -13° a 176° F (-25° a 80° C)
2.2 Cuerpo con Grado de protección NEMA 4 (NEMA 4X Optional), CSA
2.3 Angulo de cierre: 20º
2.4 Dos perforaciones para ducto ¾” – 14 NPT o métrica opcional 20 x 1.50
2.5 Actuador de ángulo ajustable en incrementos de 22-1/2º
2.6 Espacio recomendado entre interruptores: 150 pies cuando se use cable de
suspensión, cable “aircraft” (tipo aeronave) 0,094” diam. y 7x7 hebras con cubierta de
vinilo de color naranja repuesto # 003676 o del color y del tipo adecuado para el
ambiente.
2.7 Switch actuador con 2 juegos de contactos SPDT
3.0 SPARE PARTS

Switch part # 059695
Actuator arm part # 038335
REPUESTOS
Repuesto del interruptor # 059695
Repuesto del brazo del actuador # 038335
TERMINAL CONNECTIONS SAFETY PULL SWITCH

TERMINALES DE CONECCIÓN INTERRUPTOR DE CORDON DE SEGURIDAD

4.0 SPS-2D OPERATION
At the time the arm is tripped, a switch is actuated which provides a SPDT circuit to
interrupt the drive, thus stopping the conveyor.
To reset Safety Pull Switch, the reset lever must be depressed, thus placing the actuator
arm into operating position. After the Safety Pull Switch is reset, the conveyor may be
restarted.
OPERACIÓN SPS-2D
En el momento en que el brazo es desconectado, operan los contactos SPDT del switch
que hacen que se detenga el accionamiento y, por lo tanto, detenga la correa
transportadora.
Para resetear (regular) los Interruptores de Cordón de Seguridad, se debe soltar la palanca
de reseteo, colocando así el brazo del actuador en la posición de operación. Después que
el Interruptor de Cordón de Seguridad es reseteado, la correa transportadora debe ser
reiniciada.
5.0 INSTALLATION
1. Refer to 6.0 OUTLINE and MOUNTING.
2. Safety Pull Switch is to be mounted alongside conveyor stringer.
3 The recommended spacing between switches should not exceed 150 feet.
4. Cable lengths, if tied off at one end, should not exceed 75 feet.
5. Eye bolts to support the cable should be spaced at 8 feet apart.
6. Each SPS-2D is supplied with 3/4" -14 NPT or optional metric 20 x 1.50 conduit
openings.
7. Wire per the field terminal connections. Two switch units are typically used for belt
shutdown and alarm.
8. All field wiring must conform to the National Electric Code and local codes.
9. After installation, seal enclosure from the entrance of moisture.
INSTALACION
1. Refiérase a 6.0 ASPECTOS GENERALES y MONTAJE.
2. El Interruptor de Cordón de Seguridad debe ser montado a lo largo de la estructura
soporte de la correa transportadora.
3. El espacio recomendado entre los interruptores no debe exceder los 150 pies.
4. La longitud de los cables, si están unidos en un extremo, no debe exceder los 75 pies.
5. Los cáncamos para soportar el cable deben estar separados con 8 pies de distancia.
6. Cada SPS-2D es suministrado con perforaciones para ducto de ¾” – 14 NPT o métrica
opcional 20 x 1,50.
7. Cablear según lo indicado en los terminales de conexión. Dos unidades de switch se
usan típicamente para la parada y la alarma de la correa.
8. Todo el cableado de campo debe cumplir con el Código Eléctrico Nacional y los
códigos locales.
9. Después de la instalación, sellar el cuerpo del switch para que no entre humedad.

6.0 OUTLINE and MOUNTING
ASPECTOS GENERALES y MONTAJE
INSTALLATION
INSTALACION
7.0 TESTING
After installation, test unit to ensure proper mechanical and electrical operations. Make sure
cover is tightly secured and conduit sealed to prevent entry of water or moisture.
PRUEBAS
Después de la instalación, someta a prueba la unidad para garantizar una operación
mecánica y eléctrica adecuada. Asegúrese de que la cubierta esté asegurada
herméticamente y que el ducto esté sellado para evitar que entre agua o humedad.
8.0 MAINTENANCE
Periodically test switch operation (monthly recommended). Also open unit and inspect for
corrosion, water damage or wear. Always ensure that the unit is completely sealed from
moisture entry.
MANTENIMIENTO
Periódicamente, someta a prueba la operación del interruptor (se recomienda hacerlo
mensualmente). Asimismo, abra la unidad e inspeccione para verificar si hay corrosión,
daño por agua o desgaste. Siempre asegúrese de que la unidad esté completamente
sellada para evitar que entre la humedad.

BRELKO ®
CONVEYOR PRODUCTS
INSTALLATION, OPERATING & MAINTENANCE MANUAL
N
PR EW
OD
UC
T
E905 HEAD PULLEY

BELT SCRAPER
PATENTED
Project Name : .
Project Number : .
Order Number : .
: .
Model Number : .
Purchase Date : .
Purchased From : .
Installation Date : .
: .
Model number information can be found on the Label found on the scraper carton.
This information will be helpful for any future inquiries or questions about belt scraper replacement parts, specifications or
troubleshooting.
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
E905 - Page 292 to 309 Version 7.0 – © 08/2016
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: sales@brelko.com Web: www.brelko.com
BRELKO ®
CONVEYOR PRODUCTS
Table of Contents
1. Disclaimer�� 294
2. Safety Note�� 294
3. The following symbols may be used in this manual:�� 294
4. General Information�� 294
4.1. Application and Features �� 295
4.2. Reference Drawing - E905-001 �� 296
5. Handling�� 297
5.1. Receiving the goods �� 297
5.2. Work Safety �� 297
5.3. Handling �� 298
5.4. Storage �� 298
5.5. Preparations for installing Belt Scrapers �� 298
5.6. Recommended Tools List �� 298
6. Maintenance�� 299
6.1. New Installation �� 299
6.2. Routine Visual Inspection (every 2~4 weeks) �� 299
6.3. Routine Physical Inspection (every 6~8 weeks) �� 299
6.4. Parts List and Assembly Instructions �� 300
6.6. Installation Instructions �� 302
7. Procedure for Replacing/Repairing Scrapers�� 304
8. Maintenance Log �� 305
9. Conveyor Belt & Equipment Check List�� 306
10. Trouble Shooting�� 309
E905 - Page 293 to 309 Version 7.0 – © 08/2016
BRELKO ®
CONVEYOR PRODUCTS
1. Disclaimer
Brelko conveyor products (pty) ltd hereby disclaims any liability for: damage due to contamination of the material; user’s
failure to inspect, maintain and take reasonable care of the equipment; injuries or damage resulting from use or application
of this product contrary to instructions and specifications contained herein. Brelko’s liability shall be limited to repair or
replacement of equipment shown to be defective.
2. Safety Note
Observe all safety rules given herein along with owner and Government standards and regulations. Know and understand
lockout/tag-out procedures as defined by National Standards Institutes, National Standard for Personnel Protection - Lockout/
Tag-out of Energy Sources - Minimum Safety Requirements and Occupational Health and Safety.
3. The following symbols may be used in this manual:
DANGER Danger: Immediate hazards that will result in severe personal injury or death.
WARNING Warning: Hazards or unsafe practices that could result in personal injury.
CAUTION Caution: Hazards or unsafe practices that could result in product or property damages.
Important: Instructions that must be followed to ensure proper installation/operation of

Important:
equipment.
Note: Note: General statements to assist the reader.
4. General Information
Brelko belt scrapers are designed to operate with minimum maintenance. However, to maintain superior performance
some service is required. When the scraper is installed a regular maintenance program should be set up. This program
will ensure that the scraper operates at optimal efficiency and problems can be identified and fixed before the scraper
stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. Secondary
Scrapers operates at the discharge end of the conveyor and is in direct contact with the moving belt. Only visual
observations can be made while the belt is running. Service tasks can be done only with the conveyor stopped and by
observing the correct lockout/tag-out procedures.
E905 - Page 294 to 309 Version 7.0 – © 08/2016
BRELKO ®
CONVEYOR PRODUCTS
N
PR EW
OD
UC
T
E905 HEAD PULLEY

BELT SCRAPER
PATENTED
APPLICATIONS
 As a Head Pulley Scraper, working directly on the head pulley.
 As a Head Pulley Scraper, when wet and sticky materials are conveyed.
 Can be installed where there is not enough space for other scrapers.
 Suitable for all types of conveyor belts and metal fastener systems.
FEATURES
 Adjustable Brelko torsion twist tensioners allow the scraper to maintain a constant pressure on the belt, are self
adjusting and allow the scraper to deflect away from any obstruction, as a significant safety feature.
 Specially formulated polymeric blades give maximum life, and keep the possibility of damage to belt repairs, splices and
metal fasteners to a minimum.
 Patented V-base blade mounting makes blade changing quick and simple.
 Multi-blade construction allows individual blades to deflect for minor obstructions and adapt to belt profile.
 Streamlined scraper construction prevents material build-up on the scraper.
E905 - Page 295 to 309 Version 7.0 – © 08/2016
E905-TT TWIST TENSIONER MOUNT SINGLE ROW MULTI-BLADE HEAD PULLEY SCRAPER © 08-2016
TWIST UNIT TO MAINTAIN CONSTANT

PRESSURE & COMPENSATE FOR UNEVEN POLYURETHANE BLADES.
BELT THICKNESS & PULLEY RUN OUT
SAND BLASTED &
10°
EPOXY POWDER COATED WORK
CARRIER SHAFT ZONE
120mm OPTIONAL: GALVANISED
150mm OR STAINLESS STEEL
304 OR 316
20°
POWDER COATED
MOUNTING COMPONENTS
MOUNTED DIRECTLY
ONTO CHUTE OR
BOLTED TO STRUCTURE
STANDARD CONTRUCTION & FINISHES FOR BELT WIDTHS FROM

BRELKO
600mm TO 2100mm E905-TT

TWIST TENSIONER MOUNTING
CONVEYOR PRODUCTS
NOTE: FEATURES & OPTIONS SHOWN: DRW.
PLEASE REFER TO DETAILED MANUAL FOR INSTALLATION INSTRUCTIONS, MAINTENANCE & SPARE PARTS E905-001 REV. A
No.
®
BRELKO ®
CONVEYOR PRODUCTS
5. Handling
5.1. Receiving the goods
Check that the shipment contains all the products specified in the delivery note. If the goods do not match the delivery
note, if the goods show any transportation damage, list it on the freight bill. Describe the damage and the number of
wrong or faulty goods, and contact your supplier immediately.
Do not use defective parts under any circumstances. Claims must be made within 8 days from the arrival of goods.
The factory does not cover expenses caused by exchange of product when installation was not carried out according
to factory instructions.
5.2. Work Safety
Always use protective gloves and clothing. Always use a lifeline and soft-sole footwear when work will be carried out
on raised platforms. Before you move a scraper or plough, check that it is securely attached to the lifting equipment.
Always observe local safety regulations.
WARNING
Before removing/installing equipment, lock out/tag out energy source to conveyor,

and/or conveyor accessories.
Turn off and lock out/tag out energy source according to local standards.
If equipment will be installed in an enclosed area, test gas level or duct content
before using a cutting torch or welding. Using a cutting torch or welding in an area
with gas or dust may cause an explosion.
If using a cutting torch or welding machine, test atmosphere for gas level or dust
content.
E905 - Page 297 to 309 Version 7.0 – © 08/2016
BRELKO ®
CONVEYOR PRODUCTS
5.3. Handling
When scrapers are unloaded from the transportation vehicle onto customer’s platform, place them on boards spaced
max 1m apart at a minimum of 5cm from the ground.
5.4. Storage
Scrapers can be stored unpacked or in transportation package. Scrapers must not be stored on top of one another,
protect the scrapers by storing them in a cool dry area on a flat surface.
5.5. Preparations for installing Belt Scrapers
Before installation, check all measurements and any of the other geometric design
5.6. Recommended Tools List
BELT SCRAPERS
QTY DESCRIPTION
2 EXTENSION CORD (20m MINIMUM)
1 PORT-A-PACK (OXY-ACETYLENE)
1 PRICKER
1 COMBINATION GAUGE (WITH SPIRIT LEVEL)
1 STRAIGHT EDGE (1M MINIMUM)
1 90° SET SQUARE
1 5M TAPE MEASURE
2 ADJUSTABLE SPANNERS
1 PIPE WRENCH (3" MINIMUM)
1 SOCKET RATCHET SET (6mm - 30mm)
2 RINGSET SPANNERS - M13, 15, 16, 17, 18, 19, 24
1 STANLEY KNIFE
2 M46 SET SPANNERS
2 M65 SET SPANNERS
1 HARD FACE HAMMER – 4pd
1 SOFT FACE HAMMER - 1KG
3M NYLON ROPE
2 "G" CLAMPS - 6" - 8"
1 JIMMY LEVER
E905 - Page 298 to 309 Version 7.0 – © 08/2016
BRELKO ®
CONVEYOR PRODUCTS
6. Maintenance
Brelko belt scrapers are designed to operate with minimum maintenance. However, to maintain superior performance
some service is required. When the scraper is installed a regular maintenance program should be set up. This program
will ensure that the scraper operates at optimal efficiency and problems can be identified and fixed before the scraper
stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. The E901
Head Pulley Scraper operates at the discharge end of the conveyor and is in direct contact with the moving belt. Only
visual observations can be made while the belt is running. Service tasks can be done only with the conveyor stopped
and by observing the correct lockout/tag-out procedures.
6.1. New Installation
After the new scraper has run for a few days a visual inspection should be made to ensure the scraper is performing
properly. Make adjustments as needed.
6.2. Routine Visual Inspection (every 2~4 weeks)
• A visual inspection of the scraper and belt can determine:
• If the mounts are adjusted at the correct pressure for optimal cleaning
• If the belt looks clean or if there are areas that are dirty
• If the blade is worn out and needs to be replaced
• If there is damage to the blade or other scraper components
• If fugitive material is built up on the scraper or in the transfer area
• If there is cover damage to the belt
• If there is vibration or bouncing of the scraper on the belt
• If a snub pulley is used, a check should be made for material build-up on the pulley
• If any of the above conditions exist, a decision should be made on when the conveyor can be stopped for scraper
maintenance.
6.3. Routine Physical Inspection (every 6~8 weeks)
When the conveyor is not in operation and properly locked and tagged out a physical inspection of the scraper to
perform the following tasks:
• Clean material build-up off of the scraper blade and pole.
• Closely inspect the blade for wear and any damage. Replace if needed.
• Check blade for proper installation and condition. Replace if needed.
• Ensure full blade to belt contact.
• Inspect the scraper pole for damage.
• Inspect all fasteners for tightness and wear. Tighten or replace as needed.
• Replace any worn or damaged components.
• Check the pressure of the scraper blade on the belt. Adjust the pressure if necessary, refer to scraper model
installation guide.
When maintenance tasks are completed, test run the conveyor to ensure the scraper is performing properly.
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BRELKO ®
CONVEYOR PRODUCTS
PARTS LIST - REF. DRW. No.: E905-002

SHAFT
BELT WIDTH
ITEM No. DESCRIPTION SIZE LENGTH PART No.
(mm)
(mm)
A. Carrier Assembly Including shaft, “V” track Size 1 1200 400-500 2-8.1.1
and end stops. Size 2 1500 600-750 2-8.1.2
Size 3 2000 900-1200 2-8.1.3
Size 4 2500 1350-1500 2-8.1.4
Size 4 3000 1650-1800 2-8.1.41
B. Torsion twist Tensioner and mount assembly Size 1 & 2 N/A 400-750 2-2.33
including bearing, bushes, mounting brackets Size 3 N/A 900-1200 2-2.34
and tensioner units
Size 4 N/A 1350-2400 2-2.36
(Belt Widths 1500 to 2400 require 2 Twist
Tensioner Units)
C. Poly Blades 120mm N/A N/A 2-7.8

150mm N/A N/A 2-7.81
D. Optional / 3-Piece Shaft Assembly including Size 1 1200 400-500 2-8.1.1-3P

inner carrier shaft, outer carrier shafts. Size 2 1500 600-750 2-8.1.2-3P
Size 3 2000 900-1200 2-8.1.3-3P
Size 4 2500 1350-1500 2-8.1.4-3P
Size 4 3000 1650-1800 2-8.1.41-3P
Size 5 4000 2100-2400 2-8.1.5-3P
NOTE! Always quote belt width.

ASSEMBLY INSTRUCTIONS
1. All scrapers will be wrapped and clearly marked with the model number, scraper blade grade and belt width.
• Note: - Scrapers will be supplied with all nuts and bolts to complete the assembly and installation.
2. Referring to the parts list check that the correct parts and quantities have been supplied for the model and belt width of scraper
ordered.
3. Normally scrapers are supplied with blades (3) and end stops (5) assembled and fixed to the carrier shaft. If this is not the case,
assemble as shown using lithium base grease as a lubricant to ease future removal of blades. If necessary, use rubber mallet to tap
the blades into the “V” track.
4. Proceed with installation as per installation guide.
E905 - Page 300 to 309 Version 7.0 – © 08/2016
E905-TT TWIST TENSIONER MOUNT SINGLE ROW MULTI-BLADE HEAD PULLEY SCRAPER © 08-2016
C 1
5
6 9a 9 7
LEGEND
COMPONENT
DESCRIPTION
I.D.
A CARRIER ASSEMBLY (SHAFT ,V-TRACK & END CAPS)
C POLY BLADE (120 & 150 mm BLADES)

BRELKO
TWIST MOUNT ASSEMBLY

B
(BEARING , BUSHES ,MOUNTING BRACKET & TWIST UNIT)
CONVEYOR PRODUCTS
DRW.
PARTS LIST: FOR TWIST TENSIONER MOUNT PLEASE SPECIFY BELT WIDTH WHEN ORDERING E905-002 REV. A
No.
®
BRELKO ®
CONVEYOR PRODUCTS
INSTALLATION GUIDE - REF. DRW. No.: E905-003

1. Refer to the Assembly Instructions, Parts List and Parts list drawing to confirm that all the necessary parts have been supplied and
that the scraper is correctly assembled.
2. Remove mounting brackets (7) from nearside bearing assembly (9) and farside bearing assembly (8).
3. Referring to the installation data sheet and dimensions given in the dimension table determine the scraper work zone and select the
optimum position for the scraper.
4. After establishing the optimum position for the scraper on the head pulley, mark and cut out the near and farside chute openings.
The farside opening need only accommodate scraper adjustment.
• Note 1: - Shield the conveyor belt and head pulley to prevent burning during cutting and welding activities.
• Note 2: - The mounting brackets (7) may be omitted and the bearing plates bolted directly to the chute sides. Separate chute
access doors may then be required for inspection and maintenance access. Please consult a Brelko representative for this
installation option.
5. With reference to the installation data sheet select the most convenient location for the mounting brackets (7).
• Note: - Mounting brackets (7) can be welded or bolted to the chute sides.
6. Tack weld the near and farside mounting brackets (7) to the chute sides or bolt to structure.
7. Remove one or both carrier shaft (1) end caps and install scraper through nearside chute opening.
8. Position carrier (1) centrally with reference to belt edges and head pulley and attach the nearside bearing assembly (9) and farside
bearing assembly (8) to the mounting brackets (7).
9. Using nearside bearing assembly (9) and farside bearing assembly (8) as reference determine exact carrier (1) length, mark off;
remove carrier (1) and nearside bearing assembly (9) and farside bearing assembly (8).
10. Carefully cut carrier shaft (1) to required length and de-burr shaft ends, reposition carrier shaft (1) centrally with reference to belt
edges and head pulley.
11. Fit farside bearing bush (8a) over carrier shaft (1) end, and insert carrier shaft (1) end into farside bearing assembly (8). Tighten bolts
and nuts, finger tight only as further adjustment of the scraper will be required.
12. Fit nearside bearing bush (9a) over carrier shaft (1) end, and locate nearside bearing assembly (9) as shown. Tighten bolts and nuts,
finger tight only as further adjustment of the scraper will be required.
13. Complete welding of near and farside mounting brackets (7) or ensure all mounting brackets (7) nuts and bolts are firmly fastened.
14. Locate tension unit (6) and insert holding bolt into matching holes between the nearside bearing assembly (9). Tighten holding bolt
and nut, finger tight only as further adjustment of the scraper will be required.
15. With reference to the dimension data sheet move scraper into the correct scraping position. Tighten bolts and nuts; do not over
tighten nuts and bolts as further adjustment of the scraper might be required.
16. Using large tool, turn tension unit to bias scraper against head pulley and insert holding bolt. The tensioner only needs to be rotated
until the first set of holding bolt holes between nearside bearing assemblies (9) align.
17. Firmly tighten all nuts and bolts.
18. Start the conveyor and check if all blades are in full contact with the belt surface. If further adjustment is required stop the conveyor
and adjust the scraper until the next set of holding bolt holes between nearside bearing assemblies (9) align or until optimum
cleaning is achieved.
E905 - Page 302 to 309 Version 7.0 – © 08/2016
E905-TT TWIST TORSION MOUNT SINGLE ROW MULTI-BLADE HEAD PULLEY SCRAPER © 08-2016
BRACKETS TO BE WELDED TO CHUTE SIDES OR BOLTED TO STRUCTURE Ø14mm MOUNTING

NOTE: THESE MOUNTING BRACKETS CAN BE OMITTED, BUT ARE REQUIRED HOLES DIRECT ON CHUTE SIDES
WHEN THERE ARE NO CHUTE SIDES AVAILABLE. THEY ARE ALSO USED OR TO MOUNTING BRACKETS
AS AN ACCESS OPENING FOR INSTALLING AND REMOVING THE SCRAPER, AND FOR M12 MOUNTING BOLTS
TO PROVIDE ADJUSTMENT FOR FINAL POSITIONING.
10°
X WORK
ZONE
120mm (400 - 700mm) 80mm
150mm (900 - 2400mm) (TYP.)
20°
B
64
H
A
NOTE:
(C)
SUPPLLIED WITH TWO TWIST 35
10
(247) 150mm PU BLADE
TENSIONERS FOR 1500mm BELT

WIDTH AND ABOVE 60
Z 258
CARRIER PIPE TO LENGTH UPON
J
E
INSTALLATION OTHERWISE ADVICE 318
DISTANCE ACROSS OUTSIDE OF CHUTE
DETAIL B
25°
(CHUTE CUT-OUT)
VIEW ON ARROW "A"
DIMENSION TABLE (mm)

B
BELT WIDTH 400 450 500 600 750 900 1050 1200 1350 1500 1650 1800 2100 2400
No. BLADES 3 3 4 4 6 5 6 7 8 9 10 11 13 14
SIZE RANGE 1 3 3 4 5
(RECOMMENDED)
A 53 61 61 61 61
B 112 140 140 145 145
C 168 210 210 215 215
D 150 150 150 200 200
E 215 280 280 295 295 Ø20mm MOUNTING F
F 110 115 115 155 155
8
HOLES DIRECT ONTO STRUCTURE (CHUTE CUT-OUT)

G 190 190 190 250 250
(TYP.)
OR TO MOUNTING BRACKETS
H 280 350 350 360 360 FOR M16 MOUNTING BOLTS
J 100 100 100 150 150
K 300 310 310 310 310
D
L 240 250 250 250 250
M 60 60 60 60 60 G
N 35 35 35 35 35
P 5 10 10 10 10
BRELKO
E905-TT
Z 1200 1500 2000 2500 3000 4000(3 PIECE)
X 360 360 480 480 720 750 900 1050 1200 1350 1500 1650 1950 2100
TWIST TENSIONER MOUNTING
CONVEYOR PRODUCTS
DRW.
INSTALLATION DETAIL: STANDARD MOUNT. E905-003 REV. A
No.
®
BRELKO ®
CONVEYOR PRODUCTS
7. Procedure for Replacing/Repairing Scrapers

Repair/replace Belt Scraper components when, general maintenance tasks are preformed scraper damage due to
accelerated blade wear, scraper damage due to blocked chutes, clip joints/emergency belt repairs etc.
7.1. Request permit to work from an authorised person, who will isolate and lock out the belt.
7.2. Open access door, if provided, and clear loose items about the spindle before commencing with work.
7.3. Loosen the locknuts and then lower/raise the scrapers, as necessary.
7.4. If replacing scrapers, insert balance pipe – which must be longer than the carrier shaft – into the one end
of the shaft.
7.5. Loosen the shaft and turn it 180 degrees, that is, scraper tips pointing downward.
7.6. Remove one spindle on the intended exit end.
7.7. Slide out the scraper assembly from the intended exit end of the pipe.
7.8. Service the scraper on the platform.
7.9. Blade replacement:
Refer to Brelko installation instructions for belt scraper model in use.
Brelko nylon torsion holders have been designed to break out of the torsion holder support v-track to
protect the scraper, scraper mounting components, conveyor belt and conveyor belt equipment against
damage due to emergency clip joints, loose/damaged splicing, belt protrusions, chute blockages etc. If
torsion holders damaged occur follow the steps below to replace individual or all of the torsion holders:
a. Remove and clean the damaged scraper to assess the amount of damage to the scraper, the scraper
torsion holders and scraper components.
b. If the scraper has been working for more than 4 weeks and/or there has been significant blade wear
remove and replace all the torsion holders and blades and replace with new kits, this will eliminate belt
damage due to uneven scraper torsion holder and blades.
c. If the scraper has been working for 1~2 weeks replace only damaged torsion holders and blades, however
assess the damage and ensure the remaining torsion holders will not cause any damage to the conveyor
belt.
7.10. Scraper Adjustment:
Refer to Brelko installation instructions for belt scraper model in use.
a. Reposition using the balance pipe.
b. Obtain sanction for test, or permission to adjust for performance evaluation.
c. Tighten all nuts and ensure that belt cleaning or scraper performance is acceptable.
d. Clear up any loose items which resulted from your work.
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BRELKO ®
CONVEYOR PRODUCTS
CONVEYOR BELT & EQUIPMENT CHECK LIST

CUSTOMER DETAILS
Customer Name: Contact Number:
Attention: Date of Inspection
Inspected By Brelko Representative
CONVEYOR DIMENSIONS
Belt Number: Material Carried: Belt Speed:
Belt Length: Belt Width : Troughing Angle:
Top Cover Condition: Bottom Cover Condition:
Splice: Yes No Clip Joint: Yes No Cover Strip: Yes No
Conveyor Running Yes No Inspection Tags: Yes No
Edge Damage: Yes No
Comments:
HEAD END / HEAD CHUTE

Chute Condition: Head Pulley Lagging:
Snub Pulley Lagging: Build up:
Belt Movement:
Comments:
IDLER CHECK
Trough Idler Condition: Return Idler Condition:
Troughing Frame
Return Frame Condition:
Condition:
Comments:
PRIMARY SCRAPER
Position Correct: Yes No Type of Primary Scraper installed:
(Contact of Scraper Blade must be between 10 to 30 degrees, under
the pulley horizontal line.)
Mounts firmly mounted: Yes No All bolts, nuts tightened: Yes No
Adequate Tensioning: Yes No All Caps, Denso Tape in place: Yes No
Housekeeping:
Chute Material build up:
Blade Wear: Low Medium High Cleaning: Poor Fair Good
Comments:
SECONDARY SCRAPER #1
Type / Model of Secondary Scraper Installed:
Positioning Correct:
(Scraper blade must preferably be a minimum 100mm from pulley tangent.)
All Caps, Denso Tape in Place: Yes No Mounts firmly mounted: Yes No
All Bolts & Nuts Tightened: Yes No Adequate tension/adjustment: Yes No
Angle Correct Set: Yes No Carrier Frame cut to size Yes No
Angle of scraper must be 90 degrees to the conveyor belt, dependant on conditions.

Chute / Material build up: Yes No Housekeeping:
Blade wear: Low Medium High Cleaning: Poor Fair Good
Comments:
RVICE E
SE OVER
30
XC
EL
Cer Įca
DE
KRA
ISO 9001:2008
on
L E NC
DOC No ISSUE No REVISION MARCH PAGE

DEKRA ISO 14001:2004 YEARS
E
OHSAS 18001:2007 FS 023 02 02 2014 Page 1 of 3
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: info@brelko.com Web: www.brelko.com
BRELKO ®
CONVEYOR PRODUCTS
SECONDARY SCRAPER #2
Type / Model of Secondary Scraper Installed:
Positioning Correct:
Scraper blade must preferably be a minimum 100mm from pulley tangent.
All Caps, Denso Tape in Place: Yes No Mounts firmly mounted: Yes No
All Bolts & Nuts Tightened: Yes No Adequate tension/adjustment: Yes No
Angle Correct Set: Yes No Carrier Frame cut to size Yes No
Angle of scraper must be 90 degrees to the conveyor belt, dependant on conditions.
Chute / Material build up: Yes No Housekeeping:
Blade wear: Low Medium High Cleaning: Poor Fair Good
Comments:
TAKE UP PULLEYS / COUNTERWEIGHT / PLOUGH

Type / Model of Plough Installed:
Are Flat Return Idlers Installed: (In front) Yes No (Behind) Yes No
Any excessive belt movement: Yes No Adequate space for material to fall off of conveyor belt Yes No
Is the Plough firmly mounted: Yes No Is the Safety Chain firmly mounted and correctly adjusted: Yes No
Is the Plough Free moving: Yes No Is the entire Blade / Nose Piece in contact with the conveyor belt: Yes No
Housekeeping:
Comments:
CONVEYOR BELT TRACKING / ALIGNMENT

Is the Belt Tracking centre: Yes No Are there any Tracking Systems installed: Troughing Return
Is there any visible damage to structure caused by poor belt tracking: Yes No
Conveyor belt length: Are the tracking systems correctly positioned: Yes No
Are the tracking systems firmly mounted: Yes No Are all bolts & nuts tightened: Yes No
Are all Idlers in contact with the Belt - Adequate Tension on the system: Yes No Housekeeping:
Comments:
LOADING / TRANSFER CHUTE

Chute Condition: Poor Fair Good Material loading in centre of conveyor belt:
Dead Boxes: Yes No Deflector Plates: Yes No Drop Heights:
Tail Pulley Condition Good Fair Poor
Comments:
KEYSKIRTING®
Size of Keyskirt®: 1 2 3 4 Length of Keyskirt® Installed :
Other Product used
Positioning of Keyskirt® : Yes No State
as Skirting
Mounting Arrangement Std. Offset Other
All bolts & nuts securely fastened: Yes No Housekeeping:
Comments:
RVICE E
SE OVER
30
XC
EL
Cer Įca
DE
KRA
ISO 9001:2008
on
L E NC

E
OHSAS 18001:2007 FS 023 02 02 2014 Page 2 of 3
BRELKO ®
CONVEYOR PRODUCTS
FEEDBOOTS
Type of Feedboot installed: Universal Combination Is the system correctly positioned: Yes No
(System to be positioned centrally to the load area.)
Drop Height: Is the system securely mounted: Yes No
All Bolts & Nuts tightened: Yes No Condition of Idlers: Poor Fair Good
Lead in and lead out Idlers in place: Yes No Condition of UHMW Liners: Low Medium High
Housekeeping:
Comments:
HI - IMPACT SYSTEM
Type of Hi - Impact system installed :
Is the system correctly positioned: Yes No Drop heights:
System to be positioned centrally to the load area.
Is the system securely mounted: Yes No All bolts & nuts tightened: Yes No
Are all Idlers in contact with the belt: Yes No Idler condition: Poor Fair Good
BTA Condition: Poor Fair Good Are chains / D shackles in place & securely fastened: Yes No
All Hardware in Good Condition: Yes No Housekeeping:
Comments:
AIR CANNONS
5ltr Quantity 10ltr Quantity
Size of Air Cannon Installed: 25ltr Quantity 50ltr Quantity
100ltr Quantity 200ltr Quantity
Is the Air Cannon securely fastened onto the structure: Yes No Is an Air Lance installed: Yes No
Size of the Air Lance: Are the Air Cannons correctly positioned: Yes No
Power supply: Air supply:
Operating system: Single timer PLC Manual push button Sequential
All Bolts & Nuts securely tightened: Yes No All components in good order: Yes No
Distance between Air Cannon & Solenoid Valve: Any Air Leaks in the Pipe Work: No
Is a Water Trap Installed: Yes No Is a Lubricator installed: Yes No
Distance from Air Cannon: Distance from Air Cannon:
Are the safety / warning signs in place and visible: Yes No Housekeeping:
Comments:
TAIL PULLEY / PLOUGH

Type / Model of Plough Installed:
Are Flat Return Idlers installed: (In front) Yes No (Behind) Yes No
Any excessive belt movement: Yes No Adequate space for material to fall off of conveyor belt: Yes No
Is the Plough firmly mounted: Yes No Is the Safety Chain firmly mounted and correctly adjusted: Yes No
Is the Plough free moving: Yes No Is the entire Blade / Nose Piece in contact with the conveyor belt: Yes No
Housekeeping:
Comments:
RVICE E
SE OVER
30
XC
EL
Cer Įca
DE
KRA
ISO 9001:2008
on
L E NC

E
OHSAS 18001:2007 FS 023 02 02 2014 Page 3 of 3
BRELKO ®
CONVEYOR PRODUCTS
10. Trouble Shooting
Problem Possible Cause Possible Solution
Scraper under-tensioned Adjust to correct pressure - refer installation instructions
Poor cleaning Scraper over-tensioned Adjust to correct pressure - refer installation instruction
performance Scraper installed in wrong location Verify dimension - refer installation drawing
Scraper blade worn or damaged Replace scraper blade
Tension on scraper too high/low Adjust to correct tension - refer installation instruction
Scraper not located correctly Check scraper location for correct dimensions
Blade attack angle incorrect Check scraper location for correct dimensions
Rapid Blade Wear
Option: switch to alternate scraper tip grade (contact Brelko for
Material too abrasive for blade
available options)
Mechanical splice damaging blade Repair, skive or replace splice
Centre wear on Blade smaller than material path Add additional blade to match material path
blade (smile effect) Tension on scraper too high/low Adjust to correct pressure - refer installation instruction
Mechanical splice damaging blade Repair, skive or replace splice
Unusual wear or Belt damaged or ripped Repair or replace belt

damage to blade Scraper not correctly located Verify dimension - refer installation drawing
Damage to pulley or pulley lagging Repair or replace pulley
Scraper not located correctly Verify dimension - refer installation drawing
Blade attack angle incorrect Verify dimension - refer installation drawing
Scraper running on empty belt Use a spray pole when the belt is empty
Vibration or noise
Scraper tension too high/low Adjust to correct tension or slight adjust to diminish
Scraper locking bolts not secure Check and tighten all bolts and nuts
Scraper not square to head pulley Verify dimension - refer installation drawing
Material build-up in chute Clean up build-up on scraper and in chute
Scraper tension not set correctly Ensure correct tension/increase tension slightly
Scraper being
pushed away from Sticky material is overburdening scraper Increase tension; add primary (head pulley) scraper
pulley
Scraper not set up correctly Confirm location dimensions are equal on both sides
E905 - Page 309 to 309 Version 7.0 – © 08/2016
BRELKO ®
CONVEYOR PRODUCTS
DISCLAIMER - Catalogue
The information provided in these documents is advisory only. These recommendations are provided by BRELKO® in the interest of
promoting safety in the work place. These recommendations are general in nature and are not intended as a substitute for a thorough
safety program. Users should seek the advice, supervision or consultation of qualified engineers or other safety professionals. Any use
of this document, the information contained herein, or any other BRELKO® publication may only be made with the agreement and
understanding that the user and the user’s company assume full responsibility for the design, safety, specifications, suitability and
adequacy of the system component, or mechanical or electrical device designed or manufactured using this information. The user and the
user’s company understand and agree that BRELKO®, its member companies, its officers, agents and employees shall not be liable in any
manner under any theory of liability for the user or user’s reliance on these recommendations. The users and the user’s company agree
to release, hold harmless and indemnify BRELKO®, its member companies, successors, assigns, officers, agents and employees from any
and all claims of liability, costs, fees (including attorney’s fees), or damages arising in any way out of the use of this information. BRELKO®
and its member companies, successors, assigns, officers, agents and employees make no representations or warranties whatsoever, either
express or implied, about the information contained in this document, including, but not limited to, representations or warranties that the
information and recommendations contained herein conform to any federal, state or local laws, regulations, guidelines or ordinances.
DISCLAIMER - Digital Media Catalogue

The materials on the digital media are provided “as is” and without warranties of any kind either express or implied. To the fullest extent
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digital media will be uninterrupted or error-free, that defects will be corrected, or that any BRELKO® digital are free of viruses or other
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PRODUCT, PARTS LIST and INSTALLATION INSTRUCTION, DIGITAL MEDIA CATALOGUE

TERMS OF USE.
Although care has been taken to ensure, to the best of our knowledge, that all data and information contained on this digital media is
accurate to the extent that it relates to either matters of fact or accepted practice or matters of opinion at the time of publication, Brelko®
Conveyor Products assumes no responsibility for any errors in or misinterpretations of such data and/or information, or loss or damage
arising from or related to its use.
TRADEMARKS.
All registered trademarks, trademarks and/or service marks mentioned or implied on these compact discs are copyright by their
respective owners. It shall not be construed that any products sold or manufactured by Brelko® Conveyor Products are the original
product of the O.E.M.
RESTRICTIONS ON USE OF MATERIALS.

All materials contained on these digital media are the copyrighted property of Brelko®. All trademarks, service marks, and trade names
are proprietary to Brelko® Conveyor Products. No material from these compact discs be may copied, reproduced, republished, posted,
transmitted, or distributed in any way, without prior written consent of Brelko®. For purposes of these terms, the use of any such material
on any other digital media or computer environment is prohibited. All trademarks, service marks, trade names and trade dress are
proprietary to Brelko®. In the event you copy any software, files, images, images incorporated into or generated by the software, data or
data produced by the software (collectively known as, the “Software”) from these compact discs, are licensed to you by us (or third party
licensors) for your personal use only.
{NOTICE: Third party licensors may have further rules and/or restrictions regarding their software and/or products. Please see and follow
all third party licensors information} we do not transfer the title to any Software to you in any way. You own the medium on which the
Software is recorded, but we (or third party licensors) retain full and complete title to the You may not redistribute, sell, de-compile,
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or by any other form or means without prior written consent from Brelko®. Any code, text, photo, graphic, audio and/or video material
contained on these Brelko® digital media shall not be published, broadcast, rewritten for broadcast or publication or redistributed directly
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commercial use without prior consent, in writing, from Brelko®. Brelko® will not be held liable for any delays, inaccuracies, errors or
omissions there from or in the transmission or delivery of all or any part thereof or for any damages arising from any of the foregoing.
LEGAL - Page 596 to 597 Version 7.0 – © 08/2016
BRELKO ®
CONVEYOR PRODUCTS
SUBMISSIONS
We are pleased to hear from our distributors/customers and welcome your comments regarding our products and services. Unfortunately,
however, our long-standing company policy does not allow us to accept or consider creative ideas, suggestions, or materials other than
those that we have specifically requested. We hope you will understand that it is the intent of this policy to avoid the possibility of future
misunderstandings when projects developed by our professional staff might seem to others to be similar to their own projects. Please do
not send us any unsolicited original materials such as CAD drawings, ideas, equipment layouts or specifications. While we do value your
feedback on our services and products, we request that you be specific in your comments on those services and products, and not submit
any ideas, suggestions, or materials (unless specifically requested by Brelko®). If, at our request, you send certain specific submissions (i.e.,
email, attachments) or, despite reading our above warning you send us suggestions, ideas, notes, drawings, concepts, or other information
(collectively, the “Submissions”), the Submissions shall be deemed, and shall remain, the property of Brelko® unless noted otherwise.
None of the Submissions shall be subject to any obligation of confidence on our part and we shall not be liable for any use or disclosure
of any Submissions. Without limitation of the foregoing, we shall exclusively own all now known or hereafter existing rights to the
Submissions of every kind and nature and shall be entitled to unrestricted use of the Submissions for any purpose whatsoever, commercial
or otherwise, without compensation to the provider of the Submissions.
TERMINATION
These terms are effective until terminated by either party. You may terminate these terms at any time by discontinuing use of these
compact discs and destroying all materials obtained from and all related documentation and all copies and installations thereof, whether
made under the terms of these terms or otherwise.
!!!WARNING!!!
General Safety Procedures
Belt conveyors and their transfer points can be dangerous. By their very nature, they feature many “pinch” points and speeding objects.
They apply large amounts of mechanical energy to what is basically a loaded rubber band. Operations and maintenance personnel must
always be aware of the power of a conveyor, and they must maintain a healthy respect for its potential to injure or kill an untrained or
unwary individual.
General Safety Guidelines

There are certain safety procedures that should be observed regardless of the design of the conveyor or the circumstances of operation.
They include:
1. Lock out/tag out all energy sources to conveyor belt, conveyor accessories, and associated process equipment before beginning
any work-whether it is construction, installation, maintenance, or inspection in the area. Use a lock with one key for each piece of
equipment. Only the person doing the work should hold the key to the lock.
2. Employees should be properly trained on the material handling System (including emergency warning signals and emergency stop
controls) before they are allowed to work in the area or attempt to install any Brelko® equipment or system.
3. Employees and visitors should learn and observe all applicable company, local, state, and federal safety rules. It is recommended that
a formal testing program covering the safety rules be conducted annually.
4. The recommended operating speed and capacity for the conveyor and chute should not be exceeded. If assistance for product
selection is required, please contact your Brelko® representative.
5. All tools and work materials should be removed from the belt and chute before restarting a conveyor. A safety “walk around” is
recommended prior to conveyor operation, making sure that all nuts and bolts are tightened on all Brelko® equipment or systems
installed. Also ensuring that all other items adjusted during installation are tightened, safety guards replaced etc...
6. All emergency controls should be close to the system, easy to access, and free of debris and obstructions.
7. A hard hat, safety glasses, and steel-toe shoes should be worn when in the area of the conveyor. Loose or bulky clothing should not
be allowed.
8. Never poke, prod, or reach into a material handling system while it is in operation, to clean or remove foreign objects from the
Brelko® equipment or systems installed.
The above guidelines are not intended to replace the safety guidelines of the industrial area, and must be used in conjunction with the
industrial area’s safety regulations and those supplied by the manufactures of the specific systems.
LEGAL - Page 597 to 597 Version 7.0 – © 08/2016
User Manual
PowerFlex 520-Series Adjustable Frequency AC Drive

PowerFlex 523 Catalog Number 25A, Series B
PowerFlex 525 Catalog Number 25B
Original Instructions
Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
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.
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).
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, Studio 5000 Logix Designer, DriveTools SP, AppView, CustomView, QuickView, MainsFree
Programming, PointStop, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Summary of Changes New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preface
Overview Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 1
Installation/Wiring Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 2
Start Up Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Display and Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Smart Start-Up with Basic Program Group Parameters . . . . . . . . . . . . . . 65
LCD Display with QuickView Technology. . . . . . . . . . . . . . . . . . . . . . . . . 67
Using the USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Rockwell Automation Publication 520-UM001I-EN-E - July 2016 3

Table of Contents
Chapter 3
Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Basic Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Network Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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 Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 162
Appendix A
Supplemental Drive Information Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Appendix B
Accessories and Dimensions Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Appendix C
RS485 (DSI) Protocol Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 205
Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 208
Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4 Rockwell Automation Publication 520-UM001I-EN-E - July 2016

Table of Contents
Appendix D
Velocity StepLogic, Basic Logic and Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Timer/Counter Functions Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 210
Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Counter Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Appendix E
Encoder/Pulse Train Usage and Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Position StepLogic Application Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Determine Encoder Pulse Per Revolution (PPR) Specification Based on
Speed Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 218
Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Setup Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Appendix F
PID Set Up PID Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Appendix G
Safe-Torque-Off Function PowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . . 235
EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 239
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
PowerFlex 525 Safe-Torque-Off Operation . . . . . . . . . . . . . . . . . . . . . . . 239
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
PowerFlex 525 Certification for Safe-Torque-Off . . . . . . . . . . . . . . . . . . 245
Appendix H
EtherNet/IP Establishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . 247
Ground Connections for EtherNet/IP Networks . . . . . . . . . . . . . . . . . . 248

Table of Contents
Appendix I
Control Diagrams Induction Motor Tuning Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Appendix J
PowerFlex 525 PM Motor Download Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Configuration Automatic Configuration Using Drive Startup Wizard. . . . . . . . . . . . . 254
Manual Configuration Using Drive Keypad . . . . . . . . . . . . . . . . . . . . . . . 261
Additional PM Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Optional Parameter Adjustments for Optimum Performance . . . . . . . 266
Index

Summary of Changes
This manual contains new and updated information.
New and Updated This table contains the changes made to this revision.
Information Topic Page
Added footnote to indicate that circuit breaker selection is not available for certain drive 24...27
ratings.
Added PowerFlex 523 series B to Control I/O Wiring Block Diagram. 38
Added PowerFlex 523 series B to Control I/O Terminal Designations. 40
Added PowerFlex 523 series B I/O wiring examples for analog input and analog output. 45
Added note to PowerFlex 525 I/O wiring example for pulse train input. 46
Added footnote to enum “4” for P053 [Reset to Defalts] under Smart Start-Up with Basic 67
Program Group Parameters.
Added new sub topic for 32-bit parameters. 72
Added footnotes to parameters that are available in PowerFlex 523 FRN 3.xxx and later. Chapter 3
Updated descriptions for parameters that are available in PowerFlex 523 FRN 3.xxx and later.
Added formula for calculating scaled process value to parameter b010 [Process Display]. 79
Added recommendation to perform rotate tune when using VVC mode to parameter P040 85
[Autotune].
Added footnote to indicate which settings are PowerFlex 525 only for parameter d394 [Dig 114
Out Status].
Updated descriptions for parameters A465 [PID 1 Deadband] and A477 [PID 2 Deadband]. 123
Added corrective action to fault F114 (uC Failure). 162
Added analog output to PowerFlex 523 drives. 171
Added new topic “Determine Encoder Pulse Per Revolution (PPR) Specification Based on 217
Speed Resolution” to Appendix E.
Updated information to verify operation of the safety inputs in Appendix G. 240
General maintenance updates. Throughout manual

Summary of Changes
Notes:

Preface
Overview
The purpose of this manual is to provide you with the basic information needed
to install, start-up and troubleshoot the PowerFlex® 520-Series Adjustable
Frequency AC Drive.
For information on… See page…
Who Should Use this Manual 9
Recommended Documentation 9
Manual Conventions 10
Drive Frame Sizes 11
General Precautions 12
Catalog Number Explanation 13
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.
Recommended All the recommended documentation listed in this section is available online at
http://www.rockwellautomation.com/literature/.
Documentation
The following publications provide general drive information:
Title Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001
Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1
A Global Reference Guide for Reading Schematic Diagrams 100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
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

Preface Overview
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
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.
• 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

Overview Preface
• 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
the 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, etc. A cross reference of drive catalog
numbers and their respective frame sizes is provided in Appendix B.

Preface Overview
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 is not an indication that capacitors have discharged to
safe voltage levels.
ATTENTION: Only qualified personnel familiar with adjustable frequency AC
drives and associated machinery should plan or implement the installation,
start-up and subsequent maintenance of the system. Failure to comply may
result in personal injury and/or equipment damage.
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts
and assemblies. Static control precautions are required when installing, testing,
servicing or repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with static control
procedures, reference A-B 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 1
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.

Overview 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
Code Enclosure
B 240V AC 3
N IP20 NEMA / Open
D 480V AC 3
E 600V AC 3
Output Current @ 1 Phase, 100...120V Input Output Current @ 3 Phase, 380...480V Input
Code Amps Frame ND HD Code Amps Frame ND HD
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
Output Current @ 1 Phase, 200...240V Input
013 13.0 C 7.5 5.5 7.5 5.5
Code Amps Frame ND HD
017 17.0 C 10.0 7.5 10.0 7.5
HP kW HP kW
024 24.0 D 15.0 11.0 15.0 11.0
1P6(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
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
Output Current @ 3Phase, 200...240V Input
HP kW HP kW
0P9 0.9 A 0.5 0.4 0.5 0.4
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
(2) 027(2) 27.0 E 25.0 18.5 20.0 15.0
048 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.

Preface Overview
Notes:

Chapter 1
Installation/Wiring
This chapter provides information on mounting and wiring the PowerFlex 520-
series drives.
For information on... See page...
Mounting Considerations 15
AC Supply Source Considerations 19
General Grounding Requirements 20
Fuses and Circuit Breakers 23
Power and Control Module 28
Control Module Cover 31
Power Module Terminal Guard 31
Power Wiring 32
Power Terminal Block 35
Common Bus/Precharge Notes 36
I/O Wiring 36
Control I/O Terminal Block 37
Start and Speed Reference Control 49
CE Conformity 52
Most start-up 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 Nm (14...17 lb-in.)
B M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.)
C M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.)
D M5 (#10...24) 2.45...2.94 Nm (22...26 lb-in.)
E M8 (5/16 in.) 6.0...7.4 Nm (53...65 lb-in.)
• Protect the cooling fan by avoiding dust or metallic particles.

Chapter 1 Installation/Wiring
• Do not expose to a corrosive atmosphere.

• Protect from moisture and direct sunlight.
Minimum Mounting Clearances

See Appendix B 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

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.

Installation/Wiring Chapter 1
Ambient Operating Temperatures
See Appendix B for option kits.

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

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
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)

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)
Drive Rating Center Ground (Wye Neutral) Corner Ground, Impedance
Ground, or Ungrounded
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
High Altitude
120 60
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(1).
• Store within a relative humidity range of 0...95%, noncondensing.
• Do not expose to a corrosive atmosphere.
(1) The maximum ambient temperature for storing a Frame E drive is 70 °C.

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 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
Three-Phase
AC Input S/L2
T/L3
Jumper 1 2 3 4

Input Power Conditioning
The drive is suitable for direct connection to input power within the rated
voltage of the drive (see page 169). 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
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(2)
Greater than 120 kVA supply transformer • or Isolation Transformer
Line has power factor correction capacitors • Install Line Reactor(2)
Line has frequent power interruptions • or Isolation Transformer
Line has intermittent noise spikes in excess of 6000V (lightning)
Phase to ground voltage exceeds 125% of normal line to line voltage • Remove MOV jumper to ground.
Ungrounded distribution system • or Install Isolation Transformer with
grounded secondary if necessary.
B-phase grounded distribution system
240V open delta configuration (stinger leg)(1) • Install Line Reactor(2)
(1) 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,” etc. 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.
(2) See Appendix B for accessory ordering information.
General Grounding The drive Safety Ground - (PE) must be connected to system ground. Ground
Requirements 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

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 bus bar. 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 (RS485). It is acceptable to ground both
C1 and C2 terminals.
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 248.
For more information on RS485 networks, see Network Wiring on page 201.
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 located on the power terminal block
provides a grounding point for the motor cable shield. The motor cable shield
connected to one of these terminals (drive end) should also be connected to the
motor frame (motor end). Use a shield terminating or EMI clamp to connect the
shield to the safety ground terminal. The earthing plate or conduit box option
may be used with a cable clamp for a grounding point for the cable shield.
When shielded cable is used for control and signal wiring, the shield should be
grounded at the source end only, not at the drive end.

RFI Filter Grounding
Using a drive with filter may result in relatively high ground leakage currents.
Therefore, the filter must only be used in installations with grounded AC
supply systems and be permanently installed and solidly grounded (bonded)
to the building power distribution ground. 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 24...27 provide recommended AC line input fuse and
circuit breaker information. See Fusing and Circuit Breakers below for UL and
IEC requirements. Sizes 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 found on pages 24...27. If
available current ratings do not match those listed in the tables provided, choose
the next higher fuse rating.
• IEC – BS88 (British Standard) Parts 1 & 2(1), EN60269-1, Parts 1 & 2,
type GG or equivalent should be used.
• UL – UL Class CC, T, RK1, or J should be used.
Circuit Breakers
The “non-fuse” listings in the tables found on pages 24...27 include inverse time
circuit breakers, instantaneous trip circuit breakers (motor circuit protectors)
and 140M 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 self-protected
combination motor controllers are acceptable for IEC installations.
• UL – Only inverse time circuit breakers and the specified 140M self-
protected combination motor controllers are acceptable for UL
installations.
Bulletin 140M (Self-Protected Combination Controller)/UL489 Circuit Breakers
When using Bulletin 140M or UL489 rated circuit breakers, the guidelines listed
below must be followed in order 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.
(1) Typical designations include, but may not be limited to the following;
Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.

24
Fuses and Circuit Breakers for PowerFlex 520-Series Drives
Chapter 1
100...120V 1-Phase Input Protection Devices – Frames A...B

Catalog No. Output Ratings Input IEC Applications (Non-UL) UL Applications
Ratings
PF 523 PF 525 ND HD Fuses (Rating) Circuit Breakers Fuses (Max. Rating) Circuit Breakers Min.
HP kW HP kW Max Min. Max. 140U/140G 140M Class / Catalog No. 140U/140G 140M(2)(3)(4) Enclosure
Installation/Wiring
Amps(1) Vol. (in.3)
Amps
kVA
Frame Size
Contactor
Catalog No.
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 CLASS RK5, CC, J, or T / DLS-R-15 140U-D6D2-B80 140M-C2E-B63 –
25A-V2P5N104 25B-V2P5N104 0.5 0.4 0.5 0.4 2.5 1.3 9.6 A 100-C12 16 20 140U-D6D2-C12 140M-C2E-C10 CLASS RK5, CC, J, or T / DLS-R-20 140U-D6C2-C12 140M-C2E-C10 –
25A-V4P8N104 25B-V4P8N104 1.0 0.75 1.0 0.75 4.8 2.5 19.2 B 100-C23 25 40 140U-D6D2-C25 140M-D8E-C20 CLASS RK5, CC, J, or T / DLS-R-40 140U-D6D2-C25 140M-D8E-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 CLASS RK5, CC, J, or T / DLS-R-50 140U-D6D2-C30 140M-F8E-C25 –
200...240V 1-Phase Input Protection Devices – Frames A...B

Catalog No. Output Ratings Input IEC Applications (Non-UL) UL Applications
Ratings
Amps(1) Vol. (in.3)
Amps
kVA
Frame Size
Contactor
Catalog No.
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 CLASS RK5, CC, J, or T / DLS-R-15 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 140U-D6D2-C10 140M-C2E-B63 CLASS RK5, CC, J, or T / DLS-R-15 140U-D6D2-C10 140M-C2E-B63 –
25A-A2P5N104 25B-A2P5N104 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 CLASS RK5, CC, J, or T / DLS-R-15 140U-D6D2-C10 140M-C2E-C10 –
25A-A8P0N104 25B-A8P0N104 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 25 40 140U-D6D2-C25 140M-F8E-C25 CLASS CC, J, or T / 40 140U-D6D2-C25 140M-F8E-C25 –
Rockwell Automation Publication 520-UM001I-EN-E - July 2016

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 CLASS CC, J, or T / 40 140U-D6D2-C25 140M-F8E-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 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 32 50 140G-G6C3-C35 140M-F8E-C25 CLASS CC, J, or T / 50 –(5) 140M-F8E-C25 –
(1) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.
(2) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection Circuit Breakers Application Ratings.
(3) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.
(4) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems.
(5) Circuit breaker selection is not available for this drive rating.
Fuses and Circuit Breakers for PowerFlex 520-Series Drives (continued)
200...240V 3-Phase Input Protection Devices – Frames A...E

Catalog No.(1) Output Ratings Input IEC Applications (Non-UL) UL Applications
Ratings
Amps(2) Vol. (in.3)
Amps
kVA
Frame Size
Contactor
Catalog No.
25A-B1P6N104 – 0.25 0.2 0.25 0.2 1.6 0.9 1.9 A 100-C09 3 6 140U-D6D3-B30 140M-C2E-B25 CLASS RK5, CC, J, or T / DLS-R-15 140U-D6D3-B30 140M-C2E-B25 –
25A-B2P5N104 25B-B2P5N104 0.5 0.4 0.5 0.4 2.5 1.2 2.7 A 100-C09 6 6 140U-D6D3-B40 140M-C2E-B40 CLASS RK5, CC, J, or T / DLS-R-6 140U-D6D3-B40 140M-C2E-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 CLASS RK5, CC, J, or T / DLS-R-15 140U-D6D3-B80 140M-C2E-B63 –
25A-B8P0N104 25B-B8P0N104 2.0 1.5 2.0 1.5 8.0 4.3 9.5 A 100-C12 16 20 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, CC, J, or T / DLS-R-20 140U-D6D3-C10 140M-C2E-C10 –
25A-B011N104 25B-B011N104 3.0 2.2 3.0 2.2 11.0 6.3 13.8 A 100-C23 20 32 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, CC, J, or T / DLS-R-30 140U-D6D3-C15 140M-C2E-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 CLASS CC, J, or T / 45 140U-D6D3-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 35 63 140G-G6C3-C35 140M-F8E-C32 CLASS CC, J, or T / 60 –(7) 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 CLASS RK5, CC, J, or T / DLS-R-70 –(7) 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 CLASS CC, J, or T / 90 –(7) 140M-F8E-C45 1416.0(6)
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 –(7) CLASS CC, J, or T / 125 –(7) –(7) –
(1) Normal Duty (ND) and Heavy Duty (HD) ratings are available for this drive.
(6) When using a Manual Self-Protected (Type E) Combination Motor Controller with this drive power rating, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal
considerations may require a larger enclosure.

Installation/Wiring
25
Chapter 1
26
Chapter 1

Ratings
Installation/Wiring
Amps(2) Vol. (in.3)
Amps
kVA
Frame Size
Contactor
Catalog No.
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 CLASS RK5, CC, J, or T / DLS-R-6 –(7) 140M-C2E-B25 –
25A-D6P0N104 25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 16 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, CC, J, or T / DLS-R-15 –(7) 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 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, CC, J, or T / DLS-R-15 –(7) 140M-C2E-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 CLASS RK5, CC, J, or T / DLS-R-30 –(7) 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 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, CC, J, or T / DLS-R-30 –(7) 140M-C2E-C16 –
25A-D013N104 25B-D013N104 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 CLASS CC, J, or T / 35 –(7) 140M-D8E-C20 –
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 CLASS CC, J, or T / 60 –(7) 140M-F8E-C32 656.7(6)

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 CLASS CC, J, or T / 70 –(7) 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 CLASS CC, J, or T / 80 –(7) 140M-F8E-C45 –

Ratings
Amps(2) Vol. (in.3)
Amps
kVA
Frame Size
Contactor
Catalog No.
25A-E0P9N104 25B-E0P9N104 0.5 0.4 0.5 0.4 0.9 1.4 1.2 A 100-C09 3 6 140U-D6D3-B20 140M-C2E-B25 CLASS RK5, CC, J, or T / DLS-R-6 –(8) 140M-C2E-B25 –
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 CLASS RK5, CC, J, or T / DLS-R-15 –(8) 140M-D8E-B63 –
25A-E6P6N104 25B-E6P6N104 5.0 4.0 5.0 4.0 6.6 9.1 8.0 B 100-C09 10 20 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, CC, J, or T / DLS-R-20 –(8) 140M-D8E-C10 –
25A-E9P9N104 25B-E9P9N104 7.5 5.5 7.5 5.5 9.9 12.8 11.2 C 100-C16 16 25 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, CC, J, or T / DLS-R-25 –(8) 140M-D8E-C16(6) –
25A-E012N104 25B-E012N104 10.0 7.5 10.0 7.5 12.0 15.4 13.5 C 100-C23 20 32 140U-D6D3-C20 140M-C2E-C16 CLASS RK5, CC, J, or T / DLS-R-30 –(8) 140M-D8E-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 CLASS CC, J, or T / 50 –(8) 140M-F8E-C25 656.7(7)
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 CLASS CC, J, or T / 60 –(8) 140M-F8E-C32 656.7(7)
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 CLASS CC, J, or T / 50 –(8) 140M-F8E-C32 1416.0(7)
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 CLASS CC, J, or T / 60 –(8) 140M-F8E-C32 1416.0(7)
(6) When used with the 140M circuit breaker, the 25A-E9P9104 must be installed in a ventilated or non-ventilated enclosure with the minimum size of 457.2 x 457.2 x 269.8 mm (18 x 18 x 10.62 in.).

Installation/Wiring
27
Chapter 1
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.

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.

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.
2. Slide the front cover down to remove from the Control Module.
Re-attach the front cover when wiring is complete.
Power Module Terminal To access the power terminals, the terminal guard must be removed. To remove:
Guard 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.
3. Slide the terminal guard down to remove from the Power Module.
Re-attach the terminal guard when wiring is complete.
To access the power terminals for Frame A, you need to separate the Power and
Control Modules. See Separating the Power and Control Module on page 28 for
instructions.
Power Wiring ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) 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 caused by induced voltages,
unused wires in the conduit must be grounded at both ends. For the same
reason, if a drive sharing a conduit is being serviced or installed, all drives using
this conduit should be disabled. This will help minimize the possible shock
hazard from “cross coupled” power leads.
Motor Cable Types Acceptable for 100...600 Volt Installations
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated from
sensitive circuits. As an approximate guide, allow a spacing of 0.3 m (1 ft) for
every 10 m (32.8 ft) of length. In all cases, long parallel runs must be avoided. Do
not use cable with an insulation thickness less than 15 mils (0.4 mm/0.015 in.).
Do not route more than three sets of motor leads in 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 ambient must use 600V, 90 °C wire.

UL installations in 50 °C ambient must use 600V, 75 °C or 90 °C wire.
UL installations in 40 °C ambient should use 600V, 75 °C or 90 °C wire.
Use copper wire only. Wire gauge requirements and recommendations are based
on 75 °C. 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 stated in the Motor Cable Length Restrictions Tables in
“Wiring and Grounding Guide, (PWM) AC Drives,” 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 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 of the general benefits of multi-conductor cable with
the added benefit of a copper braided shield that can contain much of the noise
generated by a typical AC Drive. Strong consideration for shielded cable should
be given in installations with sensitive equipment such as weigh scales, capacitive
proximity switches and other devices that may be affected by electrical noise in
the distribution system. Applications with large numbers of drives in a similar
location, imposed EMC regulations or a high degree of communications /
networking are also good candidates for shielded cable.
Shielded cable may also help reduce shaft voltage and induced bearing currents
for some applications. In addition, the increased impedance of shielded cable may
help extend the distance that the motor can be located from the drive without the
addition of motor protective devices such as terminator networks. Refer to
Reflected Wave in “Wiring and Grounding Guide, (PWM) AC Drives,”
publication DRIVES-IN001.
Consideration should be given to all of the 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 (4) 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 4
conductors of THHN wire and wrap them tightly with a foil shield. This
construction can greatly increase the cable charging current required and reduce
the overall drive performance. Unless specified in the individual distance tables as
tested with the drive, these cables are not recommended and their performance
against the lead length limits supplied is not known.
Recommended Shielded Wire
Location Rating/Type Description
Standard (Option 1) 600V, 90 °C (194 °F) XHHW2/RHW-2 • Four tinned copper conductors with XLPE insulation.
Anixter B209500-B209507, Belden • Copper braid/aluminum foil combination shield and
29501-29507, or equivalent tinned copper drain wire.
• PVC jacket.
Standard (Option 2) Tray rated 600V, 90 °C (194 °F) • Three tinned copper conductors with XLPE insulation.
RHH/RHW-2 Anixter OLF-7xxxxx or • 5 mil single helical copper tape (25% overlap min.)
equivalent with three bare copper grounds in contact with shield.
• PVC jacket.
Class I & II; Tray rated 600V, 90 °C (194 °F) • Three bare copper conductors with XLPE insulation
Division I & II RHH/RHW-2 Anixter 7V-7xxxx-3G or and impervious corrugated continuously welded
equivalent aluminum armor.
• 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). Refer to Reflected Wave in
“Wiring and Grounding Guide, (PWM) AC Drives,” 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 the purpose of 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).

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
U/T1, V/T2, W/T3 Motor Phase Connection = Switch any two motor leads to change
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 Nm (15.6...19.1 lb-in.)
B 8.4 mm2 (8 AWG) 2.1 mm2 (14 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.)
C 8.4 mm2 (8 AWG) 2.1 mm2 (14 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.)
D 13.3 mm2 (6 AWG) 5.3 mm2 (10 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.)
E 26.7 mm2 (3 AWG) 8.4 mm2 (8 AWG) 3.09...3.77 Nm (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
auxiliary contact on the disconnect must be connected to a digital input of the
Notes 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.
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 ambient temperature.

75 °C wire must be used for 60 °C ambient temperature.

Recommended Signal Wire

Signal Type/ Belden Wire Type(s)(1) Description Min. Insulation
Where Used (or equivalent) Rating
Analog I/O & PTC 8760/9460 0.750 mm2 (18 AWG), twisted pair, 300V,
100% shield with drain(2) 60 °C (140 °F)
Remote Pot 8770 0.750 mm2 (18 AWG), 3 conductor, shielded
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

Type Wire Type(s) Description Min. Insulation
Rating
Unshielded Per US NEC or applicable – 300V,
national or local code 60 °C (140 °F)
Shielded Multi-conductor shielded 0.750 mm2 (18 AWG), 3 conductor, shielded.
cable such as Belden 8770
(or equivalent)
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 Nm (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 Control I/O Wiring Block Diagram
Series A
Typical Typical
(1) SRC wiring SNK wiring
Stop
01
DigIn TermBlk 02/(2)
Start/Run FWD
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

Series B
Typical Typical
Stop
01
DigIn TermBlk 02/(2)
Start/Run FWD
02
DigIn TermBlk 03/
Direction/Run REV
03
04
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
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 50 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 Per P045
2 “DigIn TrmBlk” See t062, t063 [DigIn TermBlk xx] below [Stop Mode]
3 “Serial/DSI” Coast
4 “Network Opt” Coast
5 “Ethernet/IP” (1) Coast
(1) Setting is specific to PowerFlex 525 drives only.


t062, t063 [DigIn TermBlk xx] I/O Terminal 01 Stop Normal Stop
48 “2-Wire FWD” t064 [2-Wire Mode] is set to: Per P045
• 0, 1, or 2 = Coast [Stop Mode]
• 3 = per P045 [Stop Mode]
49 “3-Wire Start” Per P045 [Stop Mode]
50 “2-Wire REV” t064 [2-Wire Mode] is set to:
• 0, 1, or 2 = Coast
51 “3-Wire Dir” Per P045 [Stop Mode]
IMPORTANT The drive is shipped with a jumper 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.
(5) 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 will result.
Control I/O Terminal Designations

No. Signal Default Description Parameter
R1 Relay N.O. Fault Normally open contact for output relay.
t076
R2 Relay Common Fault Common for output relay.
R3 Relay N.C. Motor Running Normally closed contact for output relay. t081
01 Stop Coast Three wire stop. However, it functions as a stop under all input P045(2)
modes and cannot be disabled.
02 DigIn TermBlk 02/ Run FWD Used to initiate motion and also can be used as a programmable P045, P046,
Start/Run FWD digital input. It can be programmed with t062 [DigIn TermBlk P048, P050,
02] as three wire (Start/Dir with Stop) or two wire (Run FWD/ A544, t062
Run REV) control. Current consumption is 6 mA.
03 DigIn TermBlk 03/ Run REV Used to initiate motion and also can be used as a programmable t063
Dir/Run REV digital input. It can be programmed with t063 [DigIn TermBlk
03] as three wire (Start/Dir with Stop) or two wire (Run FWD/
04 Digital Common – Return for digital I/O. Electrically isolated (along with the digital –
I/O) from the rest of the drive.
05 DigIn TermBlk 05/ Preset Freq Program with t065 [DigIn TermBlk 05]. t065
Pulse In Also functions as a Pulse Train input for reference or speed
feedback. Requires an NPN pulse input. The maximum
frequency is 100 kHz. Current consumption is 6 mA.
06 DigIn TermBlk 06 Preset Freq Program with t066 [DigIn TermBlk 06]. t066
Current consumption is 6 mA.
11 +24V DC – Referenced to Digital Common. –
Drive supplied power for digital inputs.
Maximum output current is 100 mA.
12 +10V DC – Referenced to Analog Common. P047, P049
Drive supplied power for 0...10V external potentiometer.


13 For Series A Not Active For external 0-10V (unipolar) input supply or potentiometer P047, P049,
0-10V In(1) wiper. t062, t063,
Input impedance: t065, t066,
Voltage source = 100 kΩ t093, A459,
Allowable potentiometer resistance range = 1...10 kΩ A471
For Series B Not Active External analog input supply, selectable by Analog Input P047, P049,
Analog Input jumper. Default is 0-10V (unipolar) input supply or t062, t063,
potentiometer wiper. t065, t066,
Input impedance: t093, A459,
Voltage source = 100 kΩ A471
Allowable potentiometer resistance range = 1...10 kΩ
Change Analog Input jumper to 4-20 mA for external 4-20 mA
input supply. Input impedance = 250 Ω
14 Analog Common – Return for the analog I/O. Electrically isolated (along with the –
analog I/O) from the rest of the drive.
15 For Series A Not Active For external 4-20 mA input supply. P047, P049,
4-20mA In(1) Input impedance = 250 Ω t062, t063,
t065, t066,
A459, A471
For Series B OutFreq 0-10 The default analog output is 0-10V. To convert a current value, t088, t089
Analog Output change the Analog Output jumper to 0-20 mA. Program with
t088 [Analog Out Sel]. Maximum analog value can be scaled
with t089 [Analog Out High].
Maximum Load: 4-20 mA = 525 Ω (10.5V)
0-10V = 1 kΩ (10 mA)
C1 C1 – This terminal is tied to the RJ-45 port shield. Tie this terminal to –
a clean ground in order to improve noise immunity when using
external communication peripherals.
C2 C2 – This is the signal common for the communication signals. –
(1) 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 will result.
(2) See Footnote (1) on page 39.

PowerFlex 525 Control I/O Terminal Block

PowerFlex 525 Control I/O Wiring Block Diagram
Typical Typical
Stop
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+
04
DigIn TermBlk 05
05
DigIn TermBlk 06
06
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
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 50 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.

P046, P048, P050 [Start Source x] I/O Terminal 01 Stop Normal Stop
1 “Keypad” Coast Per P045
2 “DigIn TrmBlk” See t062, t063 [DigIn TermBlk xx] below [Stop Mode]
3 “Serial/DSI” Coast
4 “Network Opt” Coast
5 “EtherNet/IP” Coast


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

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 Motor Running
Common for output relay.
t081
R6 Relay 2 N.C. Motor Running
Normally closed contact for output relay.
01 Stop Coast Three wire stop. However, it functions as a stop under all input P045(1)
modes and cannot be disabled.
02 DigIn TermBlk 02/ Run FWD Used to initiate motion and also can be used as a programmable P045, P046,
Start/Run FWD digital input. It can be programmed with t062 [DigIn TermBlk P048, P050,
02] as three wire (Start/Dir with Stop) or two wire (Run FWD/ A544, t062
03 DigIn TermBlk 03/ Run REV Used to initiate motion and also can be used as a programmable t063
Dir/Run REV digital input. It can be programmed with t063 [DigIn TermBlk
03] as three wire (Start/Dir with Stop) or two wire (Run FWD/
04 Digital Common – Return for digital I/O. Electrically isolated (along with the digital –
I/O) from the rest of the drive.
07 DigIn TermBlk 07/ Start Source 2 Program with t067 [DigIn TermBlk 07]. t067
Pulse In + Speed Also functions as a Pulse Train input for reference or speed
Reference2 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
C1 C1 – This terminal is tied to the RJ-45 port shield. Tie this terminal to –
a clean ground in order 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. –
S+ Safety +24V – +24V supply for safety circuit. Internally tied to the +24V DC –
source (Pin 11).
11 +24V DC – Referenced to Digital Common. –
Drive supplied power for digital inputs.


12 +10V DC – Referenced to Analog Common. P047, P049
Drive supplied power for 0...10V external potentiometer.
13 ±10V In Not Active For external 0-10V (unipolar) or ±10V (bipolar) input supply or P047, P049,
potentiometer wiper. t062, t063,
Input impedance: t065, t066,
Voltage source = 100 kΩ t093, A459,
Allowable potentiometer resistance range = 1...10 kΩ A471
14 Analog Common – Return for the analog I/O. Electrically isolated (along with the –
analog I/O) from the rest of the drive.
15 4-20mA In Not Active For external 4-20 mA input supply. P047, P049,
Input impedance = 250 Ω t062, t063,
t065, t066,
A459, A471
16 Analog Output OutFreq 0-10 The default analog output is 0-10V. To convert a current value, t088, t089
change the Analog Output jumper to 0-20 mA. Program with
t088 [Analog Out Sel]. Maximum analog value can be scaled
with t089 [Analog Out High].
Maximum Load: 4-20 mA = 525 Ω (10.5V)
0-10V = 1 kΩ (10 mA)
17 Opto Output 1 Motor Running Program with t069 [Opto Out1 Sel]. t069, t070,
Each Opto-Output is rated 30V DC 50 mA (Non-inductive). t075
18 Opto Output 2 At Frequency Program with t072 [Opto Out1 Sel]. t072, t073,
Each Opto-Output is rated 30V DC 50 mA (Non-inductive). t075
19 Opto Common – The emitters of the Optocoupler Outputs (1 and 2) are tied –
together at Optocoupler Common. Electrically isolated from the
rest of the drive.
(1) See Footnote (1) on page 39.

I/O Wiring Examples

I/O Connection Example
Potentiometer P047 [Speed Reference1] = 5 “0-10V Input”
1...10k Ω Pot.
Recommended 12
(2 W minimum) 13
14
Analog Input Bipolar Unipolar (Voltage)

0-10V, 100k Ω impedance P047 [Speed Reference1] = 5 “0-10V Input” P047 [Speed Reference1] = 5 “0-10V Input”
4-20 mA, 250 Ω and t093 [10V Bipolar Enbl] = 1 “Bi-Polar In”
impedance
±10V 13 + 13
Common 14 Common 14
Unipolar (Current)
P047 [Speed Reference1] = 6 “4-20mA Input”
PowerFlex 523 Series A, PowerFlex 523 Series B
PowerFlex 525
+ 13
14 14 4-20 mA
Common Common
Analog In
+ 15
0-10V
Analog Input, PTC Wire the PTC and External Resistor (typically matched to the PTC Hot Resistance) to I/O
For Drive Fault 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
R6
11
Re 12
13 RPTC (hot)
%VTrip = X 100
14 RPTC (hot) + Re
RPTC
05


Pulse Train Input PowerFlex 523 PowerFlex 525
PowerFlex 523
t065 [DigIn TermBlk 05]
= 52

Pulse In Pulse In
PowerFlex 525
t067 [DigIn TermBlk 07] Common Common
04 04
= 52 Pulse In 05
Digital Pulse In Digital
Input Input
Use P047, P049 and P051 07
[Speed Referencex] to
select pulse input. The device connected to terminal 5 (for PowerFlex 523) or terminal 7 (for PowerFlex 525)
Jumper for DigIn TermBlk needs to be NPN or push-pull output driver.
05 or 07 Sel must be
moved to Pulse In.
2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)
Non-Reversing
P046 [Start Source 1] = 2 11
and t062 [DigIn TermBlk 01
02] = 48 01 02
Stop-Run 02 Stop-Run
Input must be active for 04
the drive to run. When
input is opened, the drive
will stop as specified by +24V Common
P045 [Stop Mode].
If desired, a User Supplied Each digital input draws 6 mA.
24V DC power source can
be used. Refer to the
“External Supply (SRC)”
example.
2 Wire SNK Control - Internal Supply (SNK)
Non-Reversing
01
02
Stop-Run 03
04

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


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

Reversing
11
P046 [Start Source 1] = 2,
Stop 01
Stop 01 02
= 49 and t063 [DigIn
02 03
TermBlk 03] = 51 Start
03 04
A momentary input will Start
start the drive. A stop Direction
input to I/O Terminal 01 Direction
will stop the drive as +24V Common
specified by P045 [Stop Each digital input draws 6 mA.
Mode]. I/O Terminal 03
determines direction.
Reversing
Stop 01
02
03
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 18) 17
operation. CR
19
When using Opto-Output
with an inductive load +24V Common
such as a relay, install a Each Opto-Output is rated 30V DC 50 mA (Non-inductive).
recovery diode parallel to
the relay as shown, to
prevent damage to the
output.


Analog Output(2) t088 [Analog Out Sel] = 0 through 23
t088 [Analog Out Sel] The Analog Output Select jumper must be set to match the analog output signal mode set in
determines analog output t088 [Analog Out Sel].
type and drive conditions.
PowerFlex 523 Series B PowerFlex 525
0-10V,
1k Ω minimum
0-20 mA/4-20 mA,
525 Ω maximum 14 14
Common Common
+ 15
+ 16
(1) Feature is specific to PowerFlex 525 drives only

(2) Feature is not applicable to PowerFlex 523 series A drives.
Typical Multiple Drive Connection Examples

Input/Output Connection Example
Multiple Digital Input 02 04 02 04 02 04
Connections
Customer Inputs can be
wired per External Supply
(SRC).
Customer Inputs Optional Ground Connection

When connecting a single input such as Run, Stop, Reverse or Preset Speeds to multiple
drives, it is important to connect I/O Terminal 04 common together for all drives. If they are to
be tied into another common (such as earth ground or separate apparatus ground) 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.
Multiple Analog
Connections 12 13 14 13 14 13 14
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.

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 50 for information on selecting the correct digital input.

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].

Accel/Decel Selection
The Accel/Decel rate can be obtained by a variety of 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.

CE Conformity Compliance with the Low Voltage Directive and Electromagnetic Compatibility
Directive has been demonstrated using harmonized European Norm (EN)
standards published in the Official Journal of the European Communities.
PowerFlex 520-series drives comply with the EN standards listed below when
installed according to the installation instructions in this manual.
CE Declarations of Conformity are available online at:

http://www.rockwellautomation.com/products/certification/.
Low Voltage Directive (2006/95/EC and 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.
2 Normally, only non-conductive pollution occurs. Occasionally, however, a temporary
conductivity caused by condensation is to be expected, when the drive is out of operation.
EMC Directive (2004/108/EC and 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
Refer to Appendix G for installation consideration related to Machinery

Directive.
ATEX Directive (94/9/EC and 2014/34/EU)

• EN 50495 – Safety devices required for the safe functioning of equipment
with respect to explosion risks.

General Considerations
• For CE compliance, drives must satisfy installation requirements 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. See Pollution
Degree Ratings According to EN 61800-5-1 on page 52 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 provided in this document. However, many factors can
influence the EMC compliance of an entire machine or installation, and
compliance of the drive itself does not ensure compliance of all
applications.
• PowerFlex 520-series drives are not intended to be used on public low-
voltage networks 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 55) 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 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.
• The motor cable should be kept as short as possible in order 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

• 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 in order
to maintain compliance with the CE LV Directive. 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 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 RCD’s
(residual current-operated protective devices) or RCM’s (residual
current-operated monitoring devices) of type A or AC to provide
protection for other equipment in the installation. Where an RCD or
RCM is used for protection in case of direct or indirect contact, only an
RCD or RCM of Type B is allowed on the supply side of this product.
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 55. See General Grounding Requirements on page 20
for additional grounding recommendations.
• Output power wiring to the motor must employ cables with a braided
shield providing 75% or greater coverage, or the cables must be housed in
metal conduit, or equivalent shield must be provided. Continuous
shielding must be provided from the drive enclosure to the motor
enclosure. Both ends of the motor cable shield (or conduit) must terminate
with a low-impedance connection to earth.
Drive Frames A...E: At the drive end of the motor, either
a. The cable shield must be clamped to a properly installed “EMC Plate”
for the drive. Kit number 25-EMC1-Fx.
or
b. The cable shield or conduit must terminate in a shielded connector
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 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
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.
PowerFlex 520-Series RF Emission Compliance and Installation Requirements

Filter Type Standard/Limits
EN61800-3 Category C1 EN61800-3 Category C2 EN61800-3 Category C3
EN61000-6-3 EN61000-6-4 (I ≤ 100 A)
CISPR11 Group 1 Class B CISPR11 Group 1 Class A CISPR11 Group 1 Class A
(Input power ≤ 20 kVA) (Input power > 20 kVA)
Internal – 10 m (33 ft) 20 m (66 ft)
External(1) 30 m (16 ft) 100 m (328 ft) 100 m (328 ft)
(1) See Appendix B 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

Frame Category C1 Category C2
Size Enclosure Conduit or Shielded EMC Cores Required Enclosure Conduit or Shielded EMC Cores Required
Cable @ Input (Included with product) 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
A Yes Yes No No No Input/Output
B Yes Yes Output only No No Input/Output
200...240V AC (-15%, +10%) – 1-Phase Input with Internal EMC Filter, 0...230V 3-Phase Output(1)
A * * * Yes No No
B * * * Yes No No
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
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(1)
A * * * No No Input/Output
B * * * No No Input/Output
C * * * No No Input/Output
D * * * No No Input/Output
E * * * No No Input/Output
B Yes Yes No No No Input/Output
C Yes Yes No No No Input/Output
D Yes Yes No No No Input/Output
E Yes Yes No Yes No No
(1) An (*) indicates that EMC requirements are not met.

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

Notes:

Chapter 2
Start Up
This chapter describes how to start up the PowerFlex 520-series drive. To simplify
drive setup, the most commonly programmed parameters are organized in a
single Basic Program Group.
Prepare for Drive Start-Up 59
Display and Control Keys 62
Viewing and Editing Parameters 63
Drive Programming Tools 64
Smart Start-Up with Basic Program Group Parameters 65
LCD Display with QuickView Technology 67
Using the USB Port 67
IMPORTANT Read the General Precautions section before proceeding.
ATTENTION: Power must be applied to the drive to perform the following

start-up 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 Start-Up 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.

Chapter 2 Start Up
6. Verify that the Sink (SNK)/Source (SRC) jumper is set to match your
control wiring scheme. See the PowerFlex 523 Control I/O Wiring Block
Diagram on page 38 and PowerFlex 525 Control I/O Wiring Block
Diagram on page 42 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 Defalts].
To reset the communication adapters, see the user manual of the adapter
for more information.
13. Configure the basic program parameters related to the motor. See Smart
Start-Up with Basic Program Group Parameters on page 65.
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 67
for more information.
Otherwise, set the necessary parameters for your application using the
LCD keypad interface, Connected Components Workbench, or RSLogix
or Logix Designer 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 needed for the drive analog and
digital I/O to work correctly. Verify the operation. Record these
settings for your reference.

Start Up Chapter 2
16. Verify the drive and motor perform as specified.

• Verify that the Stop input is present or the drive will 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 the drive is receiving the speed reference from the correct place
and that the reference is scaled correctly.
• Verify the drive is receiving start and stop commands correctly.
• Verify input currents are balanced.
• Verify motor currents are balanced.
17. Save a backup of the drive settings using the USB utility application. See
Using the USB Port on page 67 for more information.
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.

Chapter 2 Start Up
Display and Control Keys PowerFlex 523 Menu Parameter Group and Description
Basic Display
Commonly viewed drive operating conditions.
FWD Basic Program
Commonly used programmable functions.
Terminal Blocks
Programmable terminal functions.
Communications
Programmable communication functions.
Esc Sel
Logic (PowerFlex 525 only)
Programmable logic functions.
Advanced Display
Advanced drive operating conditions.
Advanced Program
PowerFlex 525 Remaining programmable functions.
Network
Network functions that are shown only when a comm
FWD card is used.
ENET LINK Modified
EtherNet/IP
Functions from the other groups with values changed
from default.
Fault and Diagnostic
Esc Sel
Consists of list of codes for specific fault conditions.
AppView and CustomView
Functions from the other groups organized for specific
applications.
Control and Navigation Keys

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

Up Arrow Scroll through user-selectable display parameters or groups.
Down Arrow Increment values.
Escape Back one step in programming menu.
Cancel a change to a parameter value and exit Program Mode.
Esc
Select Advance one step in programming menu.

Sel Select a digit when viewing parameter value.
Enter Advance one step in programming menu.
Save a change to a parameter value.

Start Up Chapter 2
Key Name Description

Reverse Used to reverse direction of the drive. Default is active.
Controlled by parameters P046, P048 and P050 [Start Source x]
and A544 [Reverse Disable].
Start Used to start the drive. Default is active.
Controlled by parameters P046, P048 and P050 [Start Source x].
Stop Used to stop the drive or clear a fault.
This key is always active.
Controlled by parameter P045 [Stop Mode].
Potentiometer Used to control speed of drive. Default is active.
Controlled by parameters P047, P049 and P051
[Speed Referencex].
Viewing and Editing The following is an example of basic integral keypad and display functions. This
example provides basic navigation instructions and illustrates how to program
Parameters a parameter.
Step Key(s) Example Display
1. When power is applied, the last user-selected
Basic Display Group parameter number is briefly FWD
HERTZ
displayed with flashing characters. The display
then defaults to that parameter’s current value.
(Example shows the value of b001 [Output
Freq] with the drive stopped.)
2. Press Esc to display the Basic Display Group
parameter number shown on power-up. The FWD
parameter number will flash. Esc
3. Press Esc to enter the parameter group list. The

parameter group letter will flash. FWD
Esc
4. Press the Up Arrow or Down Arrow to scroll

through the group list (b, P, t, C, L, d, A, f and or
FWD
Gx).
5. Press Enter or Sel to enter a group. The right
digit of the last viewed parameter in that group FWD
will flash. or Sel

through the parameter list. or
FWD
7. Press Enter to view the value of the parameter. VOLTS

FWD
Or
Press Esc to return to the parameter list.
8. Press Enter or Sel to enter Program Mode and VOLTS

edit the value. The right digit will flash and the FWD
word Program on the LCD display will light up. or Sel PROGRAM
9. Press the Up Arrow or Down Arrow to change

the parameter value. or VOLTS
FWD
PROGRAM

Chapter 2 Start Up
Step Key(s) Example Display

10. If desired, press Sel to move from digit to digit VOLTS
or bit to bit. The digit or bit that you can change Sel FWD
will flash. PROGRAM
11. Press Esc to cancel a change and exit Program VOLTS

Mode. FWD
Or Esc or
or
Press Enter to save a change and exit Program VOLTS
Mode. FWD
The digit will stop flashing and the word

Program on the LCD display will turn off.
12. Press Esc to return to the parameter list.
Continue to press Esc to back out of the FWD
programming menu. Esc
If pressing Esc does not change the display, then
b001 [Output Freq] is displayed. Press Enter or
Sel to enter the group list again.
Drive Programming Tools Some features in the PowerFlex 520-series drive are not supported by older
configuration software tools. It is strongly recommended that customers using
such tools migrate to RSLogix 5000 (version 17.0 or greater) or Logix Designer
(version 21.0 or greater) with Add-On-Profile (AOP), or Connected
Components Workbench (version 5.0 or greater) to enjoy a richer, full-featured
configuration experience. For Automatic Device Configuration (ADC) support,
RSLogix 5000 version 20.0 or greater is required.
Description Catalog Number/Release Version
Connected Components Workbench(1) Version 5.0 or greater
Logix Designer Version 21.0 or greater
RSLogix 5000 Version 17.0 or greater
Built-in USB software tool –
Serial Converter Module(2) 22-SCM-232
USB Converter Module(2) 1203-USB
Remote Panel Mount, LCD Display(2) 22-HIM-C2S
Remote Handheld, LCD Display(2) 22-HIM-A3
(1) Available as a free download at http://ab.rockwellautomation.com/programmable-controllers/connected-components-
workbench-software.
(2) Does not support the new dynamic parameter groups (AppView, CustomView), and CopyCat functionality is limited to the linear
parameter list.
Language Support Language Keypad/LCD Display RSLogix 5000/ Connected Components

Logix Designer Workbench
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 –

Start Up Chapter 2
Language Keypad/LCD Display RSLogix 5000/ Connected Components

Logix Designer Workbench
Polish(1) Y – –
Turkish(1) Y – –
Czech(1) Y – –
(1) Due to a limitation of the LCD Display, some of the characters for Polish, Turkish, and Czech will be modified.
Smart Start-Up with Basic The PowerFlex 520-series drive is designed so that start up is simple and efficient.
The Basic Program Group contains the most commonly used parameters. See
Program Group Parameters Programming and Parameters on page 71 for detailed descriptions of the
parameters listed here, as well as the full list of available parameters.
= Stop drive before changing this parameter.
= Parameter is specific to PowerFlex 525 drives only.
PF 525
No. Parameter Min/Max Display/Options Default

P030 [Language] 1/15 1 = English 1
Selects the language displayed. 2 = Français
3 = Español
Important: The setting takes effect after the drive 4 = Italiano
is power cycled. 5 = Deutsch
6 = Reserved
7 = Português
8 = Reserved
9 = Reserved
10 = Reserved
11 = Reserved
12 = Polish
13 = Reserved
14 = Turkish
15 = Czech
P031 [Motor NP Volts] 10V (for 200V Drives), 20V 1V Based on Drive Rating
(for 400V Drives), 25V (for
600V Drives)/Drive Rated
Volts
Sets the motor nameplate rated volts.
P032 [Motor NP Hertz] 15/500 Hz 1 Hz 60 Hz
Sets the motor nameplate rated frequency.
P033 [Motor OL Current] 0.0/(Drive Rated Amps x 2) 0.1 A Based on Drive Rating
Sets the motor nameplate overload current.
P034 [Motor NP FLA] 0.0/(Drive Rated Amps x 2) 0.1 A Drive Rated Amps
Sets the motor nameplate FLA.
P035 [Motor NP Poles] 2/40 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.
P037 [Motor NP Power] 0.00/Drive Rated Power 0.01 kW Drive Rated Power
PF 525
Sets the motor nameplate power. Used in PM
regulator.
P038 [Voltage Class] 2/3 2 = “480V” 3
Sets the voltage class of 600V drives. Only applicable 3 = “600V”
to 600V drives.

Chapter 2 Start Up

PF 525

P039 [Torque Perf Mode] 0/4 0 = “V/Hz” 1
Selects the motor control mode. 1 = “SVC”
2 = “Economize”
(1) Setting is specific to PowerFlex 525 drives only. 3 = “Vector”(1)
(1)(2)(3)
(2) Setting is available in PowerFlex 525 FRN 5.xxx and 4 = “PM Control”
later.
(3) 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.
P040 [Autotune] 0/2 0 = “Ready/Idle” 0
Enables a static (not spinning) or dynamic (motor 1 = “Static Tune”
spinning) autotune. 2 = “Rotate Tune”
P041 [Accel Time 1] 0.00/600.00 s 0.01 s 10.00 s
Sets the time for the drive to accel from 0 Hz to
[Maximum Freq].
P042 [Decel Time 1] 0.00/600.00 s 0.01 s 10.00 s
Sets the time for the drive to decel from [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.
P045 [Stop Mode] 0/11 0 = “Ramp, CF”(1) 0
Stop command for normal stop. 1 = “Coast, CF”(1)
2 = “DC Brake, CF”(1)
Important: I/O Terminal 01 is always a stop input. 3 = “DCBrkAuto,CF”(1)
The stopping mode is determined by the drive 4 = “Ramp”
setting. 5 = “Coast”
Important: The drive is shipped with a jumper 6 = “DC Brake”
installed between I/O Terminals 01 and 11. Remove 7 = “DC BrakeAuto”
this jumper when using I/O Terminal 01 as a stop or 8 = “Ramp+EM B,CF”(1)
enable input. 9 = “Ramp+EM Brk”
(1) Stop input also clears active fault.
10 = “PointStp,CF”(1)
11 = “PointStop”
P046, [Start Source 1] 1/5 1 = “Keypad”(1) P046 = 1
P048, Sets the default control scheme used to start the 2 = “DigIn TrmBlk”(2) P048 = 2
P050 drive unless overriden by P048 [Start Source 2] or 3 = “Serial/DSI” P050 = 3 (PowerFlex 523)
P050 [Start Source 3]. 4 = “Network Opt” 5 (PowerFlex 525)
5 = “Ethernet/IP”(3)
(1) When active, the Reverse key is also active unless
disabled by A544 [Reverse Disable].
(2) If “DigIn TrmBlk” is selected, ensure that the digital
inputs are properly configured.

Start Up Chapter 2

PF 525

P047, [Speed Reference1] 1/16 1 = “Drive Pot” P047 = 1
P049, Sets the default speed command of the drive unless 2 = “Keypad Freq” P049 = 5
P051 overridden by P049 [Speed Reference2] or P051 3 = “Serial/DSI” P051 = 3 (PowerFlex 523)
[Speed Reference3]. 4 = “Network Opt” 15 (PowerFlex 525)
5 = “0-10V Input”
(1) Setting is specific to PowerFlex 525 drives only. 6 = “4-20mA Input”
7 = “Preset Freq”
8 = “Anlg In Mult”(1)
9 = “MOP”
10 = “Pulse Input”
11 = “PID1 Output”
12 = “PID2 Output”(1)
13 = “Step Logic”(1)
14 = “Encoder”(1)
15 = “Ethernet/IP”(1)
16 = “Positioning”(1)
P052 [Average kWh Cost] 0.00/655.35 0.01 0.00
Sets the average cost per kWh.
P053 [Reset To Defalts] 0/4 0 = “Ready/Idle” 0
Resets parameters to their factory defaults values. 1 = “Param Reset”
After a Reset command, the value of this parameter 2 = “Factory Rset”
returns to zero. 3 = “Power Reset”
4 = “Module Reset”(1)(2)(3)
(1) Power cycle of the drive, NO parameters are reset.
(2) Setting is available in PowerFlex 525 FRN 5.xxx and
later.
(3) Setting is available in PowerFlex 523 FRN 3.xxx and
later.
LCD Display with QuickView QuickView™ technology enables text to scroll across the LCD display of the
PowerFlex 520-series drive. This allows you to easily configure parameters,
Technology 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 64 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 the
purpose of upgrading drive firmware or uploading/downloading a parameter
configuration.
IMPORTANT To use the USB feature of the PowerFlex 520-series drive, Microsoft .Net
Framework 2.0 and Windows XP or later is required.
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.

Chapter 2 Start Up
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.
Double-click on 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 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.

Start Up Chapter 2
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.

Chapter 2 Start Up
Notes:

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 version 17.0 or greater, Logix Designer
version 21.0 or greater, o r Connected Components Workbench version 5.0 or
greater software. 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.
About Parameters 71
Parameter Groups 73
Basic Display Group 78
Basic Program Group 83
Terminal Block Group 89
Communications Group 101
Logic Group 107
Advanced Display Group 110
Advanced Program Group 115
Network Parameter Group 141
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 2 or more items. Each item is
represented by a number.
• Numeric Parameters
These parameters have a single numerical value (0.1V).

Chapter 3 Programming and Parameters
• Bit Parameters
Bit parameters have five individual digits associated with 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.

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 RS485
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 forumla,

([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 will be 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.

Programming and Parameters Chapter 3
Parameter Groups For an alphabetical listing of parameters, see Parameter Cross Reference by Name
on page 152.
Basic Display Output Voltage b004 Control Source b012 Elapsed Run Time b019 Accum CO2 Sav b026
DC Bus Voltage b005 Contrl In Status b013 Average Power b020 Drive Temp b027
Drive Status b006 Dig In Status b014 Elapsed kWh b021 Control Temp b028
Fault 1 Code b007 Output RPM b015 Elapsed MWh b022 Control SW Ver b029
Output Freq b001 Fault 2 Code b008 Output Speed b016 Energy Saved b023
Commanded Freq b002 Fault 3 Code b009 Output Power b017 Accum kWh Sav b024
Output Current b003 Process Display b010 Power Saved b018 Accum Cost Sav b025
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
Motor NP Volts P031 Motor NP Power(1) P037 Minimum Freq P043 Speed Reference2 P049
Terminal Blocks DigIn TermBlk 07(1) t067 Relay 1 On Time t079 Analog Out High(2) t089 Anlg Loss Delay t098
DigIn TermBlk 08(1) t068 Relay 1 Off Time t080 Anlg Out Setpt(2) t090 Analog In Filter t099
Opto Out1 Sel(1) t069 Relay Out2 Sel(1) t081 Anlg In 0-10V Lo t091 Sleep-Wake Sel t100
Opto Out1 Level(1) t070 Relay Out2 Level(1) t082 Anlg In 0-10V Hi t092 Sleep Level t101
DigIn TermBlk 02 t062 Opto Out2 Sel(1) t072 Relay 2 On Time(1) t084 10V Bipolar Enbl(1) t093 Sleep Time t102
DigIn TermBlk 03 t063 Opto Out2 Level(1) t073 Relay 2 Off Time(1) t085 Anlg In V Loss t094 Wake Level t103
2-Wire Mode t064 Opto Out Logic(1) t075 EM Brk Off Delay t086 Anlg In4-20mA Lo t095 Wake Time t104
DigIn TermBlk 05 t065 Relay Out1 Sel t076 EM Brk On Delay t087 Anlg In4-20mA Hi t096 Safety Open En(1) t105
DigIn TermBlk 06 t066 Relay Out1 Level t077 Analog Out Sel(2) t088 Anlg In mA Loss t097 SafetyFlt RstCfg(1)(3) t106
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 2 L182 Stp Logic Time 0 L190 Stp Logic Time 6 L196 Step Units 4 L208
Stp Logic 3 L183 Stp Logic Time 1 L191 Stp Logic Time 7 L197 Step Units 5 L210
Stp Logic 4 L184 Stp Logic Time 2 L192 Step Units 0 L200 Step Units 6 L212
Stp Logic 5 L185 Stp Logic Time 3 L193 Step Units 1 L202 Step Units 7 L214
Stp Logic 0 L180 Stp Logic 6 L186 Stp Logic Time 4 L194 Step Units 2 L204
Stp Logic 1 L181 Stp Logic 7 L187 Stp Logic Time 5 L195 Step Units 3 L206
Advanced Display Elapsed Time-min d363 Speed Feedback d376 PID2 Fdbk Displ(1) d385 RdyBit Mode Act(2)(4) d392
Counter Status d364 Encoder Speed(2) d378 PID2 Setpnt Disp(1) d386 Drive Status 2(2)(3) d393
Timer Status d365 DC Bus Ripple d380 Position Status(1) d387 Dig Out Status(2)(3) d394
Drive Type d367 Output Powr Fctr d381 Units Traveled H(1) d388
Analog In 0-10V d360 Testpoint Data d368 Torque Current d382 Units Traveled L(1) d389
Analog In 4-20mA d361 Motor OL Level d369 PID1 Fdbk Displ d383 Fiber Status d390
Elapsed Time-hr d362 Slip Hz Meter d375 PID1 Setpnt Disp d384 Stp Logic Status(1) d391

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

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.
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

Extruder Motor NP Hertz P032 Stop Mode P045 Anlg In4-20mA Lo t095 Encoder PPR A536
Motor OL Current P033 Start Source 1 P046 Anlg In4-20mA Hi t096 Pulse In Scale A537
Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 Ki Speed Loop A538
Motor NP Poles P035 Relay Out1 Sel t076 Slip Hz Meter d375 Kp Speed Loop A539
Language P030 Autotune P040 Analog Out Sel t088 Speed Feedback d376 Power Loss Mode A548
Output Freq b001 Accel Time 1 P041 Analog Out High t089 Encoder Speed d378 Half Bus Enable A549
Commanded Freq b002 Decel Time 1 P042 Anlg Out Setpt t090 Preset Freq 0 A410
Output Current b003 Minimum Freq P043 Anlg In 0-10V Lo t091 Stall Fault Time A492
Motor NP Volts P031 Maximum Freq P044 Anlg In 0-10V Hi t092 Motor Fdbk Type A535
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.

Basic Display Group

b001 [Output Freq] Related Parameter(s): b002, b010, P043, P044, P048, P050, P052
Output frequency present at T1, T2 & T3 (U, V & W). Does not include slip frequency.
Values Default: Read Only
Min/Max: 0.00/[Maximum Freq]
Display: 0.01 Hz
b002 [Commanded Freq] Related Parameter(s): 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 49 for more information.

Display: 0.01 Hz
b003 [Output Current]

Output current present at T1, T2 & T3 (U, V & W).
Min/Max: 0.00/(Drive Rated Amps x 2)
Display: 0.01 A
b004 [Output Voltage] Related Parameter(s): P031, A530, A534

Output voltage present at T1, T2 & T3 (U, V & W).
Min/Max: 0.0/Drive Rated Volts
Display: 0.1V
b005 [DC Bus Voltage]

Filtered DC bus voltage level of the drive.
Min/Max: 0/1200VDC
Display: 1VDC
b006 [Drive Status] Related Parameter(s): 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

Min/Max: 00000/11111
Display: 00000

Basic Display Group (continued)

b007 [Fault 1 Code] Related Parameter(s): 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 they occur (b007 [Fault 1 Code] = the most recent fault). Repetitive faults are only recorded once.
See Fault and Diagnostic Group for more information.
Min/Max: F0/F127
Display: F0
b010 [Process Display] Related Parameter(s): 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])
Min/Max: 0.00/9999.00
Display: 0.01
b012 [Control Source] Related Parameter(s): 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 49 for more information.
Example
Start Command Source Digit 1 Display reads... Description
1 = Keypad
2 = DigIn TrmBlk (Parameters t062,t063,t065-t068) 2004 Start source comes from Network Opt and Frequency source is Purge.
3 = Serial/DSI 113 Start source comes from Serial/DSI and Frequency source comes from PID1 Output.
4 = Network Opt(1)
5 = EtherNet/IP(2) 155 Start source and Frequency source comes from EtherNet/IP.
Frequency Command Source Digit 2 & 3 052 Start source comes from DigIn TrmBlk and Frequency source from 0-10V Input.
00 = Other 011 Start source comes from Keypad and Frequency source comes from Drive Pot.
01 = Drive Pot
02 = Keypad
03 = Serial/DSI
04 = Network Opt(1)
05 = 0-10V Input
06 = 4-20mA Input
07 = Preset Freq (Parameters A410-A425)
08 = Anlg In Mult(2)
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 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.

Min/Max: 0000/2165
Display: 0000


b013 [Contrl In Status] Related Parameter(s): 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
DB Trans On(1) Digit 4
Not Used
(1) The DB Transistor “on” indication must have a 0.5 s hysteresis. It will turn on and stay
on for at least 0.5 s every time the DB transistor is turned on.

Min/Max: 0000/1111
Display: 0000
b014 [Dig In Status] Related Parameter(s): t065-t068

State of the programmable digital inputs.
1 = Closed State, 0 = Open State

DigIn TBlk 7(1) Digit 3
DigIn TBlk 8(1) Digit 4
Not Used

Min/Max: 0000/1111
Display: 0000
b015 [Output RPM] Related Parameter(s): P035

Current output frequency in rpm. Scale is based on P035 [Motor NP Poles].
Min/Max: 0/24000 rpm
Display: 1 rpm
b016 [Output Speed] Related Parameter(s): P044

Current output frequency in %. Scale is 0% at 0.00 Hz to 100% at P044 [Maximum Freq].
Min/Max: 0.0/100.0%
Display: 0.1%
b017 [Output Power] Related Parameter(s): b018

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


b018 [Power Saved] Related Parameter(s): b017
Instantaneous power savings of using this drive compared to an across the line starter.
Min/Max: 0.00/655.35 kW
Display: 0.01 kW
b019 [Elapsed Run time] Related Parameter(s): A555

Accumulated time drive is outputting power. Time is displayed in 10 hour increments.
Min/Max: 0/65535 x 10 hr
Display: 1 = 10 hr
b020 [Average Power] Related Parameter(s): A555

Average power used by the motor since the last reset of the meters.
Min/Max: 0.00/(Drive Rated Power x 2)
Display: 0.01 kW
b021 [Elapsed kWh] Related Parameter(s): 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.
Min/Max: 0.0/100.0 kWh
Display: 0.1 kWh
b022 [Elapsed MWh] Related Parameter(s): b021

Accumulated output energy of the drive.
Min/Max: 0.0/6553.5 MWh
Display: 0.1 MWh
b023 [Energy Saved] Related Parameter(s): A555

Total energy savings of using this drive compared to an across the line starter since the last reset of the meters.
Min/Max: 0.0/6553.5 kWh
Display: 0.1 kWh
b024 [Accum kWh Sav] Related Parameter(s): b025

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


b025 [Accum Cost Sav] Related Parameter(s): 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]
Min/Max: 0.0/6553.5
Display: 0.1
b026 [Accum CO2 Sav] Related Parameter(s): A555

Total approximate accumulated CO2 savings of the drive compared to using an across the line starter.
Min/Max: 0.0/6553.5 kg
Display: 0.1 kg
b027 [Drive Temp]

Present operating temperature of the drive heatsink (inside module).
Min/Max: 0/120 °C
Display: 1 °C
b028 [Control Temp]

Present operating temperature of the drive control.
Min/Max: 0/120 °C
Display: 1 °C
b029 [Control SW Ver]

Current drive firmware version.
Min/Max: 0.000/65.535
Display: 0.001

Basic Program Group

P030 [Language] Language Support
Selects the language displayed. A reset or power cycle is required after selection is made. Keypad/ RSLogix 5000/ Connected
LCD Display Logix Designer Components
Workbench
Options 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 –
8 Chinese Chinese Simplified – 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 will be modified.
P031 [Motor NP Volts] Related Parameter(s): b004, A530, A531, A532, A533
Stop drive before changing this parameter.
Sets the motor nameplate rated volts.
Values Default: Drive Rated Volts
Min/Max: 10V (for 230V Drives), 20V (for 460V Drives), 25V (for 600V Drives)/Drive Rated Volts
Display: 1V
P032 [Motor NP Hertz] Related Parameter(s): A493, A530, A531, A532, A533
Sets the motor nameplate rated frequency.
Values Default: 60 Hz
Min/Max: 15/500 Hz
Display: 1 Hz
P033 [Motor OL Current] Related Parameter(s): 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
Values Default: Drive Rated Amps

Display: 0.1 A

Basic Program Group (continued)

P034 [Motor NP FLA] Related Parameter(s): P040
Sets the motor nameplate FLA. Used to assist the Autotune routine and motor control.
Values Default: Based on Drive Rating
Display: 0.1 A
P035 [Motor NP Poles] Related Parameter(s): b015

Sets the number of poles in the motor.
Values Default: 4
Min/Max: 2/40
Display: 1
P036 [Motor NP RPM]

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.
Values Default: 1750 rpm
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.
Values Default: Drive Rated Power
Min/Max: 0.00/Drive Rated Power
Display: 0.01 kW
P038 [Voltage Class]

Sets the voltage class of 600V drives. Only applicable to 600V drives.
Options 2 “480V”
3 “600V” (Default)
P039 [Torque Perf Mode] Related Parameter(s): P040, A530, A531, A532, A533, A535
Selects the motor control mode.
The PowerFlex 523 and PowerFlex 525 drives are capable of performing with the following motor control modes.
Options 0 “V/Hz”
1 “SVC” (Default)
2 “Economize”
3 “Vector”(1)
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.
(2) Setting is available in PowerFlex 525 FRN 5.xxx and later.


P040 [Autotune] Related Parameter(s): P034, P039, A496, A497
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.
Options 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 operate the drive in normal mode. Used when motor cannot
be uncoupled from the load.
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.
P041 [Accel Time 1] Related Parameter(s): 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
Values Default: 10.00 s
Min/Max: 0.00/600.00 s
Display: 0.01 s
P042 [Decel Time 1] Related Parameter(s): 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
0
Min/Max: 0.00/600.00 s
Display: 0.01 s


P043 [Minimum Freq] Related Parameter(s): b001, b002, b013, P044, A530, A531
Sets the lowest frequency the drive outputs.
Values Default: 0.00 Hz
Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz
P044 [Maximum Freq] Related Parameter(s): b001, b002, b013, b016, P043, A530, A531
Sets the highest frequency the drive outputs.
IMPORTANT This value must be greater than the value set in P043 [Minimum Freq].

Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz
P045 [Stop Mode] Related Parameter(s): t086, t087, A434, A435, A550
Determines the stopping mode used by the drive when a stop is initiated.
Options 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.
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 required for the machine to travel to
11 “PointStop” PointStop. standstill based on the programmed maximum speed and deceleration time is calculated.
If the drive is running slower than the maximum speed, the function will apply 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
[Maximum Freq]
Speed
Calculated Stop Time
[Decel Time x] Time


P046 [Start Source 1] Related Parameter(s): b012, t064, C125
P048 [Start Source 2]
P050 [Start Source 3]
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.
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.
Options 1 “Keypad” [Start Source 1] default

2 “DigIn TrmBlk” [Start Source 2] default
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.
P047 [Speed Reference1] Related Parameter(s): 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.
Options 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)
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.
P052 [Average kWh Cost] Related Parameter(s): b025

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


P053 [Reset To Defalts]
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] P038 [Voltage Class]
C124 [Comm Loss Action] C144 [EN Idle Flt Actn] C164 [Opt Data In 4] A435 [DC Brake Level]
C126 [Comm Loss Time] C145 [EN Flt Cfg Logic] C165 [Opt Data Out 1] A484 [Current Limit 1]
C127 [RS485 Format] C146 [EN Flt Cfg Ref] C166 [Opt Data Out 2] A485 [Current Limit 2]
C128 [EN Addr Sel] C147 [EN Flt Cfg DL 1] C167 [Opt Data Out 3] A486 [Shear Pin1 Level]
C129 [EN IP Addr Cfg 1] C148 [EN Flt Cfg DL 2] C168 [Opt Data Out 4] A488 [Shear Pin2 Level]
C130 [EN IP Addr Cfg 2] C149 [EN Flt Cfg DL 3] C169 [MultiDrv Sel] A490 [Load Loss Level]
C131 [EN IP Addr Cfg 3] C150 [EN Flt Cfg DL 4] C171 [Drv 1 Addr] A496 [IR Voltage Drop]
C132 [EN IP Addr Cfg 4] C153 [EN Data In 1] C172 [Drv 2 Addr] A497 [Flux Current Ref]
C133 [EN Subnet Cfg 1] C154 [EN Data In 2] C173 [Drv 3 Addr] A530 [Boost Select]
C134 [EN Subnet Cfg 2] C155 [EN Data In 3] C174 [Drv 4 Addr] A531 [Start Boost]
C135 [EN Subnet Cfg 3] C156 [EN Data In 4] C175 [DSI I/O Cfg] A532 [Break Voltage]
C136 [EN Subnet Cfg 4] C157 [EN Data Out 1] GC [Parameters in Custom Group] A533 [Break Frequency]
C137 [EN Gateway Cfg 1] C158 [EN Data Out 2] A534 [Maximum] Voltage

1 “Param Reset” Does not reset custom groups, parameter P030 [Language], and communication parameters.
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.

Terminal Block Group

t062 [DigIn TermBlk 02] t063 [DigIn TermBlk 03] Related Parameter(s): b012, b013, b014, P045, P046, P048, P049, P050, P051, t064,
t065 [DigIn TermBlk 05] t066 [DigIn TermBlk 06] t086, A410-A425, A427, A431, A432, A433, A434, A435,
t067 [DigIn TermBlk 07] t068 [DigIn TermBlk 08] A442, A443, A488, A535, A560, A562, A563, A567, A571

Programmable digital input. Changes to these inputs takes 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.
Options 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 Freq x].
(PF523: only for DigIn TermBlk 03, 05, • Selects a preset frequency and position in Positioning mode (P047, P049, P051 [Speed Referencex] = 16).
and 06) See L200...L214 [Step Units x] (only for PowerFlex 525 drives).
(PF525: only for DigIn TermBlk 05...08)
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 49 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].
• A valid Start command will override 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 will override 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 will override this input.
11 “Acc/Dec Sel2”(1) If active, determines which Accel/Decel time will be 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 will occur 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 211.
22 “Reset Countr” Resets the count in the accumulated internal active counter, d364 [Counter Status]. For more information, see Counter Function
on page 212.
23 “Rset Tim&Cnt” Resets both the internal active timer and accumulated internal active counter.
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 in conjunction 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 in conjunction with StepLogic parameters L180...L187 [Stp Logic x].

Options 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 pre-charge 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 in order 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].
34 “Home Limit”(2) In Positioning mode, indicates 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 which 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 as
well as 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, will cause 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.
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

Options 48 “2-Wire FWD” [DigIn TermBlk 02] default. Select 2-Wire FWD for this input.
(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 t064 [2-Wire Mode] for
level trigger settings.
49 “3-Wire Start” Select 3-Wire Start for this input. Drive Start Condition
(only for DigIn TermBlk 02) Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn TrmBlk” to Matrix for t062 and t063
configure [Start Source x] to a 3-wire start mode.
t062 Setting
50 “2-Wire REV” [DigIn TermBlk 03] default. Select 2-Wire REV for this input. t063 3-Wire 2-Wire
(only for DigIn TermBlk 03) Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn TrmBlk” to Setting Start FWD
configure [Start Source x] to a 2-wire run reverse mode. Also see t064 [2-Wire Mode] for level
trigger settings. 2-Wire Drive will OK
REV not start
For PowerFlex 523 drives, this setting will be disabled If [DigIn TermBlk 03] is set to
7 “Preset Freq”. 3-Wire OK Drive will
Dir not start
51 “3-Wire Dir” Select 3-Wire Dir for this input.
(only for DigIn TermBlk 03) 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 will be 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.
t064 [2-Wire Mode] Related Parameter(s): P045, P046, P048, P050, t062, t063
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].
Options 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 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 will respond 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].

t069 [Opto Out1 Sel] Related Parameter(s): P046, P048, P050, t070, t073, t077, t082,
t072 [Opto Out2 Sel] t086, t087, t093, t094, t097, A541, A564
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 outputs are None
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 overvoltage fault from 100 ms time delay on or off
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]. 100 ms time delay on or off
IMPORTANT Value for t070 or t073 [Opto Outx Level] must be entered in 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 action when On, 2 mA / ±1V
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 output to None
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 None
• A541 [Auto Rstrt Tries] is not enabled or
• 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 Level]. It None
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. –
Values Default:
Opto Out1 Sel: 2
Opto Out2 Sel: 1
Min/Max: 0/31
Display: 1
(1) Setting is available in FRN 5.xxx and later.

Terminal Block Group (continued)

t070 [Opto Out1 Level] Related Parameter(s): t069, t072
t073 [Opto Out2 Level]
32
32 bit parameter.
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° –
Values Default: 0.0

Min/Max: 0.0/9999.0
Display: 0.1
t075 [Opto Out Logic]

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

t076 [Relay Out1 Sel] Related Parameter(s): P046, P048, P050, t070, t073, t077, t082, t086, t087, t093, t094, t097, A541, A564
t081 [Relay Out2 Sel]
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 returns drive to None
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 overvoltage fault from 100 ms time delay on or off
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]. 100 ms time delay on or off
IMPORTANT Value for t077 or t082 [Relay Outx Level] must be entered in 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 action when On, 2 mA / ±1V
input loss occurs. Off, 3 mA / ±1.5V
13 “ParamControl” Output will be directly controlled by the state of the t077 or t082 [Relay Outx Level]. A value of 0 causes the output None
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 None
• A541 [Auto Rstrt Tries] is not enabled or
• 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 Level]. It None
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. –
Values Default:
Relay Out1 Sel: 0
Relay Out2 Sel: 2
Min/Max: 0/31
Display: 1


(2) Setting is available in FRN 5.xxx and later.
t077 [Relay Out1 Level] Related Parameter(s): t076, t081

t082 [Relay Out2 Level]
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° –
Values Default: 0.0

Min/Max: 0.0/9999.0
Display: 0.1
t079 [Relay 1 On Time]

t084 [Relay 2 On Time]
Sets the delay time before Relay energizes after required condition is met.
Min/Max: 0.0/600.0 s
Display: 0.1 s
t080 [Relay 1 Off Time]

t085 [Relay 2 Off Time]
Sets the delay time before Relay de-energizes after required condition ceases.
Min/Max: 0.0/600.0 s
Display: 0.1 s
t086 [EM Brk Off Delay] Related Parameter(s): P045

Sets the time 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
l
Ram
[Minimum Freq]
Time
Start EM Brk Stop EM Brk Drive stops
commanded energized (Off) commanded de-energized (On)
Min/Max: 0.00/10.00 s
Display: 0.01 s


t087 [EM Brk On Delay] Related Parameter(s): P045
Sets the time 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
Ram l
[Minimum Freq]
Time
Start EM Brk Stop EM Brk Drive stops
commanded energized (Off) commanded de-energized (On)
Min/Max: 0.00/10.00 s
Display: 0.01 s
t088 [Analog Out Sel] Related Parameter(s): t090

The 0-10V, 0-20 mA or 4-2 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)
Options Output Range Minimum Output Value Maximum Output Value = Filter(1) Related
t089 [Analog Out High] 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%.
Values Default: 0
Min/Max: 0/23
Display: 1
(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 series B drive is required.


t089 [Analog Out High]
Scales the maximum output value (V or mA) when the source setting is at maximum.(1)
Values Default: 100%
Min/Max: 0/800%
Display: 1%
t090 [Anlg Out Setpt] Related Parameter(s): t088

(1)
Sets the percentage of output desired when t088 [Analog Out Sel] is set to 6, 14 or 22 “Analog Setpoint”.
Values Default: 0.0%
Min/Max: 0.0/100.0%
Display: 0.1%
t091 [Anlg In 0-10V Lo] Related Parameter(s): P043, t092, t093

Sets the percentage (based on 10V) of input voltage applied to the 0-10V analog input 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.
Min/Max: 0.0/200.0%
Display: 0.1%
t092 [Anlg In 0-10V Hi] Related Parameter(s): P044, t091, t093

Sets the percentage (based on 10V) of input voltage applied to the 0-10V analog input 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.
Min/Max: 0.0/200.0%
Display: 0.1%
t093 [10V Bipolar Enbl] Related Parameter(s): t091, t092

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.
Options 0 “Uni-Polar In” (Default) 0-10V only
1 “Bi-Polar In” ±10V


t094 [Anlg In V Loss] Related Parameter(s): P043, P044, A426, A427
Sets the response to a loss of input. When the 0-10V input (or –10 to +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.
Options 0 “Disabled” (Default)
1 “Fault (F29)”
2 “Stop”
3 “Zero Ref”
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 Parameter(s): P043, t096

Sets the percentage (based on 4-20 mA) of input current applied to the 4-20 mA analog input used to represent P043 [Minimum Freq].
Analog inversion can be accomplished by setting this value larger than t096 [Anlg In4-20mA Hi].
Min/Max: 0.0/100.0%
Display: 0.1%
t096 [Anlg In4-20mA Hi] Related Parameter(s): P044, t095

Sets the percentage (based on 4-20 mA) of input current applied to the 4-20 mA analog input used to represent P044 [Maximum Freq].
Analog inversion can be accomplished by setting this value smaller than t095 [Anlg In4-20mA Lo].
Min/Max: 0.0/200.0%
Display: 0.1%
t097 [Anlg In mA Loss] Related Parameter(s): P043, P044, A426, A427

Sets the response to a loss of input. When the 4-20mA 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.
1 “Fault (F29)”
2 “Stop”
3 “Zero Ref”
4 “Min Freq Ref”
5 “Max Freq Ref”
6 “Key Freq Ref”
7 “MOP Freq Ref”
8 “Continu Last”


t098 [Anlg Loss Delay] Related Parameter(s): 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].
Min/Max: 0.0 /20.0 s
Display: 0.1 s
t099 [Analog In Filter]

Sets the level of additional filtering of the analog input signals. A higher number increases filtering and decreases bandwidth. Each setting doubles the applied filtering (1 = 2x filter, 2
= 4x filter, and so on).
Values Default: 0
Min/Max: 0/14
Display: 1
t100 [Sleep-Wake Sel] Related Parameter(s): 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 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.

1 “0-10V Input” Sleep enabled from 0-10V Analog Input 1
2 “4-20mA Input” Sleep enabled from 4-20 mA Analog Input 2
3 “Command Freq” Sleep enabled based on drive commanded frequency
t101 [Sleep Level]

Sets the analog input level the drive must reach to enter sleep mode.
Min/Max: 0.0/100.0%
Display: 0.1%
t102 [Sleep Time]

Sets the analog input time the drive must stay below to enter sleep mode.
Min/Max: 0.0/600.0 s
Display: 0.1 s
t103 [Wake Level]

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


t104 [Wake Time]
Sets the analog input time the drive must stay above to wake from sleep mode.
Min/Max: 0.0/600.0 s
Display: 0.1 s
t105 [Safety Open En]

Sets the action when both safety inputs (Safety 1 and Safety 2) are disabled (de-energized – no power is applied).
Options 0 “FaultEnable” (Default)
1 “FaultDisable”
t106 [SafetyFlt RstCfg]

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

Communications Group
C121 [Comm Write Mode]
Saves parameter values in active drive memory (RAM) or in drive non-volatile 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.
Options 0 “Save” (Default)

1 “RAM only”
C122 [Cmd Stat Select]

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 203
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.
Options 0 “Velocity” (Default)
1 “Position”
C123 [RS485 Data Rate]

Sets the communications baud rate (bits/second) for the RS485 port. A reset or power cycle is required after selection is made.
Options 0 “1200”
1 “2400”
2 “4800”
3 “9600” (Default)
4 “19,200”
5 “38,400”
C124 [RS485 Node Addr]

Sets the Modbus drive node number (address) for the RS485 port if using a network connection. A reset or power cycle is required after selection is made.
Values Default: 100
Min/Max: 1/247
Display: 1
C125 [Comm Loss Action] Related Parameter(s): P045

Sets the drive's response to a loss of connection or excessive communication errors on the RS485 port.
Options 0 “Fault” (Default)
1 “Coast Stop” Stops drive using “Coast to stop”.
2 “Stop” Stops drive using P045 [Stop Mode] setting.
3 “Continu Last” Drive continues operating at communication commanded speed saved in RAM.
C126 [Comm Loss Time] Related Parameter(s): C125

Sets the time that the drive remains in communication loss with the RS485 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 RS485 port.

Min/Max: 0.1/60.0 s
Display: 0.1 s

Communications Group (continued)

C127 [RS485 Format]
Determines the details related to the specific Modbus protocol used by the drive. A reset or power cycle is required after selection is made.
Options 0 “RTU 8-N-1” (Default)
1 “RTU 8-E-1”
2 “RTU 8-O-1”
3 “RTU 8-N-2”
4 “RTU 8-E-2”
5 “RTU 8-O-2”
C128 [EN Addr Sel] Related Parameter(s): C129-C132, C133-C136, C137-C140

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.
Options 1 “Parameters”
2 “BOOTP” (Default)
C129 [EN IP Addr Cfg 1] Related Parameter(s): C128

C130 [EN IP Addr Cfg 2]
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”.
Values Default: 0
Min/Max: 0/255
Display: 1


C133 [EN Subnet Cfg 1] Related Parameter(s): C128
C134 [EN Subnet Cfg 2]
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]
Values Default: 0
Min/Max: 0/255
Display: 1
C137 [EN Gateway Cfg 1] Related Parameter(s): C128

C138 [EN Gateway Cfg 2]
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]
Values Default: 0
Min/Max: 0/255
Display: 1
C141 [EN Rate Cfg]

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


C143 [EN Comm Flt Actn] Related Parameter(s): P045, C145, C146, C147-C150
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).

1 “Stop” Drive stops per P045 [Stop Mode] setting.
2 “Zero Data” Note: The Reference and Datalink values transmitted to the drive will be set to “0”.
3 “Hold Last” Note: The Logic Command, Reference, and Datalink values transmitted to the drive will be held at their last value.
4 “Send Flt Cfg” Note: The Logic Command, Reference, and Datalink values will be transmitted to the drive as configured in C145, C146, and
C147...C150.
C144 [EN Idle Flt Actn] Related Parameter(s): P045, C145, C146, C147-C150
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).

1 “Stop” Drive stops per P045 [Stop Mode] setting.
2 “Zero Data” Note: The Reference and Datalink values transmitted to the drive will be set to “0”.
3 “Hold Last” Note: The Logic Command, Reference, and Datalink values transmitted to the drive will be held at their last value.
4 “Send Flt Cfg” Note: The Logic Command, Reference, and Datalink values will be transmitted to the drive as configured in C145, C146, and
C147...C150.
C145 [EN Flt Cfg Logic] Related Parameter(s): C143, C144

32
32 bit parameter.
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 203 for more information.
Values Default: 0000
Min/Max: 0000/FFFF
Display: 0000


C146 [EN Flt Cfg Ref] Related Parameter(s): C143, C144
32
32 bit parameter.
Sets the Reference data that is sent to the drive if any of the following is true:
Values Default: 0
Min/Max: 0/50000
Display: 1
C147 [EN Flt Cfg DL 1]

Sets the Ethernet Datalink Input data that is sent to the drive if any of the following is true:
Values Default: 0
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]
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.
Values Default: 0
Min/Max: 0/800
Display: 1
C157 [EN Data Out 1]

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.
Values Default: 0
Min/Max: 0/800
Display: 1


C161 [Opt Data In 1]
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.
Values Default: 0
Min/Max: 0/800
Display: 1
C165 [Opt Data Out 1]

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.
Values Default: 0
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.
Options 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 slave
drives can be daisy-chained from its RS485 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 RS485 port.
C171 [Drv 1 Addr] Related Parameter(s): 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.
Values Default:
Drv 1 Addr: 2
Drv 2 Addr: 3
Drv 3 Addr: 4
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.
Options 0 “Drive 0” (Default)
1 “Drive 0-1”
2 “Drive 0-2”
3 “Drive 0-3”
4 “Drive 0-4”

Logic Group
L180 [Stp Logic 0] L181 [Stp Logic 1] Related Parameter(s):
L182 [Stp Logic 2] L183 [Stp Logic 3]
Values Default: 00F1
Min/Max: 0000/FAFF
Display 0001
See Appendix D and Appendix E for more information on applying Step Logic and Position StepLogic.
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]
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]
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 can not control different outputs based on the condition of different StepLogic commands.

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

Logic Group (continued)

L190 [Stp Logic Time 0] L191 [Stp Logic Time 1]
Sets the time to remain in each step if the corresponding command word is set to “Step based on time”.
Min/Max: 0.0/999.9 s
Display: 0.1 s
L200 [Step Units 0] L202 [Step Units 1]

32
32 bit parameter.
Sets the position in user-defined units the drive must reach at each step.
Min/Max: 0.00/6400.00
Display: 0.01

Advanced Display Group

d360 [Analog In 0-10V] Related Parameter(s): t091, t092
Displays the 0-10V analog input as a percent of full scale.
Min/Max: 0.0/100.0%
Display: 0.1%
d361 [Analog In 4-20mA] Related Parameter(s): t095, t096

Displays the 4-20 mA analog input as a percent of full scale.
Min/Max: 0.0/100.0%
Display: 0.1%
d362 [Elapsed Time-hr] Related Parameter(s): A555

Displays the total elapsed powered-up time (in hours) since timer reset. The timer stops when it reaches the maximum value.
Min/Max: 0/32767 hr
Display: 1 hr
d363 [Elapsed Time-min] Related Parameter(s): 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.
Min/Max: 0.0/60.0 min
Display: 0.1 min
d364 [Counter Status]

Displays the current value of the counter if enabled.
Min/Max: 0/65535
Display: 1
d365 [Timer Status]

32
32 bit parameter.
Displays the current value of the timer if enabled.
Min/Max: 0.0/9999.0 s
Display: 0.1 s
d367 [Drive Type]

Displays the Drive type setting. Used by Rockwell Automation field service personnel (not write accessible by non Rockwell Automation technical personnel).
Min/Max: 0/65535
Display: 1

Advanced Display Group (continued)

d368 [Testpoint Data] Related Parameter(s): A483
Displays the present value of the function selected in A483 [Testpoint Sel].
Min/Max: 0/FFFF
Display: 1
d369 [Motor OL Level]

Displays the motor overload counter.
Min/Max: 0.0/150.0%
Display: 0.1%
d375 [Slip Hz Meter] Related Parameter(s): P032

Displays the current amount of slip or droop (absolute value) being applied to the motor frequency. Drives applies slip based on the setting for P032 [Motor NP Hertz].
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.
Min/Max: 0.0/64000.0 rpm
Display: 0.1 rpm
d378 [Encoder Speed]

32
32 bit parameter.
Provides a monitoring point that reflects the speed measured from the feedback device. This shows the encoder or pulse train speed even if not used directly to control motor speed.(1)
Min/Max: 0.0/64000.0 rpm
Display: 0.1 rpm
d380 [DC Bus Ripple]

Displays the real-time value of the DC bus ripple voltage.
Min/Max: 0/410VDC for 230V AC drives; 820VDC for 460VAC drives; 1025VDC for 600VAC drives
Display: 1V DC
d381 [Output Powr Fctr]

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


d382 [Torque Current]
Displays the current value of the motor torque current measured by the drive.
Display: 0.01 A
d383 [PID1 Fdbk Displ]

d385 [PID2 Fdbk Displ]
Displays the active PID Feedback value.
Min/Max: 0.0/100.0%
Display: 0.1%
d384 [PID1 Setpnt Disp]

d386 [PID2 Setpnt Disp]
Displays the active PID Setpoint value.
Min/Max: 0.0/100.0%
Display: 0.1%
d387 [Position Status]

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

Min/Max: 0000/1111
Display: 0000
d388 [Units Traveled H] Related Parameter(s): d387

32
32 bit parameter.
Displays the number of user-defined units traveled from the home position. See d387 [Position Status] for direction of travel.
Min/Max: 0/64000
Display: 1


d389 [Units Traveled L] Related Parameter(s): d387
Displays the number of user-defined units traveled from the home position. See d387 [Position Status] for direction of travel.
Min/Max: 0.00/0.99
Display: 0.01
d390 [Fiber Status]

Present status of the Fibers features.

Sync Hold Digit 1
Sync Ramp Digit 2
Traverse On Digit 3
Traverse Dec Digit 4
Not Used
Min/Max: 0000/1111
Display: 0000
d391 [Stp Logic Status] Related Parameter(s): P047, L180-L187

Displays the current step of the Step Logic profile as defined by parameters L180...L187 [Step Logic x] when P047 [Speed Reference1] is set to 13 “Step Logic” or 16 “Positioning”.
Min/Max: 0/8
Display: 1
d392 [RdyBit Mode Act] Related Parameter(s): A574

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


d393 [Drive Status 2]
Displays the present operating condition of the drive.
Saf 1 Stat it (1)
Saf ty S2 (1s) (1)
Jog Braki rld

tor tdn
gin ng
DC req g
m
S1 (1)
At F Tuni g
g
e u
Flu Ove
Aut rakin
EM mit
F11 TqPer
Aut rakin
Mo oRst C
g
ety
r Li
B
o
B
e
x
Cur
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.

Min/Max: 0/65535
Display: 1
d394 [Dig Out Status]

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
Opto1 Status(1) Digit 3
Relay 2 status (Normally Closed) Not activated (Relay 2 closed) Activated (Relay 2 open)
Opto2 Status(1) Digit 4 Opto 1 status Not activated Activated
Not Used Opto 2 status Not activated Activated

Min/Max: 0/15
Display: 1

Advanced Program Group

A410 [Preset Freq 0] A411 [Preset Freq 1]
Sets the frequency of the drive outputs to the programmed value when selected.
For PowerFlex 525
Default Accel/Decel Used Preset Input 1 Preset Input 2 Preset Input 3 Preset Input 4
(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
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)
Preset Setting 0(1) 1 0 0 0
Preset Setting 1 1 1 0 0
–
(1) Preset Setting 0 is only available if P047, P049 or P051 [Speed Referencex] is set to 7 “Preset Freq”.
Values Defaults:
Preset Freq 0: 0.00 Hz
Preset Freq 2: 10.00 HZ
Preset Freq 7...15: 60.00 Hz
Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz

Advanced Program Group (continued)

A426 [Keypad Freq] Related Parameter(s): 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.
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.

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.
Options 0 “Zero MOP Ref” Resets the MOP frequency to zero on power down and stop.
1 “Save MOP Ref” (Default)
A429 [MOP Preload]

Determines the operation of the MOP function.
Options 0 “No preload” (Default)
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.
Min/Max: 0.1/600.0 s
Display: 0.1 s
A431 [Jog Frequency] Related Parameter(s): P044

Sets the output frequency when a jog command is issued.
Display: 0.01 Hz
A432 [Jog Accel/Decel]

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


A433 [Purge Frequency] Related Parameter(s): t062, t063, t065-t068
Provides a fixed frequency command value when t062, t063, t065-t068 [DigIn TermBlk xx] is set to 40 “Purge”.
Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz
A434 [DC Brake Time] Related Parameter(s): P045, A435

Sets the length of time that DC brake current is “injected” into the motor.
Min/Max: 0.0/99.9 s
Display: 0.1 s
A435 [DC Brake Level] Related Parameter(s): P045

Defines the maximum DC brake current, in amps, applied to the motor when P045 [Stop Mode] is set to either 4 “Ramp” or 6 “DC Brake”.
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.
Values Default: Drive Rated Amps x 0.05

Min/Max: 0.00/(Drive Rated Amps x 1.80)
Display: 0.01 A
A436 [DC Brk Time@Strt] Related Parameter(s): 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
Min/Max: 0.0/99.9 s
Display: 0.1 s


A437 [DB Resistor Sel] Related Parameter(s): A438, A550
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] will not take effect.

1 “Norml RA Res” 5%
2 “NoProtection” 100%
3...99 “3...99% DutyCycle”
A438 [DB Threshold] Related Parameter(s): 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 makes 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”.

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
Values Default: 0%
Min/Max: 0/100%
Display: 1%


A440 [PWM Frequency] Related Parameter(s): A540
Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting.
100
96
92
% Output Curent (A)
88
84
80
76 Note: If Vector mode (open loop) is selected and 16 kHz is selected,
72 the drive will forcibly reduce the carrier frequency to 8 kHz.
68
64
60
56
50
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].
Values Default: 4.0 kHz

Min/Max: 2.0/16.0 kHz
Display: 0.1 kHz
A441 [Droop Hertz@ FLA]

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.
Display: 0.1 Hz
A442 [Accel Time 2] Related Parameter(s): 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
0
Min/Max: 0.00/600.00 s
Display: 0.01 s
A443 [Decel Time 2] Related Parameter(s): 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]
Min/Max: 0.00/600.00 s
Display: 0.01 s


A444 [Accel Time 3]
A446 [Accel Time 4]
Sets the rate of acceleration for all speed increases when selected by digital inputs.
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.
Min/Max: 0.00/600.00 s
Display: 0.01 s
A448 [Skip Frequency 1] Related Parameter(s): A449, A451, A453, A455

A450 [Skip Frequency 2]
Works in conjunction with A449, A451, A453 and A455 [Skip Freq Band x] creating a range of frequencies at which the drive does not operate continuously.
Values Default: 0.0 Hz (Disabled)
Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz
A449 [Skip Freq Band 1] Related Parameter(s): A448, A450, A452, A454
A451 [Skip Freq Band 2]
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
Display: 0.1 Hz


A456 [PID 1 Trim Hi]
A468 [PID 2 Trim Hi]
Scales the upper value of the trim frequency when trim is active.
Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz
A457 [PID 1 Trim Lo]

A469 [PID 2 Trim Lo]
Scales the lower value of the trim frequency when trim is active.
Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz
A458 [PID 1 Trim Sel]

A470 [PID 2 Trim Sel]

Sets the PID output as trim to the source reference.
Options 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”
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)


A459 [PID 1 Ref Sel]
A471 [PID 2 Ref Sel]

Selects the source of the PID reference.
Options 0 “PID Setpoint” (Default)
1 “Drive Pot”
2 “Keypad Freq”
3 “Serial/DSI”
4 “Network Opt”
5 “0-10V Input”
7 “Preset Freq”
8 “AnlgIn Multi”(1)
9 “MOP Freq”
10 “Pulse Input”
11 “Step Logic”(1)
12 “Encoder”(1)
13 “EtherNet/IP”(1)
A460 [PID 1 Fdback Sel]

A472 [PID 2 Fdback Sel]
Selects the source of the PID feedback.
Options 0 “0-10V Input” (Default) Note: PID does not function with bipolar input. Negative voltages are ignored and treated as zero.
2 “Serial/DSI”
3 “Network Opt”
4 “Pulse Input”
5 “Encoder”(1)
6 “EtherNet/IP”(1)
A461 [PID 1 Prop Gain] Related Parameter(s): A459, A471

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


A462 [PID 1 Integ Time] Related Parameter(s): A459, A471
A474 [PID 2 Integ Time]
Sets the value for the PID integral component when PID mode is enabled.
Min/Max: 0.0/999.9 s
Display: 0.1 s
A463 [PID 1 Diff Rate] Related Parameter(s): A459, A471

A475 [PID 2 Diff Rate]
Sets the value (in 1/second) for the PID differential component when PID mode is enabled.
Min/Max: 0.00/99.99
Display: 0.01
A464 [PID 1 Setpoint] Related Parameter(s): A459, A471

A476 [PID 2 Setpoint]
Provides an internal fixed value for process setpoint when PID mode is enabled.
Min/Max: 0.0/100.0%
Display: 0.1%
A465 [PID 1 Deadband]

A477 [PID 2 Deadband]
Sets a range, in percent above and below the PID Reference, that the PID output will ignore.
Min/Max: 0.0/10.0%
Display: 0.1%
A466 [PID 1 Preload]

A478 [PID 2 Preload]
Sets the value used to preload the integral component on start or enable.
Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz
A467 [PID 1 Invert Err]

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


A481 [Process Disp Lo] Related Parameter(s): b010, P043
Sets the value displayed in b010 [Process Display] when the drive is running at P043 [Minimum Freq].
Min/Max: 0.00/99.99
Display: 0.01
A482 [Process Disp Hi] Related Parameter(s): b010, P044

Sets the value displayed in b010 [Process Display] when the drive is running at P044 [Maximum Freq].
Min/Max: 0.00/99.99
Display: 0.01
A483 [Testpoint Sel]

Used by Rockwell Automation field service personnel.
Values Default: 400
Min/Max: 0/FFFF
Display: 1
A484 [Current Limit 1] Related Parameter(s): P033

Maximum output current allowed before current limiting occurs.
Values Default: Drive Rated Amps x 1.1 (Normal Duty); Drive Rated Amps x 1.5 (Heavy Duty)
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 Parameter(s): P033

Maximum output current allowed before current limiting occurs.
Values Default: Drive Rated Amps x 1.1
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 Parameter(s): A487, A489

A488 [Shear Pin2 Level]
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.
Values Default: 0.0 A (Disabled)
Display: 0.1 A
A487 [Shear Pin 1 Time] Related Parameter(s): A486, A488

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


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

Sets the required time for the current to be below A490 [Load Loss Level] before a Load Loss fault occurs.
Values Default: 0s
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.
Options 0 “60 Seconds” (Default)
1 “120 Seconds”
2 “240 Seconds”
3 “360 Seconds”
4 “480 Seconds”
5 “Flt Disabled”
A493 [Motor OL Select] Related Parameter(s): 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
% 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]
Options 0 “No Derate” (Default)
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.
Options 0 “Reset” (Default)
1 “Save”


A495 [Drive OL Mode]
Determines how the drive handles overload conditions that would otherwise cause the drive to fault.
Options 0 “Disabled”
1 “Reduce CLim”
2 “Reduce PWM”
3 “Both-PWM 1st” (Default)
A496 [IR Voltage Drop] Related Parameter(s): P040

Value of volts dropped across the resistance of the motor stator (autotune) for induction motor.
Min/Max: 0.0/600.0VAC
Display: 0.1VAC
A497 [Flux Current Ref] Related Parameter(s): 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.
Min/Max: 0.00/(Drive Rated Amps x 1.4)
Display: 0.01 A
A498 [Motor Rr]

Rotor resistance of induction motor. The value of this parameter will populate when a full rotate tune is performed.
Min/Max: 0.00/655.35 ohm
Display: 0.01 ohm
A499 [Motor Lm]

Mutual Inductance of induction motor. The value of this parameter will populate when a full rotate tune is performed.
Min/Max: 0.0/6553.5 mH
Display: 0.1 mH
A500 [Motor Lx]

Leakage Inductance of induction motor. The value of this parameter will populate when a full rotate tune is performed.
Min/Max: 0.0/6553.5 mH
Display: 0.1 mH
A501 [PM IR Voltage]

Voltage across the stator resistance of the PM motor at the rated motor current displayed in line-to-line rms value.
Values Default: 11.50V
Min/Max: 0.00/655.35V
Display: 0.01V


A502 [PM IXd Voltage]
Voltage across the d-axis stator inductance of the PM motor at the rated motor current and the rated motor frequency displayed in line-to-line rms value.
Min/Max: 0.00/655.35V
Display: 0.01V
A503 [PM IXq Voltage]

Voltage across the q-axis stator inductance of the PM motor at the rated motor current and the rated motor frequency displayed in line-to-line rms value.
Min/Max: 0.00/655.35V
Display: 0.01V
A504 [PM BEMF Voltage]

Back electromotive force (EMF) voltage.
Values Default: 1640.0 Drive Rated Volts
Min/Max: 0.0/6000.0 Drive Rated Volts
Display: 0.1V
A509 [Speed Reg Sel] Related Parameter(s): A521, A522, A523, A524, A525, A526
Determines if PI gain of the “Vector” control mode speed regulator is set automatically or manually. Parameters A521...A526 are set automatically by this parameter.
Options 0 “Automatic” (Default)
1 “Manual”
A510 [Freq 1]
A512 [Freq 2]
A514 [Freq 3]
Sets the “Vector” control mode frequency.
Values Default:
Freq 1: 8.33%
Freq 2: 15.00%
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]
Speed control loop bandwidth for “Vector” control mode.
Min/Max: 0/40 Hz
Display: 1 Hz
A516 [PM Initial Sel]

PM initial angle detect.
Options 0 “Align” (Default)
1 “HFI” High Frequency Injection to detect initial angle.
2 “Six Pulse”
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.
Values Default: 30%
Min/Max: 0/300%
Display: 1%
A518 [PM Align Time]

Magnetic pole reorientation time.
Min/Max: 0.0/60.0 s
Display: 0.1 s
A519 [PM HFI NS Cur]

High Frequency Injection (HFI) North South Current to detect N/S Magnet.
Min/Max: 0/300%
Display: 1%
A520 [PM Bus Reg Kd]

Derivative gain for bus regulator.
Values Default: 2
Min/Max: 0/500
Display: 1


A521 [Freq 1 Kp] Related Parameter(s): A509, A510
A523 [Freq 2 Kp]
A525 [Freq 3 Kp]
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.
Min/Max: 0.0/500.0%
Display: 0.1%
A522 [Freq 1 Ki] Related Parameter(s): A509, A510

A524 [Freq 2 Ki]
A526 [Freq 3 Ki]
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.
Min/Max: 0.000/10.000 s
Display: 0.001 s
A527 [PM FWKn 1 Kp]

The gain to ensure good performance in field weakening region.
Min/Max: 0/2000%
Display: 1%
A528 [PM FWKn 2 Kp]

The gain to ensure robustness under step load in weakening region.
Min/Max: 100/8000%
Display: 1%


A529 [PM Control Cfg]
Control configuration for Feed Forward Decouple (FFD), Maximum Torque Per Amp (MTPA), and Load Disturbance Observer (LDOB).

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

Min/Max: 00000/00111
Display: 00000
A530 [Boost Select] Related Parameter(s): 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
Options 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 “0.0”
(Default for 400V and 600V
drives, 5 HP and above)
7 “2.5, CT”
(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”


A531 [Start Boost] Related Parameter(s): 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]
Min/Max: 0.0/25.0%
Display: 0.1%
A532 [Break Voltage] Related Parameter(s): 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”.
Min/Max: 0.0/100.0%
Display: 0.1%
A533 [Break Frequency] Related Parameter(s): 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”.
Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz
A534 [Maximum Voltage] Related Parameter(s): b004

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


A535 [Motor Fdbk Type] Related Parameter(s):P039, A537
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
Options 0 “None” (Default) V/Hz, SVC, Economize, Vector, PM Control –
1 “Pulse Train” V/Hz, SVC, Economize, PM Control [DigIn TermBlk 05] for PowerFlex 523
[DigIn TermBlk 07] for PowerFlex 525
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
A536 [Encoder PPR]

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 217.
Values Default: 1024 PPR
Min/Max: 1/20000 PPR
Display: 1 PPR
A537 [Pulse In Scale] Related Parameter(s): 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)
Values Default: 64
Min/Max: 0/20000
Display: 1
A538 [Ki Speed Loop]

Sets the I-gain 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)
Values Default: 2.0
Min/Max: 0.0/400.0
Display: 0.1
A539 [Kp Speed Loop]

Sets the P-gain 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)
Values Default: 5.0
Min/Max: 0.0/200.0
Display: 0.1


A540 [Var PWM Disable] Related Parameter(s): A440
Enables/disables a feature that varies the carrier frequency for the PWM output waveform defined by A440 [PWM Frequency].
Options 0 “Enabled” (Default)
1 “Disabled”
A541 [Auto Rstrt Tries] Related Parameter(s): 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.
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.
Values Default: 0
Min/Max: 0/9
Display: 1
A542 [Auto Rstrt Delay] Related Parameter(s): A541

Sets the time between restart attempts if A541 [Auto Rstrt Tries] is not zero.
Min/Max: 0.0/120.0 s
Display: 0.1 s
A543 [Start At PowerUp]

Enables/disables drive start on power up without a Run command being cycled. Requires a digital input configured for Run and a valid run signal.

1 “Enabled”
A544 [Reverse Disable] Related Parameter(s): b006

Enables/disables the function that allows the direction of motor rotation to be changed.
Options 0 “Rev Enabled” (Default)
1 “Rev Disabled”
A545 [Flying Start En]

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


A546 [FlyStrt CurLimit]
Used to determine when the drive has matched the motor frequency if flying start is enabled.
Min/Max: 30/200%
Display: 1%
A547 [Compensation]
Enables/disables correction options that may improve problems with motor instability.
Options 0 “Disabled” No compensation.
1 “Electrical” (Default) Some drive/motor combinations have inherent instabilities which are exhibited as non-sinusodial motor currents.
This setting attempts to correct this condition
2 “Mechanical” Some motor/load combinations have mechanical resonances which 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.
Options 0 “Coast” (Default) Drive faults and motor coasts to a stop.
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.

1 “Enabled”
A550 [Bus Reg Enable] Related Parameter(s): A437

Enables/disables the bus regulator.
Options 0 “Disabled”
1 “Enabled” (Default)
A551 [Fault Clear]

Resets a fault and clears the fault queue.
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 Parameter(s): A553

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


A553 [Program Lock Mod] Related Parameter(s): A552
Determines the lock mode 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.
Options 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.
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 will apply necessary current derating.
Options 0 “Normal” (Default)
1 “55C”
2 “60C”
3 “65C +Fan Kit” Fan kit required.
4 “70C +Fan Kit”
A555 [Reset Meters] Related Parameter(s): b019, b021, b022, b023, b024,
b025, b026, d362, d363
Resets the values stored in the parameters that track fault times and energy usage.
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.
Options 0 “Off” No scroll.
1 “Low Speed”
2 “Mid Speed” (Default)
3 “High Speed”
A557 [Out Phas Loss En]

Enable/disable output phase loss detection.
Options 0 “Disable” (Default)

1 “Enable”
A558 [Positioning Mode]

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


A559 [Counts Per Unit]
Sets the number of encoder counts equal to one user-defined unit.
Min/Max: 1/32000
Display: 1
A560 [Enh Control Word] Related Parameter(s): t062, t063, t065 - t068, A571
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
Values Default: 0000 0000

Min/Max: 0000 0000/1111 1111
Display: 0000 0000
Digits 0 “Home Limit” In Positioning mode, this indicates 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 over-rides 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 in order to hold the existing frequency when Sync Time is set to enable speed synchronization. When this bit is reset
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 Step-Logic 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 Step-Logic functions (speed or position)
using comms control without requiring actual digital input transitions.
A561 [Home Save]

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


A562 [Find Home Freq]
Sets the maximum frequency the drive uses when “Find Home” is issued.
Min/Max: 0.1/500.0 Hz
Display: 0.1 Hz
A563 [Find Home Dir]

Sets the direction the drive commands when “Find Home” is issued.
Options 0 “Forward” (Default)
1 “Reverse”
A564 [Encoder Pos Tol]

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.
Values Default: 100
Min/Max: 1/50000
Display: 1
A565 [Pos Reg Filter]

Sets the error signal filter in the position regulator.
Values Default: 8
Min/Max: 0/15
Display: 1
A566 [Pos Reg Gain]

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


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
Min/Max: 0.00/300.00 Hz
Display: 0.01 Hz
A568 [Traverse Inc] Related Parameter(s): A567

Sets the time required for the Traverse function to accelerate from the minimum to the maximum traverse frequency. See the diagram at A567 [Max Traverse].
Min/Max: 0.00/300.00 s
Display: 0.01 s
A569 [Traverse Dec] Related Parameter(s): A567

Sets the time required for the Traverse function to decelerate from the maximum to the minimum traverse frequency. See the diagram at A567 [Max Traverse].
Min/Max: 0.00/300.00 s
Display: 0.01 s
A570 [P Jump] Related Parameter(s): A567

Sets the frequency amplitude that is added to or subtracted from the commanded frequency. See the diagram at A567 [Max Traverse].
Min/Max: 0.00/300.00 Hz
Display: 0.01 Hz
A571 [Sync Time] Related Parameter(s): 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
Min/Max: 0.0/3200.0 s
Display: 0.1 s


A572 [Speed Ratio]
Scales the drive speed command.
Min/Max: 0.01/99.99
Display: 0.01
A573 [Mtr Options Cfg]

Sets the configuration of the motor option.
Options Description
1 = Enabled, 0 = Disabled Jerk Select Limits the rate of change to the velocity reference for improved current limiting. Set to
Jerk Select Digit 1 0 “Disabled” for positioning type applications with fast Accel or Decel times.
ZeroSpd Slip Digit 2 ZeroSpd Slip Sets slip compensation to 0.0 Hz when the following conditions are met:
Not Used • Commanded speed = 0.00 Hz
Not Used • Status of drive = “At speed”
Not Used
• ZeroSpd Slip = 1 “Enabled”
Values Default: 11
Min/Max: 00/11
Display: 00
A574 [RdyBit Mode Cfg] Related Parameter(s): d392

Determines which Stop conditions causes 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(2)
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 “FaultDisabled”(1) 0 0
(1) Condition is specific to PowerFlex 525 drives only.
(2) 1 = Active, 0 = Inactive
Options 0 “Standard” (Default)
1 “Enhanced”
A575 [Flux Braking En] Related Parameter(s): A550

Enables/disables flux braking.
Options 0 “Disable” (Default)
1 “Enable”


A576 [Phase Loss Level]
Output Phase Loss Level. Sets the threshold level which is used to determine an output phase loss condition.
Each motor phase must exceed this value. Decreasing this parameter's value lowers sensitivity.
Values Default: 25.0% for Induction motor; 4.0% for PM motor
Min/Max: 0.0/100.0%
Display: 0.1%
A580 [Current Loop BW]

Current loop bandwidth (0 = Automatically calculate the control gain of current loop).
Min/Max: 0/65535 Hz
Display: 1 Hz
A581 [PM Stable 1 Freq]

The start frequency for stabilization loop (P032 [Motor NP Hertz] x A581 [PM Stable 1 Freq]).
Values Default: 0%
Min/Max: 0/100%
Display: 1%
A582 [PM Stable 2 Freq]

Stabilization function will return to normal output after this frequency (P032 [Motor NP Hertz] x A582 [PM Stable 2 Freq]).
Values Default: 45%
Min/Max: 0/100%
Display: 1%
A583 [PM Stable 1 Kp]

Percentage of the gain for stabilization loop. The gain is set in A584 [PM Stable 2 Kp].
Values Default: 40%
Min/Max: 0/100%
Display: 1%
A584 [PM Stable 2 Kp]

The gain for stabilization loop.
Min/Max: 0/2000%
Display: 1%


A585 [PM Stable Brk Pt]
Percentage of rated power P037 [Motor NP Power] for the gain of (A584 [PM Stable 2 Kp] x A583 [PM Stable 1 Kp]).
Values Default: 40%
Min/Max: 0/100%
Display: 1%
A586 [PM Stepload Kp]

The gain to ensure robustness under step load in low speed region.
Values Default: 0%
Min/Max: 0/1000%
Display: 1%
A587 [PM 1 Efficiency]

Reduce full load current.
Min/Max: 0/2000%
Display: 1%
A588 [PM 2 Efficiency]

Reduce no load current.
Min/Max: 0/2000%
Display: 1%
A589 [PM Algor Sel] Related Parameter(s): A550

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.
Options 0 “Algorithm 1” (Default) Suggested for most motors.
1 “Algorithm 2” Enable an embedded algorithm to reduce oscillation in output waveform (use with sPM motor only, do not enable for iPM motor).
Network Parameter Group This group contains parameters for the network option card that is installed.
Refer to 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 Parameter(s): 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 they occur (b007 [Fault 1 Code] = the most recent fault). Repetitive faults are only recorded once.
Min/Max: F0/F127
Display: F0
F611 [Fault 1 Time-hr] F612 [Fault 2 Time-hr] Related Parameter(s): d362

F613 [Fault 3 Time-hr] F614 [Fault 4 Time-hr]
F615 [Fault 5 Time-hr]
F620 [Fault10 Time-hr]
Displays the value of d362 [Elapsed Time-hr] when the fault occurs.
Min/Max: 0/32767 hr
Display: 1 hr
F621 [Fault 1 Time-min] F622 [Fault 2 Time-min] Related Parameter(s): d363

F623 [Fault 3 Time-min] F624 [Fault 4 Time-min]
F625 [Fault 5 Time-min]
F630 [Fault10 Time-min]
Displays the value of d363 [Elapsed Time-min] when the fault occurs.
Min/Max: 0.0/320.0 min
Display: 0.1 min

Fault and Diagnostic Group (continued)

F631 [Fault 1 Freq] F632 [Fault 2 Freq] Related Parameter(s): b001
F633 [Fault 3 Freq] F634 [Fault 4 Freq]
F635 [Fault 5 Freq]
F640 [Fault10 Freq]
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.
Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz
F641 [Fault 1 Current] F642 [Fault 2 Current] Related Parameter(s): b003

F643 [Fault 3 Current] F644 [Fault 4 Current]
F645 [Fault 5 Current]
F650 [Fault10 Current]
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.
Display: 0.01 A
F651 [Fault 1 BusVolts] F652 [Fault 2 BusVolts] Related Parameter(s): b005

F653 [Fault 3 BusVolts] F654 [Fault 4 BusVolts]
F655 [Fault 5 BusVolts]
F660 [Fault10 BusVolts]
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.
Min/Max: 0/1200VDC
Display: 1VDC


F661 [Status @ Fault 1] F662 [Status @ Fault 2] Related Parameter(s): b006
F663 [Status @ Fault 3] F664 [Status @ Fault 4]
F665 [Status @ Fault 5]
F670 [Status @ Fault10]
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.

Running Digit 1
Forward Digit 2
Accelerating Digit 3
Decelerating Digit 4
SafetyActive(1) Digit 5

Min/Max: 0/0x1F
Display: 1
F681 [Comm Sts - DSI]

Displays the status of the RS485 serial (DSI) port to the drive.
Digit 3 (Connection Status)
1 = Condition True, 0 = Condition False 0 “Not Active”
Rx Digit 1 1 “Modbus slave network (external Modbus master)”
Tx Digit 2 2 “Modbus multi-drive w/ internal com option master”
Status Digit 3 3 “Modbus multi-drive w/ embedded com master”(1)
Error Digit 4 4 “DSI peripheral connected”
Not Used 5...8 “Reserved”
9 “RS-485 network faulted”

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 9 “Internal com option faulted”
Error Digit 4
Not Used
Min/Max: 0000/1911
Display: 0000


F683 [Com Sts-Emb Enet]
Displays the status of the embedded EtherNet/IP interface to the drive.
Digit 3 = “Embedded EtherNet/IP”
1 = Condition True, 0 = Condition False 0 “Not Active (no connection)”
Rx Digit 1 1 “Embedded EtherNet/IP active”
Tx Digit 2 2-8 “Reserved”
Status Digit 3 9 “Embedded EtherNet/IP faulted”
Error Digit 4
Not Used
Min/Max: 0000/1911
Display: 0000
F684 [EN Addr Src]

Displays the actual source of the Ethernet configuration (IP address, subnet mask, and gateway address).
Options 1 “Parameters” Read Only
2 “BOOTP”
F685 [EN Rate Act]

Displays the network data rate currently used by the embedded EtherNet/IP interface.
Options 0 “No Link” Read Only
1 “10Mbps Full”
2 “10Mbps Half”
3 “100Mbps Full”
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
Value Default: Read Only

Min/Max: 00000/11111
Display: 00000


F687 [HW Addr 1]
F688 [HW Addr 2]
F689 [HW Addr 3]
F690 [HW Addr 4]
F691 [HW Addr 5]
F692 [HW Addr 6]
Shows the MAC address for the embedded EtherNet/IP interface.
Min/Max: 0/255
Display: 1
F693 [EN IP Addr Act 1]

Shows the actual IP address 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]
Min/Max: 0/255
Display: 1
F697 [EN Subnet Act 1]

Shows the actual subnet mask used by the embedded EtherNet/IP interface at the time. This will indicate 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]
Min/Max: 0/255
Display: 1


F701 [EN Gateway Act 1]
Shows the actual gateway address used by the embedded EtherNet/IP interface at the time. This will indicate 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]
Min/Max: 0/255
Display: 1
F705 [Drv 0 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 will show 0.
Min/Max: 0/FFFF
Display: 1
F706 [Drv 0 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 will show 0.
Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz
F707 [Drv 0 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.
Min/Max: 0/FFFF
Display: 1


F708 [Drv 0 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.
Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz
F725 [EN Rx Overruns]

A count of the number of receive overrun errors reported by the embedded EtherNet/IP interface.
Min/Max: 0/65535
Display: 1
F726 [EN Rx Packets]

A count of the number of receive packets reported by the embedded EtherNet/IP interface.
Min/Max: 0/65535
Display: 1
F727 [EN Rx Errors]

A count of the number of receive errors reported by the embedded EtherNet/IP interface.
Min/Max: 0/65535
Display: 1
F728 [EN Tx Packets]

A count of the number of transmitted packets reported by the embedded EtherNet/IP interface.
Min/Max: 0/65535
Display: 1
F729 [EN Tx Errors]

A count of the number of transmit errors reported by the embedded EtherNet/IP interface.
Min/Max: 0/65535
Display: 1


F730 [EN Missed IO Pkt]
The number of I/O packets missed.
Min/Max: 0/65535
Display: 1
F731 [DSI Errors]

The number of total DSI errors.
Min/Max: 0/65535
Display: 1

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 setup 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 Key(s) Example Displays
1. Press the Up Arrow or Down Arrow to scroll to
an AppView group (G1...G8). or
FWD
2. Press Enter or Sel to enter a group. The right

most digit of the last viewed parameter in that FWD
group will flash. or Sel

the command G1->GC. or
FWD
4. Press Enter or Sel to add all the parameters in

this AppView group to the CustomView group.
The LCD display will show a confirmation. or Sel

CustomView Parameter CustomView allows you to quickly access only the parameters needed for your
application by storing them in a custom parameter group. Add your frequently
Group 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.
the CustomView group (GC). or
FWD
2. Press Enter to view the parameters that can be

added to the CustomView group. FWD

through the list of parameters. or
FWD
PROGRAM
4. Press Enter to add the parameter to the

CustomView group. The LCD display will show a
confirmation.
To delete parameters from the CustomView parameter group:

the CustomView group (GC). or
FWD
2. Press Enter to view the parameters that are in

the CustomView group. FWD

the command GC---. or
FWD
4. Press Enter or Sel to view the parameters that

are stored in the CustomView group. FWD
or Sel

through the list of parameters. or
FWD
PROGRAM
6. Press Enter to delete the parameter from the

CustomView group. The LCD display will show a
confirmation.
TIP The Connected Components Workbench software can be used to speed up this
process with drag and drop functionality.

Parameter Cross Reference by Name

Parameter Name No. Parameter Name No. Parameter Name No.
10V Bipolar Enbl(1) 093 Current Loop BW(1)(3) 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(2) 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
Com Sts-Emb Enet(1) 683 Drv 1 Logic Cmd 709 EN Gateway Act 3(1) 703
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 EN Gateway Cfg 4(1) 140
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 EN IP Addr Act 2(1) 694
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
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
Counts Per Unit(1) 559 Drv 4 Addr 174 EN IP Addr Cfg 3(1) 131
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


EN Rate Act(1) 685 Fault 6 BusVolts(1) 656 Half Bus Enable 549
EN Rate Cfg(1) 141 Fault 6 Code(1) 606 Home Save(1) 561
EN Rx Errors(1) 727 Fault 6 Current(1) 646 HW Addr 1(1) 687
EN Rx Overruns(1) 725 Fault 6 Freq(1) 636 HW Addr 2(1) 688
EN Rx Packets(1) 726 Fault 6 Time-hr(1) 616 HW Addr 3(1) 689
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
EN Subnet Act 3(1) 699 Fault 7 Code(1) 607 HW Addr 6(1) 692
EN Subnet Act 4(1) 700 Fault 7 Current(1) 647 IR Voltage Drop 496
EN Subnet Cfg 1(1) 133 Fault 7 Freq(1) 637 Jog Accel/Decel 432
EN Subnet Cfg 2(1) 134 Fault 7 Time-hr(1) 617 Jog Frequency 431
EN Subnet Cfg 3(1) 135 Fault 7 Time-min(1) 627 Keypad Freq 426
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
EN Tx Packets(1) 728 Fault 8 Current(1) 648 Language 30
Encoder Pos Tol(1) 564 Fault 8 Freq(1) 638 Load Loss Level(1) 490
Encoder PPR(1) 536 Fault 8 Time-hr(1) 618 Load Loss Time(1) 491
Encoder Speed(2) 378 Fault 8 Time-min(1) 628 Max Traverse 567
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 Fault10 Current(1) 650 Motor Lx(1) 500
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 Fault10 Time-min(1) 630 Motor NP Poles 035
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
Fault 4 Code 604 Freq 1 BW(1) 511 Mtr Options Cfg(2)(5) 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
Opto Out1 Sel(1) 069 PM FWKn 2 Kp(1)(3) 528 Relay Out2 Level(1) 082
Opto Out2 Level(1) 073 PM HIFI NS Cur(1)(3) 519 Relay Out2 Sel(1) 081
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
PID 2 Integ Time(1) 474 Preset Freq 12(1) 422 Speed Reference2 049
PID 2 Invert Err(1) 479 Preset Freq 13(1) 423 Speed Reference3 051
PID 2 Preload(1) 478 Preset Freq 14(1) 424 Speed Reg Sel(1) 509
PID 2 Prop Gain(1) 473 Preset Freq 15(1) 425 Stall Fault Time 492
PID 2 Ref Sel(1) 471 Process Disp Hi 482 Start At PowerUp 543
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
PID 2 Trim Lo(1) 469 Program Lock 552 Start Source 2 048
PID 2 Trim Sel(1) 470 Program Lock Mod 553 Start Source 3 050
PID2 Fdbk Displ(1) 385 Pulse In Scale 537 Status @ Fault 1 661
PID2 Setpnt Disp(1) 386 Purge Frequency 433 Status @ Fault 2 662
PM 1 Efficiency(1)(3) 587 PWM Frequency 440 Status @ Fault 3 663
PM 2 Efficiency(1)(3) 588 RdyBit Mode Act(2)(4) 392 Status @ Fault 4 664
PM Algor Sel(1)(3) 589 RdyBit Mode Cfg(2)(4) 574 Status @ Fault 5 665
PM Align Time(1)(3) 518 Relay 1 Off Time 080 Status @ Fault 6(1) 666
PM BEMF Voltage(1)(3) 504 Relay 1 On Time 079 Status @ Fault 7(1) 667
PM Bus Reg Kd(1)(3) 520 Relay Out1 Level 077 Status @ Fault 8(1) 668
PM Control Cfg(1)(3) 529 Relay Out1 Sel 076 Status @ Fault 9(1) 669
PM DC Inject Cur(1)(3) 517 Relay 2 Off Time(1) 085 Status @ Fault10(1) 670


Step Units 0(1) 200 Stp Logic 5(1) 185 Testpoint Sel 483
Step Units 1(1) 202 Stp Logic 6(1) 186 Text Scroll 556
Step Units 2(1) 204 Stp Logic 7(1) 187 Timer Status 365
Step Units 3(1) 206 Stp Logic Status(1) 391 Torque Current 382
Step Units 4(1) 208 Stp Logic Time 0(1) 190 Torque Perf Mode 039
Step Units 5(1) 210 Stp Logic Time 1(1) 191 Traverse Dec 569
Step Units 6(1) 212 Stp Logic Time 2(1) 192 Traverse Inc 568
Step Units 7(1) 214 Stp Logic Time 3(1) 193 Units Traveled H(1) 388
Stop Mode 045 Stp Logic Time 4(1) 194 Units Traveled L(1) 389
Stp Logic 0(1) 180 Stp Logic Time 5(1) 195 Var PWM Disable 540
Stp Logic 1(1) 181 Stp Logic Time 6(1) 196 Voltage Class 038
Stp Logic 2(1) 182 Stp Logic Time 7(1) 197 Wake Level 103
Stp Logic 3(1) 183 Sync Time 571 Wake Time 104
Stp Logic 4(1) 184 Testpoint Data 368
(1) Parameter is specific to PowerFlex 525 drives only.

Notes:

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.
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 will be
indicated through the integral LCD display.
See Display and Control Keys on page 62 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
1 Auto-Reset/Run 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 reaches
zero, the drive attempts to automatically reset the fault. If the condition that caused the
fault is no longer present, the fault will be reset and the drive will be restarted.
2 Non-Resettable This type of fault may require drive or motor repair, or is caused by wiring or programming
errors. The cause of the fault must be corrected before the fault can be cleared.

Chapter 4 Troubleshooting
Fault Indication
Condition Display
Drive is indicating a fault.
The integral LCD display provides visual notification of a fault condition by displaying the FWD
following.
• Flashing fault number
• Flashing fault indicator (LED) FAULT
Press the Esc key to regain control of the display.
Esc Sel
Manually Clearing Faults

Step Key(s)
1. Press Esc to acknowledge the fault. The fault information will be removed so that you
can use the integral keypad.
Access b007 [Fault 1 Code] to view the most recent fault information. Esc
2. Address the condition that caused the fault.
The cause must be corrected before the fault can be cleared. See Fault Types,
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.
2. Set A542 [Auto Rstrt Delay] to a value other than “0”.
Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault

without restarting the drive.
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.

Troubleshooting Chapter 4
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 will attempt to issue its
own start command based on user selected programming.
Fault Descriptions Fault Types, Descriptions and Actions

No. Fault Type(2) Description Action
F000 No Fault – No fault present. –
F002 Auxiliary Input 1 External trip (Auxiliary) input. • Check remote wiring.
• Verify communications
programming for intentional fault.
F003 Power Loss 2 Single phase operation detected with • Monitor the incoming AC line for low
excessive load. voltage or line power interruption.
• Check input fuses.
• Reduce load.
F004 UnderVoltage 1 DC bus voltage fell below the minimum Monitor the incoming AC line for low
value. voltage or line power interruption.
F005 OverVoltage 1 DC bus voltage exceeded maximum Monitor the AC line for high line voltage
value. or transient conditions. Bus overvoltage
can also be caused by motor
regeneration. Extend the decel time or
install dynamic brake option.
F006 Motor Stalled 1 Drive is unable to accelerate or • Increase P041, A442, A444, A446
decelerate motor. [Accel Time x] or reduce load so drive
output current does not exceed the
current set by parameter A484, A485
[Current Limit x] for too long.
• Check for overhauling load.
F007 Motor Overload 1 Internal electronic overload trip. • An excessive motor load exists.
Reduce load so drive output current
does not exceed the current set by
parameter P033 [Motor OL Current].
• Verify A530 [Boost Select] setting.
F008 Heatsink OvrTmp 1 Heatsink/Power Module temperature • Check for blocked or dirty heat sink
exceeds a predefined value. fins. Verify that ambient
temperature has not exceeded the
rated ambient temperature.
• Check fan.
F009 CC OvrTmp 1 Control module temperature exceeds a • Check product ambient
predefined value. temperature.
• Check for airflow obstruction.
• Check for dirt or debris.
• Check fan.
F012 HW OverCurrent 2 The drive output current has exceeded Check programming. Check for excess
the hardware current limit. load, improper A530 [Boost Select]
setting, DC brake volts set too high or
other causes of excess current.
F013 Ground Fault 1(3) A current path to earth ground has been Check the motor and external wiring to
detected at one or more of the drive the drive output terminals for a
output terminals. grounded condition.

Fault Types, Descriptions and Actions

F015(1) Load Loss 2 The output torque current is below the • Verify connections between motor
value programmed in A490 [Load Loss and load.
Level] for a time period greater than the • Verify level and time requirements
time programmed in A491 [Load Loss
Time].
F021 Output Ph Loss 1 Output Phase Loss (if enabled). • Verify motor wiring.
Configure with A557 [Out Phas Loss En]. • Verify motor.
F029 Analog In Loss 1 An analog input is configured to fault on • Check for broken/loose connections
signal loss. A signal loss has occurred. at inputs.
Configure with t094 [Anlg In V Loss] or • Check parameters.
t097 [Anlg In mA Loss].
F033 Auto Rstrt Tries 2 Drive unsuccessfully attempted to reset Correct the cause of the fault and
a fault and resume running for the manually clear.
programmed number of A541 [Auto
Rstrt Tries].
F038 Phase U to Gnd 2 A phase to ground fault has been • Check the wiring between the drive
F039 Phase V to Gnd detected between the drive and motor and motor.
in this phase. • Check motor for grounded phase.
F040 Phase W to Gnd • Replace drive if fault cannot be
cleared.
F041 Phase UV Short 2 Excessive current has been detected • Check the motor and drive output
F042 Phase UW Short between these two output terminals. terminal wiring for a shorted
condition.
F043 Phase VW Short • Replace drive if fault cannot be
cleared.
F048 Params Defaulted 1 The drive was commanded to write • Clear the fault or cycle power to the
default values to EEPROM. drive.
• Program the drive parameters as
needed.
F059(1) Safety Open 1 Both of the safety inputs (Safety 1, • Check safety input signals. If not
Safety 2) are not enabled. using safety, verify and tighten
Configure with t105 [Safety Open En]. jumper for I/O terminals S1, S2 and
S+.
F063 SW OverCurrent 1 Programmed A486, A488 [Shear Pinx • Verify connections between motor
Level] has been exceeded for a time and load.
period greater than the time • Verify level and time requirements.
programmed in A487, A489 [Shear Pin x
Time].
F064 Drive Overload 2 Drive overload rating has been Reduce load or extend Accel Time.
exceeded.
F070 Power Unit 2 Failure has been detected in the drive • Check maximum ambient
power section. temperature has not been exceeded.
• Cycle power.
• Replace drive if fault cannot be
cleared.
F071 DSI Net Loss 2 Control over the Modbus or DSI • Cycle power.
communication link has been • Check communications cabling.
interrupted. • Check Modbus or DSI setting.
• Check Modbus or DSI status.
F072 Opt Net Loss 2 Control over the network option card’s • Cycle power.
remote network has been interrupted. • Check communications cabling.
• Check network adapter setting.
• Check external network status.
F073(1) EN Net Loss 2 Control through the embedded • Cycle power.
EtherNet/IP adapter has been • Check communications cabling.
interrupted. • Check EtherNet/IP setting.
• Check external network status.
F080 Autotune Failure 2 The autotune function was either Restart procedure.
cancelled by the user or failed.


F081 DSI Comm Loss 2 Communications between the drive and • Cycle power.
the Modbus or DSI master device have • Check communications cabling.
been interrupted. • Check Modbus or DSI setting.
• Check Modbus or DSI status.
• Modify using C125 [Comm Loss
Action].
• Connecting I/O terminals C1 and C2
to ground may improve noise
immunity.
• Replace wiring, Modbus master
device, or control module.
F082 Opt Comm Loss 2 Communications between the drive and • Cycle power.
the network option card have been • Reinstall option card in drive.
interrupted. • Modify using C125 [Comm Loss
Action].
• Replace wiring, port expander,
option card, or control module.
F083(1) EN Comm Loss 2 Internal communications between the • Cycle power.
drive and the embedded EtherNet/IP • Check EtherNet/IP setting.
adapter have been interrupted. • Check drive’s Ethernet settings and
diagnostic parameters.
• Modify using C125 [Comm Loss
Action].
• Replace wiring, Ethernet switch, or
control module.
F091(1) Encoder Loss 2 Requires differential encoder. • Check Wiring.
One of the 2 encoder channel signals is • If P047, P049, P051 [Speed
missing. Referencex] = 16 “Positioning” and
A535 [Motor Fdbk Type] = 5 “Quad
Check”, swap the Encoder channel
inputs or swap any two motor leads.
• Replace encoder.
F094 Function Loss 2 “Freeze-Fire” (Function Loss) input is Close input to the terminal and cycle
inactive, input to the programmed power.
terminal is open.
F100 Parameter Chksum 2 Drive parameter non-volatile storage is Set P053 [Reset To Defalts] to 2 “Factory
corrupted. Rset”.
F101 External Storage 2 External non-volatile storage has failed. Set P053 [Reset To Defalts] to 2 “Factory
Rset”.
F105 C Connect Err 2 Control module was disconnected while Clear fault and verify all parameter
drive was powered. settings. Do not remove or install the
control module while power is applied.
F106 Incompat C-P 2 The PowerFlex 525 control module does • Change to a different power module.
not support power modules with 0.25 • Change to a PowerFlex 523 control
HP power rating. module.
F107 Replaced C-P 2 The control module could not recognize • Change to a different power module.
the power module. Hardware failure. • Replace control module if changing
power module does not work.
F109 Mismatch C-P 2 The control module was mounted to a Set P053 [Reset To Defalts] to 3 “Power
different drive type power module. Reset”.
F110 Keypad Membrane 2 Keypad membrane failure / • Cycle power.
disconnected. • Replace control module if fault
cannot be cleared.
F111(1) Safety Hardware 2 Safety input enable hardware • Check safety input signals. If not
malfunction. One of the safety inputs is using safety, verify and tighten
not enabled. jumper for I/O terminals S1, S2 and
S+.
• Replace control module if fault
cannot be cleared.


F114 uC Failure 2 Microprocessor failure. • Cycle power.
• Verify grounding requirements. See
General Grounding Requirements on
page 20 for more information.
• Replace control module if fault
cannot be cleared.
F122 I/O Board Fail 2 Failure has been detected in the drive • Cycle power.
control and I/O section. • Replace drive or control module if
fault cannot be cleared.
F125 Flash Update Req 2 The firmware in the drive is corrupt, Perform a firmware flash update
mismatched, or incompatible with the operation to attempt to load a valid set
hardware. of firmware.
F126 NonRecoverablErr 2 A non-recoverable firmware or • Clear fault or cycle power to the
hardware error was detected. The drive drive.
was automatically stopped and reset. • Replace drive or control module if
fault cannot be cleared.
F127 DSIFlashUpdatReq 2 A critical problem with the firmware Perform a firmware flash update
was detected and the drive is running operation using DSI communications to
using backup firmware that only attempt to load a valid set of firmware.
supports DSI communications.
(1) This fault is not applicable to PowerFlex 523 drives.
(2) See Fault Types for more information.
(3) This fault may be cleared by the auto-restart routine and will be attempted only once. It ignores the value set in parameter A541
[Auto Rstrt Tries].
Common Symptoms and The drive is designed to start from the keypad when shipped. For a basic test of
drive operation:
Corrective Actions
1. Remove all user I/O wire.
2. Verify safety terminals (S1, S2 and S+) jumper is in place and tightened.
3. Verify 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 Wiring Block Diagram on
page 42 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 will
run according to the speed potentiometer.

Motor does not Start.

Cause(s) Indication Corrective Action
No output voltage to the motor. None 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.
• 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 start-up. None Set A530 [Boost Select] to 2 “35.0, VT”.
Drive is Faulted Flashing red status light Clear fault.
Incorrect programming. None Check setting for b012 [Control Source].
• P046, P048, P050 [Start Source x] is set incorrectly.
Incorrect input wiring. None • Wire inputs correctly and/or install jumper.
See page 45 for wiring examples. • If the PowerFlex 525 Safe-Torque-Off function is used, verify that inputs are active.
• 2 wire control requires Run Forward, Run Reverse or Jog • If 2-wire or 3-wire mode is used, verify that t062 [DigIn TermBlk 02] and t063 [DigIn
input. TermBlk 03] are set properly.
• 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 Start from Start or Run Inputs wired to the terminal
block.
Drive is Faulted Flashing red status light Clear fault.
Incorrect programming. None Check parameter settings.
• P046, P048, P050 [Start Source x] is set incorrectly.
• t062, t063 [DigIn TermBlk 02/03] is set incorrectly.
Incorrect input wiring. None • Wire inputs correctly and/or install jumper.
See page 45 for wiring examples. • If the PowerFlex 525 Safe-Torque-Off function is used, verify that inputs are active.
• 2 wire control requires Run Forward, Run Reverse or Jog
input.
• 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.

No value is coming from the source of the command. The drive “Run” indicator is • Check b012 [Control Source] for correct source.
lit and output is 0 Hz. • If the source is an analog input, check wiring and use a meter to check for presence of
signal.
• Check b002 [Commanded Freq] to verify correct command.
Incorrect reference source is being selected by remote device or None • Check b012 [Control Source] for correct source.
digital inputs. • Check b014 [Dig In Status] to see if inputs are selecting an alternate source. Verify
settings for t062, t063, t065-t068 [DigIn TermBlk xx].
• Check P047, P049, P051 [Speed Referencex] for the source of the speed reference.
Reprogram as necessary.
• Review the Speed Reference Control chart on page 49.
• Verify communications if used.
Motor and/or drive will not accelerate to commanded speed.

Acceleration time is excessive. None Reprogram P041, A442, A444, A446 [Accel Time x].
Excess load or short acceleration times force the drive into None • Compare b003 [Output Current] with A484, A485 [Current Limit x].
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.
Speed command source or value is not as expected. None • Verify b002 [Commanded Freq].
• Check b012 [Control Source] for the proper Speed Command.
Programming is preventing the drive output from exceeding None • Check P044 [Maximum Freq] to ensure that speed is not limited by programming.
limiting values. • Verify programming of A572 [Speed Ratio].
Torque performance does not match motor characteristics. None • Set motor nameplate full load amps in parameter P034 [Motor NP FLA].
• Perform P040 [Autotune] “Static Tune” or “Rotate Tune” procedure.
• Set P039 [Torque Perf Mode] to 0 “V/Hz”.
Motor operation is unstable.

Motor data was incorrectly entered. None 1. Correctly enter motor nameplate data into P031, P032 and P033.
2. Enable A547 [Compensation].
3. Use A530 [Boost Select] to reduce boost level.
Drive will not reverse motor direction.

Reverse is disabled. None Check A544 [Reverse Disable].
Digital input is not selected for reversing control. None Check [DigIn TermBlk xx] (See page 89). Choose correct input and program for reversing
mode.
Digital input is incorrectly wired. None Check input wiring (See page 45).
Motor wiring is improperly phased for reverse. None Switch two motor leads.

Drive does not power up.

No input power to drive. None • Check the power circuit.
• Check the supply voltage.
• Check all fuses and disconnects.
Control module is not connected properly to power module. None 1. Remove power.
2. Verify that the control module is properly and fully installed on the power module.
3. Reapply power.
Motor is rotating at zero Hz or slip frequency is not correct.

Incorrect speed calculation. Improper speed. • Verify P032 [Motor NP Hertz].
• Reduce boost with A530 [Boost Select].
• Set P036 [Motor NP RPM] to motor synchronous speed.

Notes:

Appendix A
Supplemental Drive Information

Certifications 167
Environmental Specifications 168
Technical Specifications 169
Power Specifications 172
Certifications Certifications PowerFlex 523 PowerFlex 525

c-UL-us Listed to UL508C and CAN/CSA-C22.2 No. 14-05.
RCM Australian Communications and Media Authority

In conformity with the following:
Radiocommunications Act: 1992
Radiocommunications Standard: 2008
Radiocommunications Labelling Notice: 2008
Standards applied:
EN 61800-3
CE In conformity with the following European Directives:
2014/35/EU Low Voltage Directive (LVD)
2014/30/EU EMC Directive (EMC)
2014/34/EU ATEX Directive (ATEX)
2006/42/EC Machinery Directive (MD)
Standards applied:
EN 61800-3
EN 61800-5-1
TUV (Applicable to PowerFlex 525 drives only)
Functional
Safety
TÜV Rheinland
Type
Approved Standards applied:
www.tuv.com
ID 0600000000
EN ISO 13849-1
EN 61800-5-2
EN 61508 PARTS 1-7
EN 62061
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
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
TUV 12 ATEX 7199 X
KCC Korean Registration of Broadcasting and Communications Equipment
Compliant with the following standards:
Article 58-2 of Radio Waves Act, Clause 3
EAC Standards applied:
Low Voltage TP TC 004/2011
EMC TP TC 020/2011

Appendix A Supplemental Drive Information
Certifications PowerFlex 523 PowerFlex 525

AC 156 Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification
Testing of Nonstructural Components and 2003 International Building Code for worst-case
seismic level for USA excluding site class F
SEMI F47 Electric Power Research Institute
Certified compliant with the following standards:
SEMI F47
IEC 61000-4-11
IEC 61000-4-34
Lloyds Register (Applicable to PowerFlex 525 drives only)
Lloyd’s Register Type Approval Certificate 12/10068(E1)
RoHS Compliant with the European “Restriction of Hazardous Substances” Directive
The drive is also designed to meet the appropriate portions of the following specifications:
NFPA 70 - US National Electrical Code
NEMA ICS 7.1 - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable
Speed Drive Systems.
Environmental Specifications Specifications PowerFlex 523 PowerFlex 525

Altitude: See Current Derating Curves on page 17 for derating guidelines.
Without derating: 1000 m (3300 ft) max.
With derating: Up to 4000 m (13,200 ft) max., with the exception of 600V drives at 2000 m (6600 ft)
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 Fan
With derating: kit.
Storage Temperature:
Frame A...D: -40...85 °C (-40...185 °F)
Frame E: -40...70 °C (-40...158 °F)
Atmosphere:
IMPORTANT Drive must not be installed in an area where the ambient atmosphere contains volatile or
corrosive gas, vapors or dust. If the drive is not going to be installed for a period of time, it must
be stored in an area where it will not be exposed to a corrosive atmosphere.
Relative Humidity: 0...95% noncondensing

Shock: Complies with IEC 60068-2-27
Vibration: Complies with IEC 60068-2-6:1995
Operating and Nonoperating Nonoperating (Transportation)

Frame Force Force
Size (Shock/Vibration) Mounting Type (Shock/Vibration) Mounting Type
A 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only
B 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only
C 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only
D 15 g / 2 g Screw only 30 g/ 2.5 g Screw only
E 15 g / 1.5 g Screw only 30 g/ 2.5 g Screw only

Supplemental Drive Information Appendix A
Specifications PowerFlex 523 PowerFlex 525

Conformal Coating: Complies with:
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 52
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

Bus Overvoltage Trip
100...120V AC Input: 405V DC bus (equivalent to 150V AC incoming line)
Bus Undervoltage Trip
525...600V AC Input
P038 = 3 “600V”: 487V DC bus (equivalent to 344V AC incoming line)
P038 = 2 “480V”: 390V DC bus (equivalent to 275V AC incoming line)
Power Ride-Thru: 100 ms
Logic Control Ride-Thru: 0.5 s minimum, 2 s typical
Electronic Motor Overload Provides class 10 motor overload protection according to NEC article 430 and motor
Protection: over-temperature protection according to NEC article 430.126 (A) (2).
UL 508C File 29572.
Overcurrent: 200% hardware limit, 300% instantaneous fault
Ground Fault Trip: Phase-to-ground on drive output
Short Circuit Trip: Phase-to-phase on drive output
Electrical
Voltage Tolerance: -15% / +10%
Frequency Tolerance: 47...63 Hz
Input Phases: Three-phase input provides full rating. Single-phase input provides 35% rating on
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: Isolated 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

Control
Method 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 (with encoder)
(Closed Loop Velocity Vector Control and PM motor control 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): ±0.1% of base speed across a 100:1 speed range(2)
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 1000:1 speed range(2)
PM Motor (iPM motor, 10 HP ±0.1% of base speed, up to a 60:1 speed range
rating and below) (1):
Output Voltage Range: 0V to rated motor voltage
Output Frequency Range: 0...500 Hz (programmable)
Efficiency: 97.5% (typical)
Stop Modes: Multiple programmable stop modes including – Ramp, Coast, DC-Brake,
and Ramp-to-Stop
Accel/Decel: Four independently programmable accel and decel times. Each time may be
programmed from 0...600 s in 0.01 s increments.
Intermittent Overload
Normal Duty: 110% Overload capability for up to 60 s, 150% for up to 3 s
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 (200% programmable)
(1) For details on specific motor performance, see Knowledge Base article “PowerFlex 525 PM Motor Performance Testing Summary”.
(2) For more information, see Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution on page 217.

Control Inputs
Digital Bandwidth: 10 Rad/s for open and closed loop
Quantity: (1) Dedicated for stop (1) Dedicated for stop
(4) Programmable (6) Programmable
Current: 6 mA
Type
Source Mode (SRC): 18...24V = ON, 0...6V = OFF
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
Analog: Quantity: (1) Isolated, 0-10V and 4-20mA (2) Isolated, -10-10V and 4-20mA
Specification
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
Control Outputs
Relay: Quantity: (1) Programmable Form C (2) 1 Programmable Form A and
1 Programmable Form B
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
Opto: Quantity: – (2) Programmable
Specification: 30V DC, 50 mA Non-inductive
Analog Quantity: (1) Non-Isolated 0-10V or 4-20 mA(1)
Specification
Resolution: 10-bit
0-10V DC Analog: 1 k ohm minimum
4-20 mA Analog: 525 ohm maximum
(1) Feature is not applicable to PowerFlex 523 series A drives.
Encoder
Type: – Incremental, dual channel
Supply: 12V, 250 mA
Quadrature: 90 °, ±27 ° @ 25 °C
Duty Cycle: 50%, +10%
Requirements: 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 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

PowerFlex 520-Series Estimated Watts Loss (Rated Load, Speed & PWM)
Voltage Output Current (A) Total Watts Loss
100...120V, 1.6 20.0
50/60 Hz 1-Phase 2.5 27.0
4.8 53.0
6.0 67.0
200...240V, 1.6 20.0
50/60 Hz 1-Phase 2.5 29.0
4.8 50.0
8.0 81.0
11.0 111.0
200...240V, 1.6 20.0
50/60 Hz 1-Phase 2.5 29.0
w/ EMC Filter
4.8 53.0
8.0 84.0
11.0 116.0
200...240V, 1.6 20.0
50/60 Hz 3-Phase 2.5 29.0
5.0 50.0
8.0 79.0
11.0 107.0
17.5 148.0
24.0 259.0
32.2 323.0
48.3 584.0
62.1 708.0
380...480V, 1.4 27.0
50/60 Hz 3-Phase 2.3 37.0
4.0 62.0
6.0 86.0
10.5 129.0
13.0 170.0
17.0 221.0
24.0 303.0
30.0 387.0
380...480V, 1.4 27.0
50/60 Hz 3-Phase 2.3 37.0
w/ EMC Filter
4.0 63.0
6.0 88.0
10.5 133.0
13.0 175.0
17.0 230.0
24.0 313.0
30.0 402.0
37.0 602.0
43.0 697.0

PowerFlex 520-Series Estimated Watts Loss (Rated Load, Speed & PWM)
Voltage Output Current (A) Total Watts Loss
525...600V, 0.9 22.0
50/60 Hz 3-Phase 1.7 32.0
3.0 50.0
4.2 65.0
6.6 95.0
9.9 138.0
12.0 164.0
19.0 290.0
22.0 336.0
27.0 466.0
32.0 562.0
Input Current Scaling (Optional)
You can use a higher drive rating by scaling the input current based on the output
current required for your application. You can use a lower input current rating
based upon the motor FLA rating. For example, if the motor has an FLA rating of
1.6, the input rating will be 3.2 amps. See the PowerFlex 520-Series Input
Current Rating Scaled by the Motor FLA on page 173 table for more
information.
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 5 6 7 8
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
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
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

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 5 6 7 8
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
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
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
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

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
Normal Duty Heavy Duty Output Input Frame PowerFlex 523 PowerFlex 525
HP kW HP kW Current (A) Voltage Range Size Catalog No. Catalog No.
0.25 0.2 0.25 0.2 1.6 85...132 A 25A-V1P6N104(2) –
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
0.25 0.2 0.25 0.2 1.6 170...264 A 25A-A1P6N104(2) –
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
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
0.25 0.2 0.25 0.2 1.6 170...264 A 25A-B1P6N104(2) –
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(1)
0.5 0.4 0.5 0.4 1.4 323...528 A 25A-D1P4N104(2) 25B-D1P4N104(2)
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
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

Appendix B Accessories and Dimensions
PowerFlex 520-Series Drive Ratings

Output Ratings
Normal Duty Heavy Duty Output Input Frame PowerFlex 523 PowerFlex 525
HP kW HP kW Current (A) Voltage Range Size Catalog No. Catalog No.
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
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
0.5 0.4 0.5 0.4 0.9 446...660 A 25A-E0P9N104(2) 25B-E0P9N104(2)
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) 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 will support a filtered drive.
(2) These drive ratings do not come with a heatsink cooling fan and are in accordance with design specifications.
Dynamic Brake Resistors

Drive Ratings Minimum
Input Voltage HP kW Resistance Resistance
Ω ±10% Ω ±5% Catalog No.(1)(2)
100...120V 0.25 0.2 56 91 AK-R2-091P500
50/60 Hz 0.5 0.4 56 91 AK-R2-091P500
1-Phase
1.0 0.75 56 91 AK-R2-091P500
1.5 1.1 41 91 AK-R2-091P500
200...240V 0.25 0.2 56 91 AK-R2-091P500
50/60 Hz 0.5 0.4 56 91 AK-R2-091P500
1-Phase
1.0 0.75 56 91 AK-R2-091P500
2.0 1.5 41 91 AK-R2-091P500
3.0 2.2 32 47 AK-R2-047P500

Accessories and Dimensions Appendix B
Dynamic Brake Resistors

Drive Ratings Minimum
Input Voltage HP kW Resistance Resistance
Ω ±10% Ω ±5% Catalog No.(1)(2)
200...240V 0.25 0.2 56 91 AK-R2-091P500
50/60 Hz 0.5 0.4 56 91 AK-R2-091P500
3-Phase
1.0 0.75 56 91 AK-R2-091P500
2.0 1.5 41 91 AK-R2-091P500
3.0 2.2 32 47 AK-R2-047P500
5.0 4.0 18 47 AK-R2-047P500
7.5 5.5 16 30 AK-R2-030P1K2
10.0 7.5 14 30 AK-R2-030P1K2
15.0 11.0 14 15 AK-R2-030P1K2(3)
20.0 15.0 10 15 AK-R2-030P1K2(3)
380...480V 0.5 0.4 89 360 AK-R2-360P500
50/60 Hz 1.0 0.75 89 360 AK-R2-360P500
3-Phase
2.0 1.5 89 360 AK-R2-360P500
3.0 2.2 89 120 AK-R2-120P1K2
5.0 4.0 47 120 AK-R2-120P1K2
7.5 5.5 47 120 AK-R2-120P1K2
10.0 7.5 47 120 AK-R2-120P1K2
15.0 11.0 43 60 AK-R2-120P1K2(3)
20.0 15.0 43 60 AK-R2-120P1K2(3)
25.0 18.5 27 40 AK-R2-120P1K2(4)
30.0 22.0 27 40 AK-R2-120P1K2(4)
525...600V 0.5 0.4 112 360 AK-R2-360P500
50/60 Hz 1.0 0.75 112 360 AK-R2-360P500
3-Phase
2.0 1.5 112 360 AK-R2-360P500
3.0 2.2 112 120 AK-R2-120P1K2
5.0 4.0 86 120 AK-R2-120P1K2
7.5 5.5 59 120 AK-R2-120P1K2
10.0 7.5 59 120 AK-R2-120P1K2
15.0 11.0 59 60 AK-R2-120P1K2(3)
20.0 15.0 59 60 AK-R2-120P1K2(3)
25.0 18.5 53 60 AK-R2-120P1K2(3)
30.0 22.0 34 40 AK-R2-120P1K2(4)
(1) The resistors listed in this tables are rated for 5% duty cycle.
(2) Use of Rockwell Automation resistors is always recommended. The resistors 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) Requires two resistors wired in parallel.
(4) Requires three resistors wired in parallel.
EMC Line Filters

Short Circuit Current Rating = 100 kA
Drive Ratings
Input Voltage HP kW Current (A) Frame Size Catalog No.
100...120V 0.25 0.2 1.6 A 25-RF011-AL
50/60 Hz 0.5 0.4 2.5 A 25-RF011-AL
1-Phase
1.0 0.75 4.8 B 25-RF023-BL
1.5 1.1 6.0 B 25-RF023-BL

EMC Line Filters

Short Circuit Current Rating = 100 kA
Drive Ratings
Input Voltage HP kW Current (A) Frame Size Catalog No.
200...240V 0.25 0.2 1.6 A 25-RF011-AL
50/60 Hz 0.5 0.4 2.5 A 25-RF011-AL
1-Phase
1.0 0.75 4.8 A 25-RF011-AL
2.0 1.5 8.0 B 25-RF023-BL
3.0 2.2 11.0 B 25-RF023-BL
200...240V 0.25 0.2 1.6 A 25-RF014-AL
50/60 Hz 0.5 0.4 2.5 A 25-RF014-AL
3-Phase
1.0 0.75 5.0 A 25-RF014-AL
2.0 1.5 8.0 A 25-RF014-AL
3.0 2.2 11.0 A 25-RF014-AL
5.0 4.0 17.5 B 25-RF021-BL
7.5 5.5 24.0 C 25-RF027-CL
10.0 7.5 32.2 D 25-RF035-DL
15.0 11.0 48.3 E 25-RF056-EL
20.0 15.0 62.1 E 25-RF056-EL
380...480V 0.5 0.4 1.4 A 25-RF7P5-AL
50/60 Hz 1.0 0.75 2.3 A 25-RF7P5-AL
3-Phase
2.0 1.5 4.0 A 25-RF7P5-AL
3.0 2.2 6.0 A 25-RF7P5-AL
5.0 4.0 10.5 B 25-RF014-BL
7.5 5.5 13.0 C 25-RF018-CL
10.0 7.5 17.0 C 25-RF018-CL
15.0 11.0 24.0 D 25-RF033-DL
20.0 15.0 30.0 D 25-RF033-DL
25.0 18.5 37.0 E 25-RF039-EL
30.0 22.0 43.0 E 25-RF039-EL(1)
525...600V 0.5 0.4 0.9 A 25-RF8P0-BL(2)
50/60 Hz 1.0 0.75 1.7 A 25-RF8P0-BL(2)
3-Phase
2.0 1.5 3.0 A 25-RF8P0-BL(2)
3.0 2.2 4.2 A 25-RF8P0-BL(2)
5.0 4.0 6.6 B 25-RF8P0-BL
7.5 5.5 9.9 C 25-RF014-CL
10.0 7.5 12.0 C 25-RF014-CL
15.0 11.0 19.0 D 25-RF027-DL
20.0 15.0 22.0 D 25-RF027-DL
25.0 18.5 27.0 E 25-RF029-EL
30.0 22.0 32.0 E 25-RF029-EL(1)
(1) EMC Line Filter size is based on the input current of the drive. See the tables on page 26 and page 27 for more information.
(2) This 600V drive rating needs to be matched with a frame B EMC Line Filter.

EMC Plates
Frame
Item Description Size Catalog No.
EMC Plate Optional grounding plate for shielded cables. A 25-EMC1-FA
B 25-EMC1-FB
C 25-EMC1-FC
D 25-EMC1-FD
E 25-EMC1-FE
Human Interface Module (HIM) Option Kits and Accessories

Item Description Catalog No.
LCD Display, Remote Panel Digital speed control 22-HIM-C2S
Mount CopyCat capable
IP66 (NEMA Type 4X/12) indoor use only
Includes 2.0 meter cable
LCD Display, Remote Digital speed control 22-HIM-A3
Handheld Full numeric keyboard
CopyCat capable
IP 30 (NEMA Type 1)
Includes 1.0 meter cable
Panel mount with optional Bezel Kit
Bezel Kit Panel mount for LCD Display, Remote Handheld unit, IP 30 (NEMA Type 1) 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
IP 30/NEMA 1/UL Type 1 Kit Field installed kit. Converts drive to IP 30/NEMA 1/UL Type 1 A 25-JBAA
enclosure. Includes conduit box with mounting screws and B 25-JBAB
plastic top panel.
C 25-JBAC
D 25-JBAD
E 25-JBAE

Frame
Control Module Fan Kit For use with drive in environments with ambient A...D 25-FAN1-70C
temperatures up to 70 °C or horizontal mounting. E 25-FAN2-70C
Incremental Encoder Input Option

Incremental Encoder Incremental encoder input option board. 25-ENC-1
WARNING: Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525
drive. Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2
will cause damage to the PowerFlex 525 drive.

Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate

B160
Frame
Mounting Adapter Plate For use with drive when replacing Bulletin 160 drives in A 25-MAP-FA
existing installations to a PowerFlex 520-Series drive. Select B 25-MAP-FB
the catalog number based on the frame size of your Bulletin
160 drive.
Replacement Parts
PowerFlex 520-Series Power Module

Item Description
PowerFlex 520-Series Replacement power module for use with PowerFlex 520-Series drives. Includes:
Power Module • Power Module
• Power Module Front Cover
• Power Terminal Guard
• Heatsink Fan
Output Ratings
Normal Duty Heavy Duty Output Input Frame
HP kW HP kW Current (A) Voltage Range Size Catalog No.
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
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
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
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
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
0.5 0.4 0.5 0.4 1.4 323...528 A 25-PM1-D1P4

Output Ratings
Normal Duty Heavy Duty Output Input Frame
HP kW HP kW Current (A) Voltage Range Size Catalog No.
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
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
0.5 0.4 0.5 0.4 0.9 446...660 A 25-PM1-E0P9
1.0 0.75 1.0 0.75 1.7 446...660 A 25-PM1-E1P7
2.0 1.5 2.0 1.5 3.0 446...660 A 25-PM1-E3P0
3.0 2.2 3.0 2.2 4.2 446...660 A 25-PM1-E4P2
5.0 4.0 5.0 4.0 6.6 446...660 B 25-PM1-E6P6
7.5 5.5 7.5 5.5 9.9 446...660 C 25-PM1-E9P9
10.0 7.5 10.0 7.5 12.0 446...660 C 25-PM1-E012
15.0 11.0 15.0 11.0 19.0 446...660 D 25-PM1-E019
20.0 15.0 15.0 11.0 22.0 446...660 D 25-PM1-E022
25.0 18.5 20.0 15.0 27.0 446...660 E 25-PM1-E027
30.0 22.0 25.0 18.5 32.0 446...660 E 25-PM1-E032
PowerFlex 520-Series Control Module

Frame
PowerFlex 523 Control Replacement control module for use with A...E 25A-CTM1
Module PowerFlex 520-Series drives. Includes:
PowerFlex 525 Control • Control Module 25B-CTM1
Module • Control Module Front Cover
Other Parts
Frame
PowerFlex 523 Control Replacement cover for the control module I/O terminals, A...E 25A-CTMFC1
Module Front Cover EtherNet/IP and DSI ports.
PowerFlex 525 Control 25B-CTMFC1
Module Front Cover

Other Parts
Frame
PowerFlex 520-Series Replacement cover for the PowerFlex 520-Series power B 25-PMFC-FB
Power Module Front Cover module. C 25-PMFC-FC
D 25-PMFC-FD
E 25-PMFC-FE
PowerFlex 520-Series Replacement finger guard for power terminals. A 25-PTG1-FA
Power Terminal Guard B 25-PTG1-FB
C 25-PTG1-FC
D 25-PTG1-FD
E 25-PTG1-FE
PowerFlex 520-Series Replacement fan for drive power module. A 25-FAN1-FA
Heatsink Fan Kit B 25-FAN1-FB
C 25-FAN1-FC
D 25-FAN1-FD
E 25-FAN1-FE
PowerFlex 520-Series EMC Replacement EMC cores A 25-CORE-A
Cores 25-CORE-RF-A
B 25-CORE-B
25-CORE-RF-B
C 25-CORE-C
25-CORE-RF-C
D 25-CORE-D
25-CORE-RF-D
E 25-CORE-E
25-CORE-RF-E
Communication Option Kits and Accessories

Communication Adapters Embedded communication options for use with the
PowerFlex 520-Series drives:
• DeviceNet™ 25-COMM-D
• Dual Port EtherNet/IP™ 25-COMM-E2P
• PROFIBUS™ DP-V1 25-COMM-P
Compact I/O Module Three channel 1769-SM2
Universal Serial Bus™ (USB) Provides serial communication with DF1 protocol for use with 1203-USB
Converter Module Connected Components Workbench software. Includes:
• 2 m USB cable (1)
• 20-HIM-H10 cable (1)
• 22-HIM-H10 cable (1)
Serial Converter Module Provides serial communication with DF1 protocol for use with 22-SCM-232
(RS485 to RS232) Connected Components Workbench software. Includes:
• DSI to RS232 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
Serial Cable 2.0 m serial cable with a locking low profile connector to 1203-SFC
connect to the serial converter and a 9-pin sub-miniature D
female connector to connect to a computer.
Splitter Cable RJ45 one to two port splitter cable (Modbus only) AK-U0-RJ45-SC1

Communication Option Kits and Accessories

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 Windows-based software packages for programming and http://
Workbench Software configuring Allen-Bradley drives and other Rockwell ab.rockwellautomation.co
(Download or DVD-ROM) Automation products. m/programmable-
Compatibility: controllers/connected-
Windows XP, Windows Vista and Windows 7 components-workbench-
software
Bulletin 1321-3R Series Line Reactors

Output Ratings(1) Input Line Reactor(3)(4) Output Line Reactor(3)(4)
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(2)
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
20.0 15.0 15.0 11.0 1321-3R55-A (ND) 1321-3RA55-A (ND) 1321-3R55-A (ND) 1321-3RA55-A (ND)
1321-3R45-A (HD) 1321-3RA45-A (HD) 1321-3R45-A (HD) 1321-3RA45-A (HD)
380...480V 50/60 Hz 3-Phase
0.5 0.4 0.5 0.4 1321-3R2-B 1321-3RA2-B 1321-3R2-B 1321-3RA2-B
1.0 0.75 1.0 0.75 1321-3R4-C 1321-3RA4-C 1321-3R4-C 1321-3RA4-C
2.0 1.5 2.0 1.5 1321-3R4-B 1321-3RA4-B 1321-3R4-B 1321-3RA4-B
3.0 2.2 3.0 2.2 1321-3R8-C 1321-3RA8-C 1321-3R8-C 1321-3RA8-C
5.0 4.0 5.0 4.0 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B
7.5 5.5 7.5 5.5 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B
10.0 7.5 10.0 7.5 1321-3R18-B 1321-3RA18-B 1321-3R18-B 1321-3RA18-B
15.0 11.0 15.0 11.0 1321-3R25-B 1321-3RA25-B 1321-3R25-B 1321-3RA25-B
20.0 15.0 15.0 11.0 1321-3R35-B (ND) 1321-3RA35-B (ND) 1321-3R35-B (ND) 1321-3RA35-B (ND)
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
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

Bulletin 1321-3R Series Line Reactors

Output Ratings(1) Input Line Reactor(3)(4) Output Line Reactor(3)(4)
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.
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
25.0 18.5 20.0 15.0 1321-3R35-C (ND) 1321-3RA35-C (ND) 1321-3R35-C (ND) 1321-3RA35-C (ND)
1321-3R25-C (HD) 1321-3RA25-C (HD) 1321-3R25-C (HD) 1321-3RA25-C (HD)
30.0 22.0 25.0 18.5 1321-3R35-C (ND) 1321-3RA35-C (ND) 1321-3R35-C (ND) 1321-3RA35-C (ND)
(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) 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.
(3) Catalog numbers listed are for 3% impedance at 60 Hz. 5% impedance reactor types are also available. See publication 1321-TD001.
(4) Input line reactors were sized based on the NEC fundamental motor amps. Output line reactors were sized based on the VFD rated
output currents.

Product Dimensions The PowerFlex 520-series drive is available in five frame sizes. See the PowerFlex
520-Series Drive Ratings on page 175 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
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

87.0 (3.43) 172.0 (6.77)
72.5 (2.85)
180.0 (7.09)
Esc Sel
168.0 (6.61)
92.7 (3.65)
6.0 (0.24)
IP 20/Open Type – Frame C

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

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)
IP 20/Open Type – Frame E

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)


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
Maximum Air Flow (At zero static pressure) 0.575 m3/min 1.574 m3/min
Maximum Air Pressure (At zero air flow) 7.70 mmH2O 9.598 mmH2O
Acoustical Noise 40.5 dB-A 46.0 dB-A
Insulation Type UL Class A
Frame Size Frame A...D Frame E
Wire Size 0.32 mm2 (22 AWG)
Torque 0.29...0.39 Nm (2.6...3.47 lb-in.)
IP 20/Open Type with Control Module Fan Kit – Frame A...C

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.

IP 20/Open Type with Control Module Fan Kit – Frame D...E

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.

IP 30/NEMA 1/UL Type 1 – Frame A

15.0 (0.59)
72.0 (2.83) IP 30/NEMA 1/ UL Type 1 top panel
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)
51.1 (2.01)
IP 30/NEMA 1/ UL Type 1 conduit box
21.0 (0.82)
ø21.5 (ø0.85)
135.4 (5.33)
111.9 (4.41)
88.2 (3.47)
64.7 (2.55)

IP 30/NEMA 1/UL Type 1 – Frame B

15.0 (0.59)
87.0 (3.43) IP 30/NEMA 1/ UL Type 1 top panel
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)
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)

IP 30/NEMA 1/UL Type 1 – Frame C

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)
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)

IP 30/NEMA 1/UL Type 1 – Frame D

15.0 (0.59)
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)

IP 30/NEMA 1/UL Type 1 – Frame E

15.0 (0.59)
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)

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)

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

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)

EMC Line Filter – Frame C

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

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)

EMC Line Filter – Frame E

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)

Optional Accessories and Kits Installing a Communication Adapter

1. Insert the communication adapter interface connector into the Control
Module. Make sure 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.

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.

Notes:

Appendix C
RS485 (DSI) Protocol
PowerFlex 520-series drives support the RS485 (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 RS485 network using Modbus protocol in RTU
mode.
PowerFlex 520-Series Drive Network

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
RS485 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.

Appendix C RS485 (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 RS485 wiring practices apply.

• Termination resistors need to be applied at each end of the network cable.
• RS485 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 40 and page 43 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 87
P047 [Speed Reference1] Set to 3 “Serial/DSI” if the Speed Reference is controlled from the network. page 87
C123 [RS485 Data Rate] Sets the data rate for the RS485 (DSI) Port. All nodes on the network must be page 101
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 101
network requires a unique node address.
C125 [Comm Loss Action] Selects the drive’s response to communication problems. page 101
C126 [Comm Loss Time] Sets the time that the drive will remain in communication loss before the page 101
drive implements C125 [Comm Loss Action].
C127 [Comm Format] Sets the transmission mode, data bits, parity and stop bits for the RS485 (DSI) page 102
Port. All nodes on the network must be set to the same setting.
C121 [Comm Write Mode] Set to 0 “Save” when programming drive. page 101
Set to 1 “RAM only” to only write to volatile memory.

RS485 (DSI) Protocol Appendix C
Supported Modbus Function The peripheral interface (DSI) used on PowerFlex 520-series drives supports
some of the Modbus function codes.
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 (e.g. ProSoft 3150-MCM SLC Modbus scanner) and 8193
for others (e.g. PanelViews).
Writing (06) Logic Command The PowerFlex 520-series drive can be controlled through the network by
sending Function Code 06 writes to register address 2000H (Logic Command).
Data 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.
PowerFlex 525 drives can use Parameter C122 [Cmd Stat Select] to select either
Velocity or Position bit definitions.
TIP 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
2000H (8192) 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
5, 4 00 = No Command
01 = Forward Command
10 = Reverse Command
11 = No Command
6 1 = Force Keypad Control, 0 = Not Force Keypad Control
7 1 = MOP Increment, 0 = Not Increment
01 = Accel Rate 1 Enable
10 = Accel Rate 2 Enable
11 = Hold Accel Rate Selected
01 = Decel Rate 1 Enable
10 = Decel Rate 2 Enable
11 = Hold Decel Rate Selected
14, 13, 12 000 = No Command
001 = Freq. Source = P047 [Speed Reference1]
100 = A410 [Preset Freq 0]
15 1 = MOP Decrement, 0 = Not Decrement

Position Bit Definitions

Comm Logic Command – C122 = 1 “Position”
2000H (8192) 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
01 = Forward Command
10 = Reverse Command
11 = No Command
6 1 = Logic In 1
7 1 = Logic In 2
10, 9, 8 000 = Freq. and Position Step 0
001 = Freq. and Position Step 1
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
through the network by sending Function Code 06 writes to register address
Frequency Command 2001H (Comm Frequency Command).
Comm Frequency Command
Reference
Address (Decimal) Description
2001H (8193) Used by internal comm modules to control the reference of the drive. In units of
0.01 Hz.
Reading (03) Logic Status The PowerFlex 520-series drive Logic Status data can be read through the
network by sending Function Code 03 reads to register address 2100H (Logic
Data 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”
2100H (8448) 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
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)
Position Bit Definitions

Comm Logic Status – C122 = 1 “Position”
2100H (8448) 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
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

Reading (03) Drive Error The PowerFlex 520-series Error Code data can be read through the network by
sending Function Code 03 reads to register address 2101H (Drive Error Codes).
Codes
Drive Error Codes
Logic Status
Address (Decimal) Value (Decimal) Description
2101H (8449) 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
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

Drive Error Codes

Logic Status
Address (Decimal) Value (Decimal) Description
2101H (8449) 125 Flash Update Required
126 Non Recoverable Error
127 DSI Flash Update Required
Reading (03) Drive The PowerFlex 520-series Drive Operational Values can be read through the
network by sending Function Code 03 reads to register addresses
Operational Values 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
number. For example, a decimal “1” is used to address Parameter b001 [Output
(06) Drive Parameters Freq] and decimal “41” is used to address Parameter P041 [Accel Time 1].
Additional Information See http://www.ab.com/drives/ for additional information.

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 need to be met from digital
inputs 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 programmed to the
desired time. When the timer reaches the time programmed into the
output level the output will change 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 programmed to the
desired number of counts. When the counter reaches the count
programmed into the output level the output will change state. The
counter can be reset with a digital input programmed as “Reset Counter”.
TIP Use the Wizard in Connected Components Workbench to simplify setup instead
of manually configuring the parameters.

Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions
Velocity StepLogic Using IMPORTANT This function is specific to PowerFlex 525 drives only.
Timed Steps
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 IMPORTANT This function is specific to PowerFlex 525 drives only.
Basic Logic Functions
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”.

Velocity StepLogic, Basic Logic and Timer/Counter Functions Appendix D
• 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.
• 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 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 run
time 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”
– t063 [DigIn TermBlk 03] = 19 “Timer Start”
– t076 [Relay Out1 Sel] = 25 “Timer Out”
– t077 [Relay Out1 Level] = 20.0 Secs
– A411 [Preset Freq 1] = 30.0 Hz
• The control terminal block is wired such that a start command will also
trigger 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 5 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”
– t077 [Relay Out1 Level] = 5.0 Counts

Velocity StepLogic, Basic Logic and Timer/Counter Functions Appendix D
Output
Frequency
Start
Relay Out
Photo Eye
DigIn TermBlk 05
Counter In
DigIn TermBlk 06
Reset Counter
Limit Switch
Velocity StepLogic Code Descriptions for Parameters L180...L187

Parameters 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 StepLogic Output State Commanded Direction
Used
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
4 Step if “Logic In 1” 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
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
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

Appendix E
Encoder/Pulse Train Usage and Position

StepLogic Application
Encoder and Pulse Train The PowerFlex 520-series drives include a pulse train input built into the
terminal block. PowerFlex 525 drives also support an optional encoder card. The
Usage 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, 12 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 will use the encoder or pulse train in several ways depending on the settings
of other parameters. The drive will use 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 will be 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 will use 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 covered in this chapter
is specific to PowerFlex 525 drives only.

Appendix E Encoder/Pulse Train Usage and Position StepLogic Application
Encoder Interface
The incremental encoder option card can source 5 or 12 volt power and accept 5,
12 or 24 volt single ended or differential inputs. See Appendix B for ordering
information.
IMPORTANT Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525 drive.
Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2 will
cause damage to the PowerFlex 525 drive.
No. Signal Description

+V +V 5...12V Power(1)(2)
Internal power source 250 mA (isolated).
Cm Cm Power Return
B- B- Encoder B (NOT)
B Quadrature B input.
B Encoder B
A-
A- Encoder A (NOT)
A Single channel, pulse train or quadrature A input.
A Encoder A

12V 5V  Output DIP switch selects 12 or 5 volt power supplied at terminals “+V” and “Cm”
for the encoder.
(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
Encoder Power +12V DC Encoder Power
(250 mA)
– Internal Drive +V – External
Common
Power Cm Common Power Source
B- to
+
B SHLD
to SHLD External
A-
Internal (drive) A
Power
Supply
12V DC, 250mA
Encoder Signal to Power Supply Encoder Signal

– Single-Ended, Common – Differential,
+V +V to SHLD
Dual Channel Cm Dual Channel Cm
B NOT
B NOT B-
B- B
B B
B A NOT
A NOT A-
A- A
A A
A
to SHLD
Wiring Notes The encoder option card can supply 5V or 12V power (250 mA maximum) for
an encoder. Be sure the DIP switch is set properly for the encoder. In general, 12V
will provide higher noise immunity.
The encoder can handle 5V, 12V, or 24V inputs, but the pulse train can handle
only 24V inputs. The inputs will 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.

Encoder/Pulse Train Usage and Position StepLogic Application Appendix E
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 Per Use the following formula to determine the encoder pulse per revolution (PPR)
specification based on the speed resolution.
Revolution (PPR)
1
Specification Based on Speed Speed resolution (Hz) = encoder pulse number x 4
x pole pairs
Resolution
10-3 sec
TIP The operating speed range will depend on the motor control mode selected
(SVC or VVC). For more information, see Performance with Encoder on
page 170.
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
Therefore, using a 1024 PPR quadrature encoder will give a speed resolution of
0.49 Hz.

Positioning Overview The PowerFlex 525 drive includes a simple position regulator which can be used
in a variety of position applications without the need for multiple limit switches
or photo-eyes. This can be used as a stand-alone controller for simple
applications (up to 8 positions) or in conjunction with a controller for more
flexibility.
Please 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 variety
of applications. Certain parameters will need to be adjusted in all cases.
Applications
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 no encoder is used. This can not 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 will fault 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 will fault 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
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 will need to 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 (i.e., 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 1cm 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 one cm of travel. Then all other
positions could be setup in units of “cm”.
A564 [Encoder Pos Tol] indicates the desired position tolerance for the system.
This will determine how close the drive must be to the commanded position
before the drive will indicate “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 Step Logic times. This mode ignores the Step Logic
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 Step Logic Commands settings and instead the drive will move
directly to whatever step is currently commanded by A410...A425 [Preset
Freq x] and L200...L214 [Step Units x]. This is useful 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 Step Logic options such as incremental move are not
available in this mode.
2 “Step Logic” 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 Step Logic profile.
3 “Preset StpL” is identical to 2 “Step Logic” except the drive will use the
current status of the Preset Inputs to determine which Step Logic 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 “Step Logic” except the drive will use

the step prior to its last stop command to determine which Step Logic 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 will 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 8 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 8
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 the drive will run at during the corresponding step. For example, if
[Preset Freq 2] is set to 40 Hz, the drive will accelerate 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]
IMPORTANT The default value for A410 [Preset Freq 0] is 0.00 Hz. This value needs to 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 the drive
will remain 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 will remain in Step 2 for 5.0 seconds. Note that this is the total time in that
step, not the time at that position. Therefore, it will include the time 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 Step Logic functions. Note that in Positioning mode these parameters
have a different function than when used for normal velocity Step Logic. Each of
the 4 digits controls one aspect of the each 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
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
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 Settings (Digit 2 and 1)
Positioning Settings (Digit 4) Setting Description
0 Skip Step (Jump Immediately)
Required Accel/Decel StepLogic Direction Type of 1 Step Based on [Stp Logic Time x]
Setting Param. Used Output State From Home Command
2 Accel/Decel 1 Off REV Absolute
3 Accel/Decel 1 Off REV Incremental
6 Step if either “Logic In 1” or “Logic In 2” is Active
4 Accel/Decel 1 On FWD Absolute
7 Step if both “Logic In 1” and “Logic In 2” are Active
5 Accel/Decel 1 On FWD Incremental
8 Step if neither “Logic In 1” nor “Logic In 2” is Active
6 Accel/Decel 1 On REV Absolute
9 Step if “Logic In 1” is Active and “Logic In 2” is Not Active
7 Accel/Decel 1 On REV Incremental
A Step if “Logic In 2” is Active and “Logic In 1” is Not Active
b Step after [Stp Logic Time x] and “Logic In 1” is Active
C Step after [Stp Logic Time x] and “Logic In 2” is Active
A Accel/Decel 2 Off REV Absolute
d Step after [Stp Logic Time x] and “Logic In 1” is Not Active
b Accel/Decel 2 Off REV Incremental
E Step after [Stp Logic Time x] and “Logic In 2” is Not Active
C Accel/Decel 2 On FWD Absolute
F Do Not Step/Ignore Digit 2 Settings
d Accel/Decel 2 On FWD Incremental
E Accel/Decel 2 On REV Absolute
F Accel/Decel 2 On REV Incremental
TIP Use the Wizard in Connected Components Workbench to simplify setup instead
of manually configuring the parameters.
Note: Incremental move commands will 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 will have a larger effect on most systems than the filter.
Homing Routine This drive supports incremental encoders only. Therefore, when the drive powers
up it will reset 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 will set the drive to “Home” at its current position
and d388 [Units Traveled H] and d389 [Units Traveled 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 will continuously read
a position of “0” (home) and the position routine will 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 will indicate the system is in the home position.
A562 [Find Home Freq] sets the frequency the drive will use while it is
moving to the home position during the automatic homing routine.
A563 [Find Home Dir] sets the direction the drive will use 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 will then ramp 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 will then reverse direction at 1/10th A562 [Find Home Freq]
to the point where the Home Limit switch reactivates. Approximately one second
after the routine finds home the drive will stop. 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 will stop. If the Find Home is removed
before the homing is complete, the drive will begin running the position
routine without the proper home. In this case Home will not be reset and the
position will be in relation to the power up position.
Encoder and Position d376 [Speed Feedback] indicates the measured speed feedback or the calculated
speed feedback when no feedback device is selected. Parameter d376 [Speed
Feedback 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).
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 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 8 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 will 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 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.
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 will accelerate 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 Step Logic 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 Step Logic functions (speed or
position) using comms control without requiring actual digital input
transitions.
L200...L214 [Step Units x]

All of the position steps can be written to while the drive is running. The changes
will take place at the next move. For example, if step 0 is over-written while the
drive is moving to step 0, the drive will move to the previous commanded
position at step 0. The next time the drive is commanded to return to step 0 it will
proceed 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 Step Logic 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) can make setup of
the positioning functions much easier. Refer to the latest versions for additional
tools or wizards which can aid in the setup.

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 set point. 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 set point, 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 set point.
• 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.

Appendix F PID Set Up
• The Desired System Pressure set point is maintained as valves in the system
are opened and closed causing changes in flow.
• 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 set
point.
• 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.

PID Set Up Appendix F
• As tension increases or decreases during winding, the Speed Reference is

trimmed to compensate. Tension is maintained near the Equilibrium set
point.
0V
PID Reference = PID Feedback =

Equilibrium Set Point Dancer Pot Signal
Esc Sel
10V
[Speed Referencex]
PID Reference and Feedback PID mode is enabled by setting P047, P049 or P051 [Speed Referencex] to
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] will be used to set the value of the PID Reference.
1 “Drive Pot” The drive potentiometer will be used to set the value of the PID Reference.
2 “Keypad Freq” The drive keypad will be 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.
5 “0-10V Input” Selects the 0-10V Input. Note that the PID will not function with a bipolar analog input. It will
ignore any negative voltages and treat them like a zero.
6 “4-20mA Input” Selects the 4-20 mA Input.
7 “Preset Freq” A410...A425 [Preset Freq x] will be used as an input for the PID Reference.
8 “AnlgIn Multi”(1) The product of the 0-10V and 4-20mA Inputs will be used as an input for the PID Reference.
9 “MOP Freq” A427 [MOP Freq] will be used as an input for the PID Reference.
10 ”Pulse Input” Pulse train will be used as an input for the PID Reference.
11 “Step Logic”(1) Step Logic will be used as an input for the PID Reference.
12 “Encoder”(1) Encoder will be used as an input for the PID Reference.
13 “Ethernet/IP”(1) The reference word from the Ethernet/IP communication network becomes the PID Reference.

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
0 “0-10V Input” Selects the 0-10V Input (default setting). Note that the PID will not function with a bipolar analog
input. It will ignore 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.
Analog PID Reference Signals Parameters t091 [Anlg In 0-10V Lo] and t092 [Anlg In 0-10V Hi] are used to
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 will ignore.
Example
• A465 [PID 1 Deadband] = 5.0%
• The PID Reference is 25.0%
• The PID Regulator will not act on a PID Error that falls between 20.0 and
30.0%
PID Preload
The value set in A466 or A478 [PID x Preload], in Hz, will be pre-loaded into
the integral component of the PID at any start or enable. This will cause 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
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 233), 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 233), 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 233), 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
Oscillation – Under Damped
PID Reference
PID Feedback
Time

Good Response – Critically Damped
PID Reference
PID Feedback
Time

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.
PowerFlex 525 Safe-Torque-Off Overview 235
EC Type Examination Certification 236
EMC Instructions 236
Using PowerFlex 525 Safe-Torque-Off 236
Enabling PowerFlex 525 Safe-Torque-Off 239
Wiring 239
Verify Operation 240
PowerFlex 525 Safe-Torque-Off Operation 239
Connection Examples 241
PowerFlex 525 Certification for Safe-Torque-Off 245
IMPORTANT The Safe-Torque-Off function covered in this chapter is specific to

PowerFlex 525 drives only.
PowerFlex 525 Safe-Torque- The PowerFlex 525 Safe-Torque-Off function:

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
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.

Appendix G Safe-Torque-Off Function
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
compliant with the requirements for machines defined in Annex I of the
Certification 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:

www.rockwellautomation.com/products/certification/.
EMC Instructions PowerFlex 525 Safe-Torque-Off function requires CE Conformity as described

on page 52.
Using PowerFlex 525 Safe- The PowerFlex 525 Safe-Torque-Off function is intended to be part of the safety
related control system of a machine. Before use, a risk assessment should be
Torque-Off 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.

Safe-Torque-Off Function Appendix G
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-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 password 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
HFT 1 (1oo2)
PTI 20 YEARS
Hardware Type Type A
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
Type Wire Type(1) Description
Min. Insulation
Rating
Shielded Multi-conductor shielded cable such as Belden 8770 (or equiv.) 0.750 mm2 (18 AWG), 300V, 60 °C (140 °F)
3 conductor, shielded.
(1) Recommendations are for 50 °C ambient temperature.
See I/O Wiring on page 36 for wiring recommendations and Control I/O
Terminal Designations on page 43 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-Torque- The PowerFlex 525 Safe-Torque-Off function disables the drive’s output IGBT’s
by breaking the link with the drive microcontroller. When used in combination
Off Operation 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. Refer to 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 236.
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
Drive Status Configured by t105 Fault F111 Fault F111 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.
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.

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.

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
operation.
Operating Principle
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
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.

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
operation.
Operating Principle
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
function.

PowerFlex 525 Certification Certification information can be viewed at

http://www.rockwellautomation.com/global/certification/
for Safe-Torque-Off

Notes:

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.

Appendix H EtherNet/IP
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.
Ground Connections for Connect terminal C1 to a clean ground when using a network with a star
topology. It is acceptable to ground both C1 and C2 terminals.
EtherNet/IP Networks
PowerFlex 525 Embedded Ethernet/IP Adapter
FWD
ENET LINK
EtherNet/IP
Esc Sel
Terminals C1/C2
C1 This terminal is tied to the RJ-45 port shield. Tie this
terminal to a clean ground in order to improve noise
immunity when using external communication
peripherals.
C2 This is the signal common for the communication
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
CS1/CS2 Provides a clean ground for the communication bus
cable shields.
CS1 or CS2 should be connected to a clean ground or
PE ground on the drive.
Terminals CS1/CS2

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

Control Mode
Mid Speed
Control Mode
High Speed
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]

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

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.
Download Files 252
Automatic Configuration Using Drive Startup Wizard 254
Manual Configuration Using Drive Keypad 261
Additional PM Motor Configuration 262
Optional Parameter Adjustments for Optimum Performance 266
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, you also
need to install version 1.05 or later Add-on profile (AOP) and update to the
latest drive database for Connected Components Workbench.
These files are available for download at the Rockwell Automation Product
Compatibility and Download Center. For instructions, see Download Files on
page 252.

Appendix J PowerFlex 525 PM Motor Configuration
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
http://www.rockwellautomation.com/rockwellautomation/support/
pcdc.page
IMPORTANT You must sign in to the Rockwell Automation website before

downloading a firmware revision.
2. Click the Find Downloads link.

PowerFlex 525 PM Motor Configuration Appendix J
3. Enter “PowerFlex 525” into the Product Search field.

The results appears 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.
6. Go back to step 2 and enter “AB Drives” into the Product Search field.
The results appear in the box below.
7. Select both entries, then click Downloads.
8. Click the Show Downloads icon, then click the links to download the
database files to your computer.

Automatic Configuration To use the PowerFlex 525 Startup Wizard in Connected Components
Workbench to automatically configure the parameters, make sure you have
Using Drive Startup Wizard installed the following:
• PowerFlex 525 drive firmware revision 5.001 or later.
• PowerFlex 525 drive Add-on Profile 1.05 or later.
• Latest drive database for Connected Components Workbench.
For instructions, see Download Files on page 252.
Alternatively, you can manually configure the parameters by using the drive
keypad. For instructions, see Manual Configuration Using Drive Keypad on
page 261.
1. From Connected Components Workbench software, click the Wizard

Browser icon.
2. In the Available Wizards dialog box, click on 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.
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.
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.
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.

Direction Test
IMPORTANT When configuring a PM motor, 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 required.
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.
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.
• 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.
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 262 for instructions.

Manual Configuration Using Besides using the PowerFlex 525 Startup Wizard in Connected Components
Workbench, you can also manually configure the parameters by using the drive
Drive Keypad keypad. Make sure you have installed the PowerFlex 525 drive firmware revision
5.001 or later. For instructions, see Download Files on page 252.
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”
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 262 for instructions.
Additional PM Motor After completing the initial configuration, there are additional steps that need to
be performed to complete the whole PM motor setup.
Configuration
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 autotune 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.

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]
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

Obtain Parameters A502 [PM IXd Voltage]
from Autotune A503 [PM IXq 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

Additional Setup for Closed Loop PM Motor
After performing an autotune 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, 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, 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.
TIP 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.

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]
P043 [Minimum Freq]
PLACEHOLDER
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

Obtain Parameters A502 [PM IXd Voltage]
from Autotune A503 [PM IXq 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

Optional Parameter There are a few parameters that you can use to obtain optimum performance
during the test run. Usually, the default value of these parameters work well, but
Adjustments for Optimum 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
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
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.

Notes:

Index
Numerics output, 34
drive
2-wire auxiliary contact, 34, 36
inputs, 50 basic operation, 60, 65, 162
3-wire common bus, 36
inputs, 50 mount, 15
programming, 61, 64
safety, 239
A drive damage
accel preventing, 19
override priority, 51 ungrounded distribution systems, 19
selecting, 51
accessing
control terminals, 31
E
power terminals, 31 encoder
applications programming, 215
safety, 237 wiring, 216
auxiliary contact environment
drive, 34, 36 storage, 18
Ethernet
programming, 247
B
basic operation, 65
drive, 60, 65, 162
F
programming, 65 fault monitoring
safety, 240 ground, 21
fuses
rating, 23
C
circuit breakers
inputs, 23 G
ratings, 23 ground
common bus fault monitoring, 21
drive, 36 motor, 21
communications RFI filter, 22
positioning, 225 safety, 21
configuring shielding, 21
RS485(DSI), 202
control terminals
accessing, 31
H
counter homing
programming, 209, 212 automatic, 223
manual, 223
programming, 223
D
decel I
override priority, 51
selecting, 51 inputs
derating 2-wire, 50
factor, 125 3-wire, 50
temperature, 17 circuit breakers, 23
digital inputs power, 20
selecting, 50
start source, 50 L
dimensions
mounting, 16, 185 logic
disconnect basic, 209, 210
timed steps, 209, 210

Index
M timed steps, 209, 210

timer, 209, 211
Modbus tools, 64
reading, 205, 207, 208 pulse train
writing, 203, 205, 208 programming, 215
motor
ground, 21
start, 34 R
stop, 34 rating
mount
fuses, 23
drive, 15 ratings
mounting
circuit breakers, 23
dimensions, 16, 185 reading
Modbus, 205, 207, 208
N recommended
wiring, 36, 239
noise immunity
reflected
wiring, 37, 202
wave protection, 34
RFI filter
O ground, 22
RS485(DSI)
output
configuring, 202
disconnect, 34
override priority
accel, 51 S
decel, 51
speed reference, 49 safety
start source, 49 applications, 237
basic operation, 240
drive, 239
P ground, 21
testing, 238
parameters wiring, 239
AppView, 76, 150 selecting
CustomView, 151 accel, 51
programming, 63, 67 decel, 51
PID digital inputs, 50
programming, 229 speed reference, 49
positioning start source, 49
communications, 225 separating
programming, 218, 220 power and control module, 28
power shielded
inputs, 20 wiring, 33
power and control module shielding
separating, 28 ground, 21
power terminals speed reference
accessing, 31 override priority, 49
preventing selecting, 49
drive damage, 19 start
programming, 65 motor, 34
basic logic, 209, 210 start source
counter, 209, 212 digital inputs, 50
drive, 61, 64 override priority, 49
encoder, 215 selecting, 49
Ethernet, 247 stop
homing, 223 motor, 34
parameters, 63, 67 storage
PID, 229
positioning, 218, 220 environment, 18
pulse train, 215

Index
T V
temperature voltage reflections
derating, 17 wiring, 34
wiring, 33
testing
safety, 238 W
timer wave protection
programming, 209, 211 reflected, 34
tools wiring
programming, 64 encoder, 216
noise immunity, 37, 202
recommended, 36, 239
U RS485 (DSI), 201
unshielded safety, 239
wiring, 33 shielded, 33
temperature, 33
unshielded, 33
voltage reflections, 34
writing
Modbus, 203, 205, 208

Index
Notes:

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Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support/, you can find technical manuals, a knowledge base of FAQs, technical and
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Rockwell Automation provides country of origin certificates at RAEXMClassification@ra.rockwell.com.
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
TechConnect support programs. For more information, contact your local distributor or Rockwell Automation
representative, or visit http://www.rockwellautomation.com/support/.
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this
manual. You can contact Customer Support for initial help in getting your product up and running.
United States or Canada 1.440.646.3434
Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html, or contact your local Rockwell
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*PN-386600*
PN-386600
Publication 520-UM001I-EN-E – July 2016 PN-386600
Supersedes Publication 520-UM001H-EN-E – April 2016 Copyright © 2016 Rockwell Automation, Inc. All rights reserved.
P/N 050089 DETECTOR, DAMAGED BELT, NEMA 4
Model DB Damaged Belt Detector
VIEW OF CONVEYOR SHOWING UNIT

MOUNTED WITH CABLE UNDERNEATH
(2 REQUIRED)
PATENTED
AN EARLY WARNING SYSTEM FOR DAMAGED BELTS

Get an extra measure of protection for valuable conveyor belts with DB-100 unit showing cable
these new Damaged Belt Detectors. Economical and easy to install, mounting bracket.
they warn supervisory personnel of impending belt failures due to
rips, punctures, splice failures, or sharp objects protruding through
the belt fabric.
Damaged Belt Detectors mount in pairs positioned on either side of

the belt. The units are connected by two spans of vinyl coated aircraft EASY TO MAINTAIN
cable. One end of the cable mounts permanently to a support bracket Damaged Belt Detectors are virtually mainte-
and the other connects to a spring-loaded ball located in the unit. The nance free — thanks to their simple, yet tough,
cables loop underneath the belt from each side crossing at the mid- construction. The units can be wired normally
point. A belt problem is detected when an object or a piece of dam- open or normally closed. Everything you need to
aged belt hangs below the belt’s surface and sweeps away one or install your system is included, and accessory or
both cables. As the cable is detached, it pulls a spring-loaded ball out replacement items are always available for imme-
of a socket, causing two micro switches to sound an alarm or to shut diate shipment.
down the conveyor. One end of each cable is permanently affixed to
the bracket preventing the loss of the cable. COST EFFECTIVE
It’s simple, effective, and it gives that extra warning of possible belt When you consider the cost of the average
failure. But, even though the idea is simple, these detectors are not replacement belt, or the cost of repairing the
lightweights. They’re rugged, heavy duty units that are designed to mechanical damage from a torn belt, a damage
work in any industrial environment including hazardous locations. detection system is very inexpensive by compari-
son. Other than internally wired belts (tears are
So check out the cost/benefit ratio on this valuable detection system. electronically indicated), there’s nothing like this
Like a good insurance policy, it's protection you can’t afford to be system available in the U.S. It’s a lot of protection
8 without. for very little cost. 11-15-95
T. Kastner
TOP VIEW OF OPEN ACTUATION
DB-100 UNIT MECHANISM
TWO MICRO SWITCHES
MODEL DB SHOWN WITH PROTECTIVE RUBBER BOOT WHICH SLIPS

OFF WITH BALL AND CABLE WHEN UNIT IS ACTUATED
HOW IT OPERATES
The Damaged Belt Detector operates using a spring-loaded ball and
socket connected to two plunger type micro switches. As an object DIMENSIONS
hanging below the belt sweeps away the cable, it pulls the ball con-
nector from its socket (only 2 lbs. of force required). When this hap-
pens a spring-loaded shaft is released causing the plungers of the
two micro switches to ride down cam surfaces machined on the shaft. 51/2"
This deactuates the switches causing them to sound an alarm, turn
on a warning light, or shut down the system. To reactivate the detec- 79/16"
tors, all that’s required is to snap the ball connector and cable back
into its socket. 61/8"
67/8"
CROSS-SECTION OF CONVEYOR BELT 21/4"
SHOWING INSTALLATION OF UNITS AND CABLE
13/32" DIA. 6"

5"
Max. 2"
37/16"
21/2" 11/2"
4"
1"NPT Eyebolt
Conduit Adjustable
INSTALLATION NOTES Opening in 5 positions
When installing a Damaged Belt Detection system on your conveyor,
the following points should be considered:
• The force required to extract the ball end of the pull cable from a
SPECIFICATIONS
Model DB-100: Two (2) SP/DT micro switches,
detector unit increases proportionally with the distance from the
NEMA 4 construction.
detector. Therefore, the cable extending beyond the midpoint of the
Model DBX-100: Two (2) SP/DT micro switches,
installed cable span, and the anchoring point of the cable on the
NEMA 7/9 construction.
opposite side, is considered inactive for damaged detection purpos-
Standard Construction: Suitable for inside &
es. Thus, a second unit is mounted opposite the first to effectively
outside applications as covered by NEMA 4 dust-
cover this inactive section. (See accompanying drawing.)
tight and raintight construction.
• A damaged portion of a belt may in certain instances be confined to Explosion Proof Construction: For inside and
the top surface of the belt. This renders it undetectable by a system outside applications requiring NEMA 7/9 explo-
mounted between belt surfaces. However, this damaged section will sion proof construction.
fall below the surface on the belt’s return run. In order to detect this Housing: Aluminum (Standard).
type of damage to a belt, a second detection system can be installed Conduit Opening: 1" NPT. Standard units have
below the return belt’s surface. This will provide even more reliable two conduit opening, explosion proof have just one.
protection for your belt systems. External Hardware: Strainless Steel.
• Detection units must be mounted high enough for the cables to Switches: SP/DT micro switch. Rated 20 amp at
cover the entire active area under the belt. In other words, the cables 125, 150 or 480V AC. Switches may be wired for
must follow the contour of the belt closely enough to detect damaged single throw operation, either normally open or
sections of the belt both at the center or near the edge. normally closed as required. 9
Micro-Tech™
9105/9205 Feeder
Controller
User Manual
REC 4299 Rev E
Part Number 127427—English
© 2012 Thermo Fisher Scientific, Inc. All rights reserved.
Revision History
Revision Date Released Eco Number Details of the Release
Number
Rev A May 2013 3322 First release of the newly created Micro-Tech 9105/ 9205
Feeder Controller User Manual.
Rev B September 2013 3363 Corrections.
Rev C November 2013 3403 Corrections.
Rev D July 2014 3488 New software version 141.00.01.10. Added notes
requiring use of certified bushings for openings.
Rev E October 2014 3765 Corrections.
Software Version: 141.00.01.10
For future reference, write your belt-scale code below.
Micro-Tech belt-scale code = _______

Occupational Safety and Health Act (OSHA) Seller's obligation under said warranty is conditioned upon the return of the
The Occupational Safety and Health Act clearly places the burden of defective equipment, transportation charges prepaid, to the seller's factory in
compliance on the user of the equipment and the act is generalized to the extent that Minneapolis, Minnesota, and the submission of reasonable proof to seller prior to
determination of compliance is a judgment decision on the part of the local return of the equipment that the defect is due to a matter embraced within seller's
inspection. Hence, Thermo Fisher Scientific will not be responsible for meeting the warranty hereunder. Any such defect in material and workmanship shall be presented
full requirements of OSHA in respect to the equipment supplied or for any penalty to seller as soon as such alleged errors or defects are discovered by purchaser and
assessed for failure to meet the requirements, in respect to the equipment supplied, as seller is given opportunity to investigate and correct alleged errors or defects and in
interpreted by an authorized inspector. Thermo Fisher Scientific will use their best all cases, buyer must have notified seller thereof within one (1) year after delivery, or
efforts to remedy such violation at a reasonable cost to the buyer. one (1) year after installation if the installation was accomplished by the seller.
Safety in Transportation and Handling Said warranty shall not apply if the equipment shall not have been operated
The Micro-Tech is an integral part of your plant and when transporting, and maintained in accordance with seller's written instructions applicable to such
handling, and installing the unit, your own plant safety instructions must be applied. equipment, or if such equipment shall have been repaired or altered or modified
Because your Micro-Tech and associated systems are tailored to application without seller's approval; provided, however, that the foregoing limitation of warranty
requirements, it is impossible to be precise about product mass/weight. If precise insofar as it relates to repairs, alterations, or modifications, shall not be applicable to
values are required, the shipping crate will be marked with the overall shipping mass routine preventive and corrective maintenance which normally occur in the operation
of the product and this may be used as a reasonable guideline. of the equipment.
Safe Practices During Use, Maintenance, and Repair “EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED
This manual contains details, as appropriate, including the appropriate tools. HEREIN, SELLER DISCLAIMS ANY AND ALL WARRANTIES WITH
However, because of its importance, the warning contained in the installation section RESPECT TO THE EQUIPMENT DELIVERED HEREUNDER, INCLUDING
is repeated here. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
TO GUARANTEE PERSONAL SAFETY, CARE MUST BE TAKEN WHEN USE. THE SOLE LIABILITY OF SELLER ARISING OUT OF THE WARRANTY
WORKING ON OR AROUND THE MICRO-TECH. AS WITH ALL SUCH CONTAINED HEREIN SHALL BE EXCLUSIVELY LIMITED TO BREACH OF
DEVICES THE MAIN SUPPLIES (ELECTRICAL AND OTHER) TO THE THOSE WARRANTIES. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH
SYSTEM MUST BE LOCKED OFF WHEN PERFORMING REPAIR OR OF THE WARRANTIES SET OUT ABOVE SHALL BE LIMITED TO THE
MAINTENANCE WORK. REPAIR OR REPLACEMENT OF ANY DEFECTIVE ACCESSORY, PART OR
Low Voltage Directives MATERIAL WITH A SIMILAR ITEM FREE FROM DEFECT, AND THE
All of the recommendations for LVD apply to the prevention of electrical CORRECTION OF ANY DEFECT IN WORKMANSHIP. IN NO EVENT SHALL
shock. If access to the electronics enclosure is required, the incoming AC power SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
supply should be isolated remotely and locked-off. Access to the electronics DAMAGES.”
enclosure by untrained personnel is not recommended. Purchaser agrees to underwrite the cost of any labor required for replacement;
Circuit Breaker including time, travel, and living expenses of a Thermo Fisher Scientific Field
The Micro-Tech should be permanently connected to its AC supply. Please Service Engineer at the closest factory base.
ensure that when installing the Micro-Tech, a switch or circuit breaker is used and is
positioned close to the Micro-Tech in easy reach of the operator. The switch or circuit Thermo Fisher Scientific Bulk Weighing and Monitoring 501 90th Avenue NW
breaker shall be marked as the disconnecting device for the Micro-Tech. Minneapolis, MN 55433 Phone: (800) 445-3503 Fax: (763) 783-2525
DO NOT install the Micro-Tech in a position that makes it hard to use the AC mains
isolator. Disclaimer
Thermo Fisher Scientific Warranty Though the information provided herein is believed to be accurate, be advised that the
The seller agrees, represents, and warrants that the equipment delivered information contained herein is not a guarantee for satisfactory results. Specifically,
hereunder shall be free from defects in material and workmanship. Such warranty this information is neither a warranty nor guarantee, expressed or implied, regarding
shall not apply to accessories, parts, or material purchased by the seller unless they performance, merchantability, fitness, or any other matter with respect to the
are manufactured pursuant to seller's design, but shall apply to the workmanship products, and recommendation for use of the product/process information in conflict
incorporated in the installation of such items in the complete equipment. To the with any patent. Please note that Thermo Fisher Scientific reserves the right to change
extent, purchased parts or accessories are covered by the manufacturer's warranty; and/or improve the product design and specifications without notice.
seller shall extend such warranty to buyer.

About This Manual
This manual tells you how to install, operate, and troubleshoot the
Micro-Tech. If you encounter a technical term or unit of measure that
you do not recognize in the manual or in the Micro-Tech screens
themselves, please consult the glossary at the end of the manual.
Conventions
The following conventions are used in this manual.
l The names of Micro-Tech buttons, functions, and so on are shown

using initial upper-case letters—for example, Menu, Run, Edit,
Choice, Tph (standard U.S. tons per hour), and so forth.
l Italics are used in the text for emphasis.
NOTE. Provides information of special importance. 
HINT. Indicates a hint about understanding or operating the Micro-

Tech. 
Safety Precautions
Listed below are the safety messages for your Micro-Tech and its
associated scale system. Please read all safety messages very carefully,
because this information is important—for your own personal safety and
the safety of others.
WARNING. Failure to observe could result in death or serious

injury. 
CAUTION. Failure to observe may cause minor injury or damage to

the equipment. 
Thermo Fisher Scientific Micro-Tech 9105/9205 User Manual, Rev E i

Table of Contents
Introduction ............................................................................. 1-1

Chapter 1
Unpacking the Micro-Tech ................................................................ 1-1
Overview of the Micro-Tech ............................................................. 1-1
Important Safety Information ............................................................ 1-4
General Safety Precautions ............................................................. 1-4
Incoming Power Safety ................................................................... 1-4
EMC Instructions ............................................................................ 1-4
Hardware Installation ......................................................................... 1-5
Important Wiring and Safety Information ...................................... 1-5
Installing the Field Model ............................................................... 1-5
Mounting ...................................................................................... 1-5
Connecting the Incoming Power Supply ..................................... 1-6
Installing the Panel Model .............................................................. 1-7
Mounting ...................................................................................... 1-7
Connecting the Incoming Power Supply ..................................... 1-8
Configuring Jumpers and Switches ................................................ 1-8
Micro-Tech Features .......................................................................... 1-8
Standard Features ............................................................................ 1-8
Inputs and Outputs .......................................................................... 1-9
Micro-Tech Menus and Functions ..................................................... 1-9
Monitoring Functions.................................................................... 1-10
Print Functions .............................................................................. 1-10
Communication Functions ............................................................ 1-10
Symbol Identification....................................................................... 1-11
Standards Applied ............................................................................ 1-12
Specifications ................................................................................... 1-14
Chapter 2 Set-Up ....................................................................................... 2-1

Using the Console .............................................................................. 2-1
Display Screen ................................................................................ 2-2
Keypad ............................................................................................ 2-2
Soft Key Buttons ............................................................................. 2-2
Status LEDs .................................................................................... 2-2
Measuring Functions ....................................................................... 2-3
Determining the Belt-Scale Code ...................................................... 2-4
The Quick and Easy Route ............................................................. 2-4
Acquiring Basic System Data ............................................................ 2-5
Scale Type Determines Parameters Needed ................................... 2-5
Thermo Fisher Scientific Micro-Tech 9105/9205 User Manual, Rev E ii

Table of Contents
Non-Pivoting Scales........................................................................ 2-6

The Next Step .............................................................................. 2-7
Pivoting Scales ................................................................................ 2-7
Pivot-to-Load-Cell Distance ........................................................ 2-8
Number of Weight Idlers ............................................................. 2-8
Pivot-to-First-Idler Distance ........................................................ 2-9
Pivot-to-Test-Weight Height ....................................................... 2-9
Pivot-to-Test-Weight Length ....................................................... 2-9
Pivot-to-Carriage Height ............................................................ 2-10
Roller-to-Stringer Height ........................................................... 2-10
Number of Load Cells ................................................................ 2-10
Idler Spacing .............................................................................. 2-11
Conveyor Angle ......................................................................... 2-11
Load Cell Capacity, Sensitivity, and Resistance ....................... 2-12
Speed Input ................................................................................ 2-12
Test Duration ................................................................................... 2-13
Example ........................................................................................ 2-13
Manually Determine Test Duration .............................................. 2-14
The Next Steps .............................................................................. 2-15
Initializing the Software ................................................................... 2-15
Overview ....................................................................................... 2-15
Cold-Starting the Micro-Tech ....................................................... 2-16
Setting the Date ............................................................................. 2-16
Setting the Time ............................................................................ 2-18
Choosing a Language .................................................................... 2-20
Entering Scale Data....................................................................... 2-21
Selecting English/Metric Units ..................................................... 2-23
Setting the Totalization Units ....................................................... 2-24
English Totalization Units ......................................................... 2-24
Metric Totalization Units ........................................................... 2-25
Setting the Length Units ............................................................... 2-25
English Length Units ................................................................. 2-25
Metric Length Units ................................................................... 2-26
Setting the Rate Units ................................................................... 2-27
English Rate Units ..................................................................... 2-27
Metric Rate Units ....................................................................... 2-28
Mixed Rate Units ....................................................................... 2-29
Setting the Load-Cell Units .......................................................... 2-30
Entering the Maximum Scale Capacity ........................................ 2-31
Entering the Scale Divisions ......................................................... 2-32
Entering the Belt-Scale Code ........................................................ 2-33
Entering the Appropriate Conveyor Data ..................................... 2-34
Pivot-to-Load-Cell Distance ...................................................... 2-35
Number of Weigh Idlers ............................................................ 2-35
Pivot-to-First-Idler Distance ...................................................... 2-35
Pivot-to-Test-Weight Height ..................................................... 2-35
Thermo Fisher Scientific Micro-Tech 9105/9205 User Manual, Rev E iii

Table of Contents
Pivot-to-Test-Weight Length ..................................................... 2-35

Pivot-to-Carriage Height ............................................................ 2-35
Roller-to-Stringer Height ........................................................... 2-35
Number of Load Cells ................................................................ 2-35
Idler Spacing .............................................................................. 2-36
Conveyor Angle ......................................................................... 2-36
Load Cell Capacity, Sensitivity, and Resistance ....................... 2-36
Setting the Speed Input .............................................................. 2-36
Establish Test Duration ................................................................. 2-37
Running the Micro-Tech .................................................................. 2-43
Run Screen .................................................................................... 2-43
Calibrating the Micro-Tech.............................................................. 2-45
Doing a Zero Calibration .............................................................. 2-45
Doing an R-Cal Span Calibration ................................................. 2-48
Controller Outputs ........................................................................... 2-52
Control Run Screen ....................................................................... 2-52
Chapter 3 Maintenance and Troubleshooting ........................................ 3-1

Critical Checkpoints........................................................................... 3-1
Frequently Asked Questions .............................................................. 3-2
Chapter 4 Service, Repair, and Replacement Parts ............................... 4-1

Overview ............................................................................................ 4-1
RMA .................................................................................................. 4-1
Getting Ready to Order ...................................................................... 4-2
Contacting Thermo Fisher Scientific ................................................. 4-3
Parts List ............................................................................................ 4-4
Appendix A Additional Installation Information ........................................A-1

System Data Sheet ............................................................................ A-1
Door Label ........................................................................................ A-3
Belt-Scale Codes ............................................................................... A-4
Establishing Belt-Length-Test Duration ........................................... A-8
Acquire Test Duration.................................................................... A-8
Partial Belt-Length Method ........................................................... A-9
Full Belt-Length Method ............................................................. A-12
Material Factoring ........................................................................... A-15
Reset Weight Factor ..................................................................... A-15
Static Weight ................................................................................ A-17
Auto Span..................................................................................... A-18
Record Results ............................................................................. A-19
Motherboard Terminal Block Definitions ...................................... A-23
Premium A/D Terminal Block Definitions ..................................... A-25
Motherboard Jumper Locations ...................................................... A-26
Premium A/D Jumper Locations .................................................... A-27
iv Micro-Tech 9105/9205 User Manual, Rev E Thermo Fisher Scientific

Table of Contents
Motherboard Jumper Settings ......................................................... A-28

Premium A/D Jumper Settings ....................................................... A-31
A/D Jumpers—Load-Cell Sense ..................................................... A-31
Load-Cell Specifications ................................................................. A-32
Speed Sensor Specifications ........................................................... A-33
Programmable Digital Inputs/Outputs ............................................ A-34
Digital Input Expansion Boards ...................................................... A-35
DC Input Board ............................................................................ A-35
Opto22 Input Board ..................................................................... A-36
Digital Output Expansion Boards ................................................... A-37
Relay Output Board ..................................................................... A-37
Opto22 Output Board ................................................................... A-38
DIO 8in/8out Board ........................................................................ A-39
Analog I/O Boards .......................................................................... A-40
Type A: 4–20mA Output Board .................................................. A-40
Type B: Analog I/O Board ........................................................... A-41
Dual-Plant Load-Cell A/D Board ................................................... A-43
Communication Board .................................................................... A-45
Profibus-DP Board .......................................................................... A-47
Glossary ...................................................................................... 1
Attached Drawings ..................................................................... 2
Thermo Fisher Scientific Micro-Tech 9105/9205 User Manual, Rev E v

List of Figures
List of Figures
Figure 1–1. Field-Mounted Version of the Micro-Tech .............. 1-2

Figure 1–2. Panel-Mounted Version of the Micro-Tech ............ 1-3
Figure 1–3. Connectors on Underside of Enclosure ................. 1-7
Figure 2–1. Main Features of the Micro-Tech Console ............. 2-1
Figure 2–2. Pivot-to-Load-Cell Distance ................................... 2-8
Figure 2–3. Number of Weight Idlers ........................................ 2-8
Figure 2–4. Pivot-to-First-Idler Distance ................................... 2-9
Figure 2–5. Pivot-to-Test-Weight Height................................... 2-9
Figure 2–6. Pivot-to-Test-Weight Length .................................. 2-9
Figure 2–7. Pivot-to-Carriage Height ...................................... 2-10
Figure 2–8. Roller-to-Stringer Height ...................................... 2-10
Figure 2–9. Idler Spacing........................................................ 2-11
Figure 2–10. Conveyor Angle ................................................. 2-11
Figure 2–11. Location of Load-Cell Data ................................ 2-12
Figure 2–12. Belt-Scale-Code Entry Screen ........................... 2-33
Figure 2–13. Run Screen........................................................ 2-44
vi Micro-Tech 9105/9205 User Manual, Rev E Thermo Fisher Scientific

List of Tables
List of Tables
Table 1–1. Symbol Identification ............................................. 1-11
Table 1–2. Micro-Tech Technical Specifications ..................... 1-14
Table 2–1. Initialization Data Sheet (Non-Pivoting) ................... 2-6
Table 2–2. Initialization Data Sheet (Pivoting) ........................... 2-7
Table 4–1. Micro-Tech Parts List............................................... 4-4
Table A–1. List of Belt-Scale Codes......................................... A-4
Table A–2. Motherboard Load-Cell Technical Specifications
(Model 9105)........................................................................... A-32
Table A–3. Premium A/D Board Load-Cell Technical
Specifications (Model 9205) ................................................... A-32
Table A–4. Speed Sensor Specifications ............................... A-33
Thermo Fisher Scientific Micro-Tech 9105/9205 User Manual, Rev E vii

Chapter 1
Introduction
This manual provides the information you need to install, operate, and
troubleshoot the Micro-Tech. Please read the entire manual before
working with your Micro-Tech. For personal and system safety, and for
the best product performance, make sure you thoroughly understand the
manual before installing or using your Micro-Tech.
The Micro-Tech has been properly packaged for shipment at the factory.
Unpacking the Please inspect all packages for damage before opening the shipping
Micro-Tech package, because the carrier is likely responsible for any damage. Once
removed from the package, the Micro-Tech can be safely stored with its
cover and latches secured and with the hole plugs installed. During
storage, do not expose the Micro-Tech to moisture or to temperatures
outside the range of –22 to +158°F (–30° to +70°C).
The Micro-Tech 9000 Field Mount Integrator (Figure 1-1) or Panel

Overview of Mount Integrator (Figure 1-2) is a bus-based microcomputer driven
the Micro- instrument.
Tech By suitable processing of input signals, the Integrator delivers visible
and electrical output representing the rate of material movement, or
other factors specific to the model.
The Micro-Tech has provisions for four outputs on the digital output
board, plus one DC output from the mother board—making a total of
five, one of which can be defined as a Fault output. In addition, many
automatic and check functions are available to monitor its calibration
functions and maintenance schedule.
There are two models of Micro-Tech: the field-mounted version
(figure 1–1) and the panel-mounted version (figure 1–2). For the panel-
mounted version, provide a cut-out (see figure 1–2 for dimensions) in
the panel and, after removing the holding brackets and installing the
gasket, insert the Micro-Tech.
Thermo Fisher Scientific Micro-Tech 9105/9205 User Manual, Rev E 1-1

Introduction
Overview of the Micro-Tech
Figure 1–1. Field-Mounted Version of the Micro-Tech
1-2 Micro-Tech 9105/9205 User Manual, Rev E Thermo Fisher Scientific

Introduction
Overview of the Micro-Tech
Figure 1–2. Panel-Mounted Version of the Micro-Tech

Introduction
Important Safety Information
Important Safety Information
Please read the following warnings and cautions before installing, operating, or maintaining the Micro-Tech.
General Safety Precautions Incoming Power Safety
CAUTION. Do not install, operate, or perform any maintenance Please read the following warnings and cautions, when working
procedures until you have read all the safety precautions listed below.  with incoming power to the Micro-Tech or its associated systems.
CAUTION. Do not connect power to the electronics or turn on the unit
CAUTION. Do not connect power until you have read and
until you have read and understood this entire manual. The precautions
understood this entire section. Improper connection may result in
and procedures presented in this manual must be followed carefully in
damage to your Micro-Tech. 
order to prevent equipment damage and protect the operator from
possible injury.  WARNING. All wiring must be in accordance with standards
CAUTION. For North America locations a certified Nema 4/4X (IEC, EN) national and local codes (NEC, VDE, and so forth)
bushing must be used for openings. For other locations see your local outline provisions, for safely installing electrical equipment.
Electrical Authorities.  Installation must comply with specifications regarding wire types,
WARNING. Covers over the electronics should always remain in place conductor sizes, branch circuit protection, and disconnect devices.
during operation. They should be removed only for maintenance Failure to do so may result in personal injury and/or equipment
procedures with the machine’s power OFF. Be sure to replace all covers damage. 
before resuming operation. 
WARNING. Ground impedance must conform to the requirements
WARNING. All switches (such as control or power) must be OFF when
of national and local industrial safety regulations and/or electrical
checking input AC electrical connections, removing or inserting printed
codes. The integrity of all ground connections should be
circuit boards, or attaching voltmeters to the system. 
periodically checked. For installations within a cabinet, a single
WARNING. Incoming voltages must be checked with a voltmeter
safety ground-point or ground bus-bar connected directly to
before being connected to the electronics. 
building steel should be used. All circuits including the AC input
WARNING. Extreme caution must be used in testing in, on, or around
ground conductor should be grounded independently and directly to
the electronics, PC boards, or modules. There are voltages in excess of
this point/bar. Grounding all enclosures and conduits is strongly
115V or 230V in these areas. Avoid high voltage and static electricity
recommended. 
around the printed circuit boards. 
WARNING. Maintenance procedures should be performed only by CAUTION. Verify that the input voltage is correct with an AC
qualified service personnel and in accordance with voltmeter before you connect it to the Micro-Tech. 
procedures/instructions given in this manual. 
CAUTION. Earth ground must be provided to the Micro-Tech. Do
WARNING. During maintenance, a safety tag (not supplied by Thermo
not use conduit to provide this ground. 
Fisher Scientific) should be displayed in the ON/OFF switch areas as a
precaution instructing others not to operate the unit.  CAUTION. A readily accessible disconnect device (maximum 20
WARNING. Only qualified service technicians should be allowed to amp) must be incorporated in the field wiring. This disconnect
open and work in the electronics, power supply, control, or switch device should be within easy reach of the operator and must be
boxes.  marked as the disconnecting device for the equipment. 
WARNING. This equipment should not be operated or utilized in EMC Instructions
applications other than those stated in the original order.  The Micro-Tech may cause radio interference if used in a
WARNING. All panels covering the electronics must be in place and residential or domestic environment. The installer is required to take
tight before wash down procedures. Damage to the electronics could measures to prevent interference, in addition to the essential
result from water, moisture, or contamination in the electronics requirements for CE compliance provided in this manual, if
housing.  necessary.
Conformity of the Micro-Tech with CE/EMC requirements does not

guarantee an entire machine or installation complies with CE/EMC
requirements.

Introduction
Hardware Installation
This section tells you how to complete the hardware installation for your
Hardware Micro-Tech. Please go to the appropriate section, depending on which
Installation model of Micro-Tech you purchased (field-mounted or panel-mounted).
Important Wiring Before installing the Micro-Tech, please read the following important
safety information about wiring up the Micro-Tech.
and Safety
Information
l Ensure power is OFF at the main disconnect.
l Do not route load-cell and signal cables in the same conduit with
power cables or any large source of electrical noise.
l Earth ground all instrument chassis’ and conduits. A ground
connection between all conduits is required.
l Connect the shields only where shown.
l Check that all wires are tight in their connections.
l Never use a “megger” to check the wiring.
l A readily accessible disconnect device must be incorporated in the
field wiring. This disconnect should be within easy reach of the
operator and must be marked as the disconnecting device for the
Micro-Tech and associated equipment.
l All conduits should enter the bottom of the enclosure. Do not run
conduit through the top or sides of the enclosure.
Installing the The integrator should not be exposed to excessive vibration, heat, direct
sunlight, or moisture. The ideal mounting location would be on a
Field Model separate wall or beam in view of the device being monitored. Refer to
system wiring diagram for the maximum allowed distance from the
monitored device to the Micro-Tech.
Mounting Mount the Micro-Tech to a rigid, flat, vertical surface using four
mounting holes provided on the back of the enclosure. Care should be
taken to ensure the mounting surface is flat, so as not to twist or warp
the fiberglass enclosure when tightening the mounting bolts.

Introduction
Connecting the To connect the incoming power, use the following procedure. Please
Incoming Power note that all units shipped from the factory are configured for 100 to 240
Supply VAC.
1. A customer-supplied 2 amp 250 VAC normal-blow fuse must be

connected in the “hot” power lead between the AC Mains and the
Micro-Tech “AC Power Input” terminal block.
2. Unlatch and open the enclosure door.
3. Route incoming power wiring through a conduit hole at the bottom

right of the enclosure. For North America locations a certified Nema
4/4X bushing must be used for openings. For other locations see
your local Electrical Authorities. Leave ample loose wiring
(typically 8 inches / 20 cm) to facilitate removing the terminal
connectors.
4. Locate the wiring panel (see figure 1-4 below), which lies on the
underside of the electronics enclosure. The wire-safety ground-
terminal is located on the enclosure back panel.
5. Wire HOT to Terminal H on the AC PWR IN terminal.
6. Wire NEUTRAL to Terminal N on the AC PWR IN terminal.
7. If additional I/O is required at the line voltages, these wires should

be routed through a conduit hole on the bottom right of the
enclosure. Leave ample loose wiring (typically 8 inches / 20 cm) to
facilitate removing the terminal connectors.
8. In the case of sourcing power for the AC outputs/inputs from the

integrator, source the power from the AUX PWR OUT terminal.
9. All additional field wiring operation at voltages less than 30 V must

be located on the left bottom of the enclosure. Leave ample loose
wiring (typically 8 inches / 20 cm) to facilitate removing the terminal
connectors.

Introduction
10. Close and latch the enclosure door.
Figure 1–3. Connectors on Underside of Enclosure
Installing the This model of the Micro-Tech is designed to be mounted in an

instrument panel. The instrument panel should not be exposed to
Panel Model
excessive vibration, heat, or moisture. The front bezel, when properly
seated, forms a dust seal. A two-inch clearance around the top and
bottom of the Micro-Tech is required for convection cooling. Additional
clearances may be required if other equipment mounted directly below
the Micro-Tech generates excessive heat. A 2-3 inch (50-75mm)
clearance in the back is necessary for wiring access and fuse
replacement. A 1 inch (25mm) clearance on each side is necessary for
inserting the chassis-holding brackets from the back after inserting the
Micro-Tech.
Mounting Provide a cut-out (see figure 1-2 for dimensions) in the panel and, after
removing the holding brackets, and installing the gasket, insert the
Micro-Tech. From the back, insert the holding brackets on both sides of
the Micro-Tech. Tighten the holding brackets to support the Micro-Tech
and form a dust seal.

Introduction
Micro-Tech Features
Connecting the To connect the incoming power to the Micro-Tech, use the following
Incoming Power procedure. Please note that all units are 24VDC only.
Supply
1. For input power, use 16 AWG / 1.5 mmsq standard wires.
2. Wire the safety ground to the terminal labeled “E” on the Power
Input Terminal.
3. Wire the +24VDC to the terminal labeled “+” on the Power Input
Terminal.
4. Wire the 24VDC Common to the terminal labeled “–” on the Power
Input Terminal.
Configuring In most instances, your Micro-Tech is shipped to you from the factory
with all the needed jumpers installed and the switches set in the correct
Jumpers and positions for your particular installation and application. As a result, you
Switches should not need to connect any jumpers or set any switches but, if you
do, all the appropriate settings are shown in the specific model reference
manual.
The following sections give you a quick overview of the Micro-Tech’s

Micro-Tech features, functions, and capabilities.
Features
Standard The Micro-Tech has many hardware and software features. The standard
features of the Micro-Tech are listed below.
Features
l Menu-driven scroll entries on a four line display.
l Four LED status indicators.
l Audit trail.
l Automatic zero and span calibration.
l Auto zero tracking (where applicable)
l Several software options that may be turned on by keypad entry or
by installing optional plug-in PC boards.
l Optically coupled digital inputs and outputs.
l Alarms and failure detection.

Introduction
Micro-Tech Menus and Functions
l Communication standards such as RS232C, RS485, and networking

multi-drop.
l Allen-Bradley DF1 and Modbus RTU.
l Ethernet/IP and Modbus/TCP
Inputs and The standard Micro-Tech configuration is as follows. For more

information about the Micro-Tech’s communication protocols, see the
Outputs specific model reference manual.
l USB port.
l Two serial communication ports.
l Two digital inputs on motherboard.
l One DC output from the mother board (J29).
l Ethernet TCP/IP.
l Four circuit board expansion slots that can accommodate the
following boards, if needed.
l Three programmable digital inputs on plug-in card.
l Four programmable digital outputs on a plug-in card.
l Single channel current output board
l Dual channel current output, analog input board (2 analog in and
2 analog out)
l 8 digital inputs/8 digital outputs board
l Serial communication board
l Profibus-DP board
Each Micro-Tech has been designed for a specific application and is

Micro-Tech capable of performing all of the necessary measuring functions. All of
Menus and the required functions are resident in the software of the microprocessor.
Optional functions are automatically turned on when the relevant
Functions hardware is installed, or after the operator has selected them through the
keypad. Setup of the Micro-Tech is easy and is performed from the
keypad on the front of the device. The setup parameters may be divided
into the following main groups.
l Menu 1: Calibration
l Menu 2: Set-up
l Menus 3–6: Options set-up

Introduction
Micro-Tech Menus and Functions
Monitoring The Integrator includes internal diagnostics that generate alarms in case
of hardware failures or programming errors.
Functions
Alarms are visible on the display and can be acknowledged and reset
through keypad, digital input, or serial line. Alarms can be delayed to
avoid intervention in case of short time peaks. Each individual alarm can
be programmed to operate as alarm, shut down, or ignored. Two LEDs
indicate the cumulative status of alarms and shut down. Digital outputs
are also provided for the following:
l Hardware failure
l Alarm cumulative
l Shut down cumulative
Print Functions Timed or command prints can be obtained by connecting a serial printer
to the Comm output on the motherboard, or an optional communication
board. Data may also be downloaded to a USB memory device. Time
and date are permanently stored in the battery-backed memory. The
integrator Set-Up, Totals, Zero results, and Audit Trail of the instrument
can be printed.
Communication There are two communication ports on the Motherboard. Comm A is

RS232C/RS-485 (jumper selectable), isolated. Comm B is RS-485 only,
Functions non-isolated. One additional communication board may be installed. For
detailed descriptions of communication protocols, see the specific model
reference manual.
There are three types of standard communication functions, as described

below.
l Serial Communications
The communication protocol allows a remote intelligent device to
read the contents of the registers and write to some registers. During
the communication activity, the Micro-Tech always acts as a Slave,
meaning it responds to a request from a Master device on the line,
but never attempts to send messages out. One electrical interface
may be selected and accessed through one communication port.
l Field Bus I/O

Profibus-DP I/O communication protocol board is typically used to
transfer I/O images between a main PLC and the remote devices

Introduction
Symbol Identification
(normally remote I/O racks—rack adapters) or to transfer (read and

write blocks of data with intelligent remote devices (node adapters),
the Micro-Tech in this case. The Remote I/O is a typical
master/slave communication where the main PLC is the master or
scanner and the remote devices are slaves or adapters.
l Ethernet Port
The Micro-Tech has a built-in Ethernet port. Communications
protocols Ethernet/IP and Modbus/TCP can be used. The Micro-
Tech is a slave device only, and cannot initiate messages.
Here are the details of the symbols used on the Micro-Tech.

Symbol
Identification
Table 1–1. Symbol Identification
Symbol Description
Alternating current
Earth (ground) TERMINAL
PROTECTIVE CONDUCTOR
TERMINAL
Caution, risk of electric shock
Caution (refer to accompanying

documents)

Introduction
Standards Applied
Conformity with the Low Voltage (LVD) Directive and Electromagnetic

Standards Compatibility (EMC) Directive has been demonstrated using
Applied harmonized European Norm (EN) standards published in the Official
Journal of the European Communities, and International (IEC)
applicable standard used in North America.
The Micro-Tech™ 9000 series comply with the EN and IEC standards
listed below, when properly installed in accordance with this and other
relevant manuals.
l CAN/CSA-C22.2 No.61010.1-04
Safety Requirements for Electrical Equipment for Measurement,
Control, and Laboratory Use.
Part 1: General Requirements.
l UL 6101-1(2nd Edition)
Safety Requirements for Electrical Equipment for Measurement,
Control, and Laboratory Use.
l UL 60950-1
Information Technology Equipment—Safety
l IEC/EN 61010-1:2001
Safety requirements for electrical equipment for Measurement,
Control, and laboratory use.
Part 1: General requirements.
The Micro-Tech™ 9000 series has been tested with the EN and IEC
standards listed below.
l IEC/EN 61326-1
Electrical equipment for measurement, control and laboratory use—
EMC requirements.
Part 1: General requirements
l EN 55011
Limits and methods of measurement of radio disturbance

Introduction
Standards Applied
characteristics of industrial, scientific and medical (ISM) radio-

frequency equipment.
l EN 55022
Information technology equipment. Radio disturbance
characteristics. Limits and methods of measurement.
The Micro-Tech™ 9000 series complies with the following EN

directives.
l 2006/95/CE—Low Voltage Directive.
l 2004/108/CE—EMC Directive.

Introduction
Specifications
Here is a table showing the relevant technical specifications for the

Specifications Micro-Tech.
Table 1–2. Micro-Tech Technical Specifications

Description Specification
Field Mount Enclosure NEMA 4X, IP66, dust and watertight, 17.01 [432] x 14.18 [360] x
6.59 [167] inches, fiberglass reinforced polyester.
Steel chassis providing EMI/RFI shielding.
Panel Mount Enclosure Size: 12.11 [308] x 4 [102] x 7.95 [202] inches.
Material: Zinc-plated mild steel.
Environmental Conditions Mounting Should be mounted as close to the measuring device as
possible without being exposed to excessive heat or moisture.
Field Mount suitable for outdoor mounting.
Temperature (Ambient) Storage: -22° to +158° F (-30° to +70° C).
Operating: –4° to +140° F (-20° to +60° C).
Relative Humidity Maximum relative humidity 80% for temperatures up to 31°C
decreasing linearly to 50% humidity at 40°C.
Pollution Degree Level 2 per IEC 61010-1
Altitude Up to 6,561 ft (2000m)
Installation Category 2
Shock 15G peak for 11ms duration (±1.0 ms)
Vibration 0.006 in./0.152 mm displacement, 1G peak
Emission Limitation According to IEC/EN 61326-1, Class A
Noise Immunity According to IEC/EN 61326-1, Industrial Environmental
Nominal Voltage Field Mount: 100 - 240 VAC.
Panel Mount: 24VDC +10%,-15% (user supplied).
Nominal Frequency Field Mount: 50-60 Hz.
Panel Mount: DC only.
Fusing 250VAC, 2A fast acting, on motherboard
Power Consumption 50 VA max.
Maximum Non-Destructive Input Voltage Field Mount: 265 VAC.
Panel Mount: 28VDC.
DC Power Supply Required for Panel Mount Output voltage: 24 VDC.
Isolation: No.
Output current: 2A minimum, short circuit protected.

Introduction
Specifications
Processor Coldfire MCF5234 32-bit microprocessor
2 MB Flash memory
128K NVRam
2 Integrated UARTs and Ethernet communication peripherals.
Removable Storage USB flash driver port
RAM Battery Life expectancy of the RAM support battery is a minimum of 10
years, if power is not applied. Under normal operation where
power is on continuously, life expectancy is much longer.
Inputs #1, #2 Optically isolated. Powered by + 24VDC supply.
Built-in current source for dry contact use. (Gold plated contacts
recommended)
Frequency range Voltage/current type sensor: 0.25 to 2.0 kHz.
Contact closure type sensor: 0.25 to 30 Hz.
Low threshold: +1.3 VDC min.
High threshold: +2.2 VDC max.
Low or High Pulse Duration Voltage/current type sensor: 200 us min.

Contact closure type sensor: 15 ms min.
Hysteresis 0.8 VDC minimum.
Input impedance 10 k-ohm typical, 500 ohm minimum.
Input source current -2 mA nom. at 0 VDC.
Max. non-destructive input voltage ±28 peak, continuous.
Digital Output (Output #5) Able to drive TTL, CMOS, or relay solenoids.
Current sinking driver.
+24 VDC internal supply, 100mA DC maximum.
Standard Communication Serial Interface UART 0 RS-232C provides support for modem.
RS-485; 2 and 4 wire multi-drop.
Data rate: 110 to 19200 bits/second, operator selectable from
the keypad. Data format: Asynchronous, bit-serial, selectable
parity, data length, and stop bits.
Optical isolation: 250 VRMS max. Input Voltage: ±30 Vdc max.
(RS-232C) ±15/-10 Vdc max. (RS-485).
Cable length: RS-232C, 50ft [15m] max; RS-485, 4000 ft
[1219m] max.
Standard Communication Serial Interface UART 2 RS-485; 2 and 4 wire multi-drop in RS- 485.
(For use with Thermo Fisher Scientific equipment Data rate: 110 to 19200 bits/second, operator selectable from
only.) the keypad. Data Format: Asynchronous, bit-serial, selectable
parity, data length, and stop bits.
Isolation: Non-Isolated.
Cable Length: 4000ft [1219m] max.

Introduction
Specifications
Ethernet Communication Physical: 100baseT, RJ45 Ethernet port
Embedded Web server
Supported Protocols: Modbus TCP, Ethernet IP.

Chapter 2
Set-Up
This chapter tells you how to start up your Micro-Tech, initialize its
software, and get your Micro-Tech and its associated scale up and
running. As part of the initialization process you will perform a belt-
length test and, once this is done, do the initial zero and span calibrations
of the scale. Your Micro-Tech is then ready to go into operation.
There are four major parts to the Micro-Tech console, as follows.

Using the
Display screen
Console l
l Keypad
l Soft keys
l Status LEDs
Figure 2–1. Main Features of the Micro-Tech Console

Set-Up
Using the Console
Display Screen This displays the built-in Micro-Tech menus as well as any entries you
make using the keypad. The display also shows the current functions
(such as Edit, Enter, and Clear) that are assigned to the four Micro-Tech
soft keys situated below the display.
Keypad The keypad allows you to scroll through the Micro-Tech menus, enter
numbers and letters into the Micro-Tech’s menus, and control the
operation of the Micro-Tech using the Run button. As you will already
have noticed—similar to the keys on a cell phone—the Micro-Tech’s
number keys have multiple uses. All are context sensitive, meaning, for
example, that when the Micro-Tech is displaying a menu, the number
“8” key operates as a down-arrow key, but when the Micro-Tech is
expecting you to enter a number, it operates as an “8” key. Similarly, in
the print menu, when you are naming your output, repeatedly pressing
the “8” key brings up, in succession, the letters V and W.
l Arrow Keys
The up-arrow and down-arrow keys allow you to scroll through the
Micro-Tech menu screens—up and down as well as left and right in
some menus.
l Control Keys
The Micro-Tech has two control keys—the Menu button and the
Run button. Once the Micro-Tech is up and running, pressing the
Menu button brings up the menu screens. Pressing the Run button
returns the Micro-Tech to its normal operating mode.
Soft Key Buttons The four blue keys below the display screen are “soft keys,” that is, they
have different functions depending on which menu you are using. The
soft keys are assigned to various menu-selection and data-entry
functions—such as Edit, Clear, Reset, Totals, and so forth.
Status LEDs The status LEDs above the display, when lighted, alert you to the fact
that the Micro-Tech is currently in either the Ready, Auto, Alarm, or
Remote mode.

Set-Up
Using the Console
Measuring The belt feeder controller can be directly connected to six 350 ohm load
cells and receives the signal of a speed sensor in order to calculate belt
Functions
speed, belt loading, and feed rate.
Rate is integrated in time to calculate the amount of material conveyed
by the belt (total), and is displayed in three individual registers: total,
reset total, operator total. The belt feeder controller can perform
automatic zero and span calibrations. When the belt is running and the
rate is below a certain percentage, the Integrator can perform auto zero
tracking, to minimize the error of zero due to material and dust. Analog
(current) output signals or communications can be used to transmit rate,
speed or belt loading to other control devices. Displayed variables and
analog outputs can be smoothed via damping filters, individually
programmable.

Set-Up
Determining the Belt-Scale Code
It is critical that you know the correct belt-scale code of the conveyor
Determining and scale the Micro-Tech is working with, for the following reasons.
the Belt-Scale
Code l The scale may produce inaccurate and unreliable results if you use
the wrong belt-scale code.
l The Micro-Tech software uses a belt-scale code that is specific to

each particular system, and this belt-scale code must be entered
during the software initialization process.
l Knowing the correct belt-scale code will minimize the amount of

time and effort needed to set up the Micro-Tech.
l Non-pivoting scales have far fewer required set-up parameters than

pivoting scales. As a result, if you have a non-pivoting scale (with a
belt-scale code of 49, for example), there are only 11 required
parameters. In contrast, if you have a pivoting scale (with a belt-scale
code of 1, for example), there are 18 required parameters. So,
knowing your belt-scale code in advance will make the whole set-up
process go more smoothly.
The Quick and The quickest and easiest way to determine the belt-scale code of the
scale the Micro-Tech is working with, is to look at the Micro-Tech
Easy Route
“System Data Sheet” or “Door Label.”
l System Data Sheet

A System Data Sheet is supplied with the product documentation
that accompanied your unit. See Appendix A for an example of a
typical System Data Sheet.
l Door Label
A Door Label is supplied with every Micro-Tech. For panel-
mounted versions of the Micro-Tech, the Door Label is in the
product documentation that accompanied your unit. For field-
mounted versions, the Door Label is glued inside the main door of
the enclosure. See Appendix A for an example of a typical Door
Label.

Set-Up
Acquiring Basic System Data
If your System Data Sheet and/or Door Label is lost or defaced, table A–
1 in Appendix A lists the belt-scale codes for a variety of commonly
used conveyor and scale set-ups.
Once you know your belt-scale code, write it in the space below. You
will need this information later when you initialize the Micro-Tech
software.
Belt-Scale Code __________
HINT. Write the belt-scale code inside the front cover of this manual
for future reference. 
Now that you know the correct belt-scale code of the scale you are
Acquiring using, you are ready to collect some additional data about the type of
Basic System conveyor and scale you are using at your particular facility. You will
need this information when you initialize the Micro-Tech software, and
Data can save time and effort by gathering this conveyor data now rather than
later.
Scale Type The type of scale and conveyor you have installed at your facility
determines the number and type of parameters you need to enter when
Determines initializing the Micro-Tech software. As a general rule, non-pivoting
Parameters scales have fewer required parameters than pivoting scales. Clearly, we
Needed cannot list every single scale configuration in this manual, so we will
restrict ourselves to showing you two examples to give you a feel for
how the belt-scale code works and how it determines what parameters
you need to know when initializing the software.
l If you have a non-pivoting scale—Go to the next page.
l If you have a pivoting* scale—Go to page 2-7.

Set-Up
(* Also known as a lever-ratio, pivot point, or trunion scale.)
Non-Pivoting Here is a list of belt-scale codes for non-pivoting scales. (For a complete
list of belt-scale codes, see table A–1 in Appendix A.)
Scales
l Non-pivoting belt-scale codes*: 43–53, 60, 214, 215.
(* Please note that this is not an exhaustive list, because newer or
custom scales are not listed.)
We suggest you print or photocopy this page and insert the required data
into the table below. Doing so will save you considerable time when you
come to initialize the Micro-Tech software.
Table 2–1. Initialization Data Sheet (Non-Pivoting)

Details of Your Defaults from
Parameter* Particular System Table A–1, or other
Number of weigh idlers 4
Number of load cells 4
Idler spacing (inches) 48
Conveyor angle (degrees) 0
Load-cell capacity (lbs.) 250
Load-cell sensitivity (mV/V) 3.0
Load-cell resistance #1 thru #4 (ohms) 350
Belt length (feet) —
Time for one belt revolution (seconds) —
Number of revolutions for test >3
Time to complete test revolutions (seconds) —
* The example above, including the defaults, is for belt-scale code 49. Your weighing
system will, most likely, have a slightly different list of required parameters and defaults.
NOTE. For more information about the parameters listed above, please
see pages 2-8 through 2-12. 

Set-Up
The Next Step You are now ready to measure the belt speed of your conveyor system.
Go to page 2-13.
Pivoting Scales Here is a list of belt-scale codes for pivoting scales. (For a complete list
of belt-scale codes, see table A–1 in Appendix A.)
l Pivoting belt-scale codes*: 0–42, 54–59.
(* Please note that this is not an exhaustive list, because newer or
custom scales are not listed.)
We suggest you print or photocopy this page and insert the required data into the table below.
Doing so will save you considerable time when you come to initialize the Micro-Tech software.
Table 2–2. Initialization Data Sheet (Pivoting)
Details of Your Defaults from
Parameter* Particular System Table A–1, or other
Pivot-to-load cell distance (inches) 32
Number of weight idlers 1
Pivot-to-first-idler distance (inches) 24
Pivot-to-test weight height (inches) 0
Pivot-to-test weight length (inches) 24
Pivot-to-carriage height (inches) 6.5
Roller-to-carriage height (inches) 6.5
Number of load cells 1
Idler spacing (inches) 36
Conveyor angle (degrees) 0
Load-cell capacity (lbs.) 250
Load-cell sensitivity (mV/V) 3.0
Load-cell resistance, #1 (ohms) 350
Type of speed input —
Belt length (feet) —
Time for one belt revolution (seconds) —
Number of revolutions for test >3
Time to complete test revolutions (seconds) —
* The example above, including the defaults, is for belt-scale code 1. Your weighing system will,
most likely, have a slightly different list of required parameters and defaults.

Set-Up
NOTE. For more information about the parameters listed above, please
see pages 2-8 through 2-12. 
Pivot-to-Load-Cell Measure the distance from the pivot to the load cell, and enter the result
Distance in table 2-1 or 2–2.
Figure 2–2. Pivot-to-Load-Cell Distance
Number of Weight Count the number of weight idlers and enter the result in table 2–1 or 2–
Idlers 2.
Figure 2–3. Number of Weight Idlers

Set-Up
Pivot-to-First-Idler Measure the distance between the pivot and the first idler, and enter the
Distance result in table 2–1 or 2–2. Please note, there may be subsequent (that is,
additional) idlers.
Figure 2–4. Pivot-to-First-Idler Distance

Pivot-to-Test-Weight If the static-weight option is installed, measure the height from the pivot
Height to the test weight, and enter the result in table 2–1 or 2–2. If the test
weight is below the pivot, the value is negative. If this option is not
available, leave at the default value.
Figure 2–5. Pivot-to-Test-Weight Height
Pivot-to-Test-Weight If the static-weight option is installed, measure the length from the pivot
Length to the test weight, and enter the result in table 2–1 or 2–2. If this option
is not available, leave at the default value.
Figure 2–6. Pivot-to-Test-Weight Length

Set-Up
Pivot-to-Carriage If the static-weight option is installed, measure the height from the pivot
Height to the carriage, and enter the result in table 2–1 or 2–2. If this option is
not available, leave at the default value.
Figure 2–7. Pivot-to-Carriage Height

Roller-to-Stringer If the static-weight option is installed, measure the height from the carry
Height roller to the conveyor stringer, and enter the result in table 2–1 or 2–2.
If this option is not available, leave at the default value.
Figure 2–8. Roller-to-Stringer Height
Number of Load Cells Determine the number of load cells, and enter the result in table 2–1 or
2–2.

Set-Up
Idler Spacing Measure the idler spacing, which should all be evenly spaced, and enter
the result in table 2–1 or 2–2.
Figure 2–9. Idler Spacing
Conveyor Angle Measure the angle of the conveyor (in degrees) and enter the result in
table 2–1 or 2–2. An easy way to arrive at a measurement in degrees for
angle Ø, is to measure the length AC, divide by length AB, and look up
the cosine.
Figure 2–10. Conveyor Angle
If the conveyor slopes up, the angle is positive, meaning the conveyor
has a positive incline. If the conveyor slopes down, the angle is negative,
meaning the conveyor has a negative incline. The appropriate sign (+
or –) for the incline must be entered in the appropriate Micro-Tech menu
(see page 2-36).

Set-Up
Load Cell Capacity, All Thermo Fisher load cells have the capacity, sensitivity, and
Sensitivity, and resistance marked (as shown below) on the end of the cable. In case the
Resistance label is not present please refer to the data sheet supplied with the load
cell. Enter the capacity, sensitivity, and resistance in table 2–1 or 2–2.
Figure 2–11. Location of Load-Cell Data
Speed Input The Speed Input parameter tells the Micro-Tech whether your conveyor
system is equipped with one (or, in some special instances, two*)
optional speed sensors. An optional speed sensor feeds very precise
conveyor speed readings to the Micro-Tech. If you did not order an
optional speed sensor, enter “simulated” in table 2–1 or 2–2.
* Two speed inputs, typically, are used in systems equipped with two
scales.
In summary, your choices for speed input are as follows.

l Single—Your conveyor is equipped with one speed sensor.
l Two—You have two scales, each equipped with a speed sensor.
l Simulated—There is no speed sensor attached to your conveyor.
Note, however, that a conveyor-run digital input is required for the
simulated option to work.

Set-Up
Test Duration
You are now going to measure how long it takes for the belt in your
Test Duration conveyor system to make one revolution at maximum speed. You will
use this information to verify that the scale’s zero and span can be
properly set during the approximately six minutes it takes the Micro-
Tech to complete the zero-calibration procedure and span calibration
procedure.
The take-home message here is that, for the scale’s zero & span to be
accurate, the zero and span calibration procedures must fulfill the
following requirements.
l The belt must make at least three complete revolutions.
l The test must have a total running time of six (or more) minutes.
To help you work through the necessary calculations, here is a real-life

example.
Example We have just finished installing a 56ft-long conveyor at our facility that
has a belt length of 120 feet—that is, if the belt was removed from the
system, cut and laid out flat, it would extend to 120 feet. Next, we need
to know how long it takes for the belt to make precisely one revolution
when running at maximum speed.
1. To do this, we drew a prominent chalk line across the belt directly

above the load cell, and timed (to the nearest second) how long it
took for the belt to make exactly one revolution. We discovered it
took precisely 1 minute and 15 seconds. Thus,
—Time for completing one revolution = 75 seconds.
2. Six minutes contain 360 seconds (6 x 60 seconds). So the number of

revolutions the belt makes in 360 seconds is 4.80 (360/75).
—Number of belt revolutions made in 6 minutes = 4.80
—Revs rounded up to the nearest whole number = 5
(If this number is less than 3, you must lengthen the time of the
test so that the belt completes the required minimum of three
complete revolutions.)

Set-Up
Test Duration
3. Because one belt revolution takes 75 seconds to complete, it takes

375 seconds (5 x 75) to complete the required test revolutions. Thus,
—Time to complete the test revolutions = 375 seconds
4. In summary, the data we have collected so far is as follows.

—Belt length = 120 feet
—Time for one belt revolution = 75 seconds
—Number of revolutions needed for test = 5
—Time to complete the five test revolutions = 375 seconds
5. Now it’s your turn to collect your own data and enter it into table 2–
1 or 2–2.
Manually You are now going to collect data from your own particular conveyor
system to determine the Test Duration. Here’s how.
Determine Test
Duration
1. Using a 100 ft tape measure, measure the length of the belt to the
nearest 0.1 feet. Enter the result for “Belt Length” in your
“Initialization Data Summary,” table 2–1 or 2–2.
2. When the belt is stationary, draw a chalk line across the belt.
3. Start the belt and wait until it is running at maximum speed.
4. Use the chalk mark to time one complete revolution of the belt. Enter
the result (in seconds) in table 2–1 or 2–2.
5. Calculate (to at least one decimal place) the number of revolutions

the belt makes in six minutes—as described in the example above.
Round up the number of revolutions to the next whole number. Enter
the result, “Number of revolutions for test,” in table 2–1 or 2–2.
6. Multiply “Number of revolutions for test” by the time taken (in

seconds) for one revolution. Enter the result, “Time to complete test
revolutions,” in table 2–1 or 2–2.

Set-Up
Initializing the Software
The Next Steps You are now going to familiarize yourself with the Micro-Tech’s
console, and use it to enter into the Micro-Tech all the data you entered
in table 2–1 or 2–2.
This section gives you step-by-step instructions to guide you through the
Initializing the software-initialization process.
Software
NOTE. You must complete the entire software initialization and scale-
calibration procedure before putting the Micro-Tech into operation.
There are no shortcuts! 
Overview There are five steps in the software initialization process, as follows.
l Enter the correct date and exact current time.
l Choose the appropriate language for the display.
l Choose the appropriate units of measure (standard tons, long tons,

metric tons, and on).
l Enter the correct belt-scale code for your particular scale.

Set-Up
l Enter the parameters you recorded in your “Initialization Data

Summary” table above (table 2–1 or 2–2).
Cold-Starting the The first time you power up the Micro-Tech, you are doing what is
known as a “cold-start.” Once the Micro-Tech is up and running, you
Micro-Tech
can use the cold-start procedure (described below) to—in computer
terms—“reboot” the Micro-Tech. In other words, when you do a cold
start, the Micro-Tech’s RAM memory is erased and everything is
returned to its initial start-up state. As a result, cold-starts are used, for
example, to restore all the Micro-Tech settings from a previously made
back-up flash drive.
To cold-start the Micro-Tech, do the following.
1. Turn on the Micro-Tech’s power switch while simultaneously

pressing and holding soft-key #1 and the Run button.
2. The Micro-Tech starts up, and the Alarm LED will light to indicate
that the Micro-Tech has not yet been initialized or calibrated. After a
brief delay the Default screen appears, as shown in the section
below.
Setting the Date You are now ready to set the current date and time. (In the following
example we are going to set the date to May 21, 2013.)
READY AUTO ALARM REMOTE
Install Factory
Defaults?
NO YES
1. Make sure the conveyor is empty and running at maximum speed.

Set-Up
2. Press the Yes button and the date screen appears.
Exact date?
- Date 01 – 01 – 2012
DAY 1
EDIT
3. Press the Edit button. (The Micro-Tech clears the Day entry field
leaving just the underline.)
4. Use the keypad to enter the correct day. Remember to enter two
numbers for day. If you make a mistake, press the Clear button. (We
entered 21 for day, as shown below.)
Exact date?
- Date 01 – 21 – 2012
DAY 21
EDIT
NOTE. The Micro-Tech displays the date in the month-day-year

format, and requires two numbers in the month and day fields and four
numbers in the year field (MM-DD-YYYY). In addition, the Micro-
Tech will not display the correct date in the Date line until you have
completed the entire process. You can change the date and time formats
later, if you would like to use a different one. 
5. Press the Enter button. Follow steps 3 and 4 above to enter the
correct month and year.

Set-Up
6. Press the Enter button. The display should now look something like
this. (You may have to repeatedly press the Edit and Enter buttons
on start up, scrolling through the fields again, to get to this screen.)
Either way, make sure this screen is displayed before proceeding.
Exact date?
- Date 05 – 21 – 2013
YEAR 2013
EDIT
7. You are now ready to enter the correct time, as described below.
Setting the Time In the following example we are going to set the time to 2:09 p.m. To set
the correct time, do the following.
1. Press the down-arrow button. The display should currently look like
this.
Exact time?
- Time 12:00 am
EDIT AM/PM
2. Press the Edit button. (The Micro-Tech clears the hour entry field

Set-Up
3. Use the keypad to enter the correct hour. Remember to enter two
numbers for hour.
4. Press the Enter button.
5. Press the down-arrow button to move to the minute field.
Exact time?
- Time 2:00 am
EDIT AM/PM
6. Press the Edit button. (The Micro-Tech clears the minute entry field
7. Use the keypad to enter the correct minutes. Remember to enter two
numbers for minutes.
9. Press the “AM/PM” button to toggle the setting to “PM.” Your

screen should now look something like this.
Exact time?
- Time 2:09 pm
EDIT AM/PM

Set-Up
10. The time is now set. Press the down-arrow button to bring up the
USB screen. The Micro-Tech pauses for about 10 seconds, while it
checks for the presence of a flash drive in the USB port. (If you
were rebooting the Micro-Tech to restore your previously saved
settings, this is where you would insert the back-up flash drive into
the USB port.)
Wait...
Check USB present
ABORT
11. After waiting briefly, press the down-arrow button to bring up the
language screen.
Choosing a The default language shown in the Micro-Tech display is English. You
can, however, choose other languages.
Language
1. The Micro-Tech display should currently look like this.
- MEMORY ERASED -
Choose the language
key to continue to
> ENGLISH <
CHOICE ENTER CLEAR
NOTE. Ignore the “Memory Erased” message. The date and time you
already entered have been retained. 

Set-Up
2. To select the current language, press the Enter button and the scale
set-up screen appears.
3. To choose another language, repeatedly press the Choice button until

the language you want is displayed, then press the Enter button.
Entering Scale This menu allows you to enter the number of load cells and A/D
(analog/digital) channels you are using with your Micro-Tech. The
Data
default value for the Micro-Tech is determined by the belt-scale code.
Initial scale setup
and calibration
Press down SCROLL
2. The Micro-Tech menus are also known as the Micro-Tech “scrolls.”

Please note that the Micro-Tech keypad contains an up-scroll button
and a down-scroll button, which are also known as the up-arrow and
down-arrow buttons. Thus, the notation in the display saying “Press
down SCROLL,” is a cue to press the down-arrow (or down-scroll)
button, as described the next step (step 3).
3. Press the down-arrow button (or Scroll button) and the “Scale Data
Scroll 1” screen appears.

Set-Up
- SC DATA SCROLL 1 -
Number of scales
EDIT
4. Press the down-arrow button and the “A/D Channel” screen appears.
READY AUTO ALARM REMOTE READY AUTO ALARM REMOTE
- SC DATA SCROLL 1A - - SC DATA SCROLL 1A -
Type of scale Type of scale
> One A/D Channel < > Two A/D Channel <
CHOICE CHOICE
The default value is “One” A/D channel. However, if your system has
two load cells, choose the “Two” A/D channels option. Review the
system-specific wiring diagram to determine the number of load cells on
your scale. The “Type of scale” scroll is not available on a model 9205.
5. Press the down-arrow button to bring up the units menu.

Set-Up
Selecting This menu allows you to choose what units of measurement the Micro-
Tech uses when displaying its results. The Micro-Tech can display
English/Metric information using the following units of measurement.
Units
l Standard English units—such as pounds, standard tons, and long
tons.
l Metric units—such as kilograms and tonnes.
l Both English and metric units. (The “Mixed” option.)
- DISPLAY SCROLL 1 -
Measure Units
> English <
CHOICE
2. The default selection for Measure Units depends on which Language

was selected initially.
3. To choose a different selection (English, Metric, Mixed), repeatedly

press the Choice button until the choice you want is displayed, then
press the Enter button.
4. Press the down-arrow button to bring up the totalization units screen.
5. In pages 2-24 through 2-29, do the following.

l Follow the “English” headings, if you are using units.
l Follow the “Metric” headings, if you are using metric units.
l Go to page 2-29, if you are using mixed units.

Set-Up
Setting the This menu allows you to select the specific units of measure that are
displayed by the Micro-Tech when reporting its results (known as
Totalization Units
“Totalization”). Clearly, which units of measure are available in this
menu depends on the choice you made in previous topic (“Selecting
English/Metric Units).
English Totalization The Micro-Tech display should currently look like this, if you chose
Units English units.
Totalization Units
> Tons <
CHOICE
1. Tons (the standard U.S. ton, 2,000 lbs—also known as the British
“short ton”) is the default value.
2. To choose long tons (“LTons” 2,240 lbs) or pounds (“Pounds”),

repeatedly press the Choice button until the unit you want is
displayed, then press the Enter button.
3. Press the down-arrow button to bring up the length units screen (go
to page 2-25)

Set-Up
Metric Totalization The Micro-Tech display should currently look like this, if you chose
Units metric units.
Totalization Units
> tonnes <
CHOICE
1. Metric tonnes (1,000 kg) is the default value.
2. To choose kilograms (“kg”), press the Choice button (“kg” is

displayed), then press the Enter button.
3. Press the down-arrow button to bring up the length units screen (see
the next section).
Setting the This menu allows you to choose the length units used by the Micro-
Length Units Tech. Clearly, which length units are available in this menu depends on
the choices you made in previous menus (English, Metric, Mixed).
English Length Units The Micro-Tech display should currently look like this, if you chose
English units.
Length Units
> Feet <
CHOICE

Set-Up
1. Feet is the default value.
2. As no other choices are available, press the down-arrow button to

bring up the rate units screen (go to page 2-27).
Metric Length Units The Micro-Tech display should currently look like this, if you chose
metric units.
Length Units
> meters <
CHOICE
1. Meters is the default value.
2. As no other choices are available, press the down-arrow button to

bring up the rate units screen (see the next section).

Set-Up
Setting the Rate This menu allows you to choose the rate units used by the Micro-Tech.
Clearly, which rate units are available in this menu depends on the
Units choices you made in previous menus (English, Metric, Mixed).
English Rate Units The Micro-Tech display should currently look like this, if you chose
English units.
Rate Units
> Tph <
CHOICE
1. Standard U.S. tons (equivalent to British “short tons”) per hour

(“Tph”) is the default value.
2. Repeatedly press the Choice button to select other rate units (shown
below), then press the Enter button.
l “LTph”—Long tons per hour
l “Lb/mn”—Pounds per minute
l “T/mn”—Standard tons per minute
l “Lt/mn”—Long tons per minute
l “percent %”
l “Lb/hr”—Pounds per hour
3. Press the down-arrow button to bring up the load-cell units screen

(go to page 2-30).

Set-Up
Metric Rate Units The Micro-Tech display should currently look like this, if you chose
metric units.
Rate Units
> t/h <
CHOICE
1. Metric tonnes per hour (“t/h”) is the default value.
l “kg/mn”—Kilograms per minute
l “t/mn”—Metric tonnes per minute
l “percent %”
l “kg/h”—Kilograms per hour

(go to page 2-30).

Set-Up
Mixed Rate Units The Micro-Tech display should currently look like this, if you chose
mixed units.
Rate Units
> t/h <
CHOICE
1. Metric tonnes per hour (“t/h”) is the default value.
l “Lb/h”—Pounds per hour
l “Tph”—Standard tons per hour
l “LTph”—Long tons per hour
l “kg/mn”—Kilograms per minute
l “t/mn”—Metric tonnes per minute
l “Lb/mn”—Pounds per minute
l “T/mn—Standard tons per minute
l “LT/min”—Long tons per minute
l “percent %”
l “kg/h”—Kilograms per hour

(see the next section).

Set-Up
Setting the Load- As a general rule, when setting the load-cell units, use the following as a
guide.
Cell Units
l If you are using English units, select pounds.
l If you are using metric units, select kg.
The only choices in this menu are to use either pounds or kilograms.
The Micro-Tech display should look something like this.
Loadcell Units
> Pounds <
CHOICE
1. Accept the default value (“Pounds” or “kg”).
2. To choose a different load-cell unit (for example because you are

using a custom load cell in your particular application), press the
Choice button, then press the Enter button.
3. Press the down-arrow button to bring up the maximum scale-

capacity screen (see the next section).

Set-Up
Entering the This menu allows you to enter the maximum scale capacity of the
particular scale you are using in your facility. Please note that the
Maximum Scale
maximum scale capacity is expressed as a rate—for example, tons per
Capacity hour (Tph), tonnes per hour (t/h), and so on. In other words, do not enter
the maximum weight the scale can be loaded with, because the Micro-
Tech is looking for a rate.
The Micro-Tech display should look something like this, depending on

the choices you made in the menus above.
Max. scale capacity
500.00 Tph
EDIT
1. To enter the maximum capacity of your particular scale, press the

Edit button and use the keypad to enter the appropriate value, using
the decimal point, if needed. In addition, please note the following.
l If you need to enter a value such as 1234.5 tons per hour, soft
key 3 allows you to enter the decimal point. (See screen shot
below.)
l There cannot be more than three numerals after the decimal.
(Thus, 12.345 is allowed but not 12.3456, which will be
truncated to three decimal places.)
l Whatever value you enter cannot contain more than seven
characters, including the decimal point.
l The maximum rate (that is, the scale capacity) cannot exceed
200,000 units of measure.

Set-Up
2. We entered 1,750 tons per hour (Tph), as shown below.
Max. scale capacity
1750 Tph
ENTER • CLEAR
3. Press the Enter key.
4. Press the down-arrow key to bring up the scale-divisions screen.
Entering the This menu allows you to tell the Micro-Tech how to report the quantity
of material that crosses the scale in one hour. For example, if 1,750 tons
Scale Divisions cross the scale in an hour and you want the results reported to one
decimal place (that is, to the nearest 200 lbs.), you would choose a scale
division of 0.1. As a result, hourly rates would be reported as—for
example—1742.8 Tph (tons per hour).
Please note that the choice of division has no bearing on the accuracy of
the underlying numbers, and that if your control system contains a PLC
(programmable logic controller), you may need to choose a smaller (or
larger) scale division.
The Micro-Tech display should look something like this.
Scale divisions
>1 <
CHOICE

Set-Up
1. The Micro-Tech displays an appropriate scale division depending on

the value you entered in the “Maximum Scale Capacity” menu.
Possible scale divisions are 50, 20, 10, 5, 2, 1, 0.5, 0.2, 0.1, 0.05,
0.02, and 0.01.
2. To choose the appropriate scale division, press the Choice button

until the division you want is displayed, then press the Enter button.
3. Press the down-arrow key to bring up the belt-scale-code screen.
Entering the Belt- This menu requires you enter the belt-scale code for the particular scale
Scale Code you are using in your facility. The current weigh-bridge configurations
offered by Thermo Fisher Scientific as well as the necessary belt-scale
codes, are listed in table A–1 in Appendix A. In addition, your specific
weigh-bridge configuration should be listed on the “Scale Data Sheet”
and the “Door Label” that accompanied your Micro-Tech.
The Micro-Tech display should look like this.
Belt scale code #
EDIT DETAIL
Figure 2–12. Belt-Scale-Code Entry Screen
NOTE. You absolutely must enter the correct belt-scale code in this
menu for the Micro-Tech to work properly with your particular
weighing system. This is the most critical step in the entire set-up
process! 

Set-Up
1. To enter the correct belt-scale code, press the Edit button and use the
keypad to enter the appropriate value.
2. Press the Enter button to return to the belt-scale-code entry screen.
Entering the Depending on which belt-scale code you selected, the Micro-Tech will
now display a list of the conveyor and scale parameters it needs to know
Appropriate to work properly with your particular system. You should already have
Conveyor Data entered the needed values in table 2–1 or 2–2.
The basic idea here is to press the Details button, then repeatedly press
the down-arrow button, which allows you to scroll through a list of
parameters to make quite sure they are correct.
NOTE. You must check the conveyor values suggested by the Micro-
Tech. If there is a mismatch between the suggested values and the actual
values for your particular conveyor system, you must enter the correct
values into the Micro-Tech. Incorrect parameters in these menus may
lead to inaccurate weight readings when the Micro-Tech is put into
operation. 
To check the parameters, do the following.
1. The first thing to do is to locate the Micro-Tech’s System Data Sheet

(see Appendix A for an example of what this looks like) and grab
your filled-in copy of table 2–1 or 2–2. Make sure you have these in
front of you, as you work through the following Micro-Tech set-up
menus.
2. Make sure the screen shown in figure 2–11 above is currently being
displayed.
3. Press the Details button, and the first parameter appears. Your list of
parameters will, most likely be different, from the ones shown

Set-Up
below. These are just examples of a typical set-up menu, and are
here to show you how the process works. The general outline is the
same for all systems, but the specifics may be different.
Pivot-to-Load-Cell The pivot-to-load cell distance is explained in figure 2–1. Check the
Distance value. Press the down-arrow button to move on.
Number of Weigh Check the value, then press the down-arrow button to move on.
Idlers
Pivot-to-First-Idler The pivot-to-first-idler distance is explained in figure 2–3. Check the

Distance value. Press the down-arrow button to move on.
Pivot-to-Test-Weight The pivot-to-test-weight height is explained in figure 2–4. Check the

Height value. Press the down-arrow button to move on.
Pivot-to-Test-Weight The pivot-to-test-weight length is explained in figure 2–5. Check the

Length value. Press the down-arrow button to move on.
Pivot-to-Carriage The pivot-to-carriage height is explained in figure 2–6. Check the value.
Height Press the down-arrow button to move on.
Roller-to-Stringer The roller-to-stringer height is explained in figure 2–7. Check the value.
Height Press the down-arrow button to move on.
Number of Load Cells Check the value, then press the down-arrow button to move on.

Set-Up
Idler Spacing The idler spacing is explained in figure 2–8. Check the value. Press the
down-arrow button to move on.
Conveyor Angle The conveyor angle is explained in figure 2–9. The default value is zero
degrees, meaning your conveyor runs in the horizontal position.
1. If the conveyor runs at an incline, (positive or negative), press the

Edit button.
2. Use the keypad to enter the correct angle. (The default is a positive
incline.)
3. To enter a negative incline, press the “+/–” button to display a

negative sign in front of the number.
5. Press the down-arrow button to move on.
Load Cell Capacity, Every load cell has a cord to which is attached a label that displays the
Sensitivity, and capacity, sensitivity, and resistance of the load cell. Please refer to figure
Resistance 2–10 for information about locating this label. You must enter the
resistance separately for each load cell.
Setting the Speed For more information about speed inputs, see page 2-12. Your choices in
Input this menu are as follows.
l Single—Your conveyor is equipped with one speed sensor.
l Two—You have two conveyors, each equipped with a speed sensor.
l Simulated—There is no speed sensor attached to your conveyor(s).

Set-Up
Establish Test To start entering the data the Micro-Tech needs to establish the test
duration for your scale, do the following.
Duration
1. Use the arrow buttons to navigate to the Test Duration screen, which
looks like this.
- CAL DATA SCROLL 11 -
Nr. of test duration
> 1 <
CHOICE
Nr. = Number.
The zero test can be either “long” or “short.” You should always use the
long test when initializing the Micro-Tech. The long and short tests are
assigned the following code numbers.
l Long-duration test = 1
l Short-duration test = 2
2. To accept the long-duration test (code = 1), press the down-arrow

button and the following screen appears.
Establish test duration
ACQ MANUAL

Set-Up
3. Press the Manual button and the following screen appears.
Start belt. Press
CONTINUE when belt
is at maximum speed
ABORT CONTINUE
NOTE. The belt must be running empty and at maximum speed during
the procedure to establish the appropriate test time. Pressing the Abort
button at any time returns you to the “Establish Test Duration”
screen. 
4. Start the belt and, when it is running at maximum speed, press the
Continue button. The following screen appears. (The default value is
200 feet.)
Ent. len. of
one belt revolution
Length 200 ft
EDIT ABORT
5. Press the Edit button and use the keypad to enter the length of the
belt. (We entered 120 feet, as described in our example on page 2-
13)

Set-Up
6. Press the Enter button and the following screen appears.
Enter the number
of belt revolutions
to be timed 1 rev
EDIT ABORT
7. Press the Edit button. Use the keypad to enter the number you
calculated earlier (and entered in table 2–1 or 2–2) for the “Number
of revolutions for test.” (We entered 5 revolutions, as described in
our example on page 2-13.)
8. Press the Enter button and the following screen appears. (The default
value is 30 seconds.)
Enter time for
revolutions to pass
reference 30 sec
EDIT ABORT
9. Press the Edit button. Use the keypad to enter the number you
calculated earlier (and entered in table 2–1 or 2–2) for the “Time to

Set-Up
complete test revolutions.” (We entered 375 seconds, as described in

our example on page 2-13.)
10. Your screen should now look something like this.
Enter time for
revolutions to pass
reference 375 sec
ENTER ABORT CLEAR
11. Press the Enter button and the following screen appears. The time
display will start counting down to zero. The Micro-Tech is now
performing the initial zero calibration—as shown by the
Calibration LED, which comes on.
Tim. belt travel
375 sec
ABORT

Set-Up
12. When the count-down reaches zero, the following screen appears,
telling you how many feet of belt in total was tested, and the time
(in seconds) it took to complete the test. (The data in your screen
will, of course, be different.)
TEST DURATION
Length = 600 ft
Time = 375 sec
CONTINUE
(In our example, belt length =120 ft. So, 600 feet [120 x 5] were tested
during five revolutions of the belt.)
13. Press the Continue button and the following screen appears. The
Micro-Tech is now setting the appropriate span number for the
scale.
SET-UP
in
progress

Set-Up
14. When the span number has been set, the following screen appears
briefly in the display. Notice that the red “Alarm” LED in the
console goes off and the green “Ready” LED comes on.
S1 calibrated
If you get an “S1 not calibrated” message, check all the numbers you
entered in your Initialization Data Summary table (table 2–1 or 2–2).
Then go back to the “Entering the Appropriate Conveyor Data” section
above (see page 2-34) and carefully re-enter all the data into the Micro-
Tech. If the calibration fails again, check the load cell (or cells) are
working and sending signals to the Micro-Tech.
15. After a brief pause, the following screen appears.
Press RUN to start

or MENU for scrolls

Set-Up
Running the Micro-Tech
16. Press the Run button and the Micro-Tech Run screen appears,
which looks like this.
0.0 Tons
0.0 Tph
TOTALS
Continue with the following steps, finishing with “Calibrating the

Micro-Tech” section to perform the initial zero and span calibrations for
your scale. This is a very important step, because the scale will not give
accurate readings until these calibrations are done.
To run the Micro-Tech, do the following.

Running the
Micro-Tech
1. Make sure the Micro-Tech is powered up.
2. Make sure the Run screen (see below) is currently being displayed.
3. Start the conveyor running and begin loading it up.
Run Screen The screen below is known as the Run screen. it shows the total tons
(Tons) that have crossed the scale since the values were last reset, as

Set-Up
Running the Micro-Tech
well as the tons per hour (Tph) of material that is currently running over
the scale.
0.0 Tons
0.0 Tph
TOTALS
Figure 2–13. Run Screen
By pressing the down arrow key the 2nd Run screen can be accessed.
The 2nd Run Screen shows Rate on line 1, Reset Total on line 2, and
Operator total on line 3. This screen also has the AUTO and REMOTE
softkeys. The AUTO softkey is used to switch between Automatic or
Manual control. The REMOTE softkey is used to switch between
Remote or Local setpoint.
0.0 Tph
RT 0.0 Tons
OT 0.0 Tons
AUTO REMOTE
2nd Run Screen

Set-Up
Calibrating the Micro-Tech
The Control Run screen can be accessed by pressing the down arrow
key.
PV 0.0 Tph
Setpt 0.0 Tph
+++++<
EDIT ADV
Control Run Screen
Depending on your particular application, the Micro-Tech should be

Calibrating calibrated on a daily, weekly, monthly, or other regularly scheduled
the Micro- basis. You should run the zero calibration routine often to ensure that the
accuracy of the scale is optimized.
Tech
Doing a Zero To run a zero calibration on your scale, do the following.

Calibration
1. Make sure the Run screen is currently being displayed.
2. Press the Menu button and the “Main Menu 1” screen appears.
MAIN MENU 1
Press MENU for more
ZERO CAL SPAN CAL MATL CAL

Set-Up
3. Press the Zero Calibration button and the following screen appears.
ZERO CAL
Run the belt empty, then
press START
START EXIT MANUAL
4. Make sure the belt is running empty and at maximum speed, then
press the Start button. The count-down screen appears. (The data in
your screen will, of course, be different.)
AUTO ZEROING
Time remaining 375

Rate 0.00 Tph
Tot 0.000 Tons
ABORT
NOTE. The number of seconds shown in “Time remaining” is

calculated based on the current speed-sensor pulse frequency, and
estimates the time remaining for a complete test. 
5. The calibration time (in seconds) that you established during the
Micro-Tech cold-start procedure, will start counting down. When the
counter reaches zero, the calibration is complete and the change-zero
screen appears.

Set-Up
AUTOZERO COMPLETE
Change zero?
Error 0.01%
YES NO ADV
In our example, the display shows that the newly established zero is just
0.01% different from the previous zero, meaning that both zeros are
essentially the same and the scale is performing consistently. However,
as there has been a small amount of drift, we decide to reset the zero to
the newly established zero point.
6. Press the Yes button to accept the new zero, and the zero-changed
screen appears.
ZERO # CHANGED
New zero # 20000

Old zero # 19980
RUN MENU ADV
7. Press the Run soft key in the display to return the Micro-Tech to the
Run mode.
8. Run several zero calibrations to assess the repeatability of the

readings.

Set-Up
Doing an R-Cal To perform an R-Cal span calibration for your scale, do the following.
Span Calibration
1. Make sure the Run screen is currently being displayed.
2. Press the Menu button and the “Main Menu 1” screen appears.
MAIN MENU 1
Press MENU for more
ZERO CAL SPAN CAL MATL CAL
3. Press the Span Calibration button and the following screen appears.
AUTO SPAN R Cal
Run the belt empty, then
press START
START EXIT MANUAL

Set-Up
4. Make sure the belt is running empty at maximum speed, then press
the Start button. The count-down screen appears. (The data in your
screen will, of course, be different.)
AUTO SPANNING
Time remaining 375

Rate 150 Tph
Tot 0.000 Tons
ABORT
NOTE. The number of seconds shown in “Time remaining” is

calculated based on the current speed-sensor pulse frequency, and
estimates the time remaining for a complete test. 
5. The calibration time (in seconds) that you established during the
Micro-Tech cold-start procedure, will start counting down. When the
counter reaches zero, the calibration is complete and the change-span
screen appears.
AUTOSPAN COMPLETE
Change span?
Error 0.01%
YES NO ADV

Set-Up
Performing an R-Cal For the First Time During Initialization

If you are performing an R-Cal for the first time as part of the Micro-
Tech initialization process, make sure that the R-Cal error is less than
0.75%. (If the error is greater than 0.75%, there may be a problem. See
the manual’s the troubleshooting section on page 3-1 for additional
help.)
(The numbering below is continued from the previous page.)
6. Press the Yes button to set the span.
7. Press the Run button (in the display not the keypad) to return the
Micro-Tech to the Run mode. Congratulations! You are now ready
to put your Micro-Tech into operation.
Performing Any Subsequent R-Cal

Once you have initialized your Micro-Tech and are doing an R-Cal as
part of your weekly, daily, or other routing testing, proceed as follows.
In the example screen above, the display shows that the established span
is just 0.01% different from the previous span, meaning that both spans
are essentially the same and the scale is performing consistently. This
error is below the critical threshold error of 0.5% (or 0.25% for a Model
9205 integrator). As a result, the span should not be changed. Record the
span results for future reference.
However, if the error is greater than 0.5% (0.25% for Model 9205
integrator), there may be a problem—see the manual’s troubleshooting
section in the following chapter for additional help. Record the span
results for future reference.
(The numbering below is continued from page 2-49.)
6. This is important! Press the No button (that is, do not change the
span) and the following screen appears. (Your numbers will, of
course, be different.)

Set-Up
SPAN # UNCHANGED
New span # 199980

Old span # 199980
RUN MENU ADV
7. Press the Run soft key in the display to return the Micro-Tech to the
Run mode.
8. Run several span calibrations to assess the repeatability of the

readings.

Set-Up
Controller Outputs
The belt-feeder controller output can be PID or PEIC control. PEIC

Controller control can be an analog output or time proportional “increase/decrease”
Outputs digital outputs.
Control Run The Control Run screen allows you to view the belt-feeder controller’s
setpoint, process variable, and controller action. From the Run screen,
Screen press the down-scroll key for access, or press the up-scroll key to return
to Reset Total or Run Menu. Pressing Run does not return to Main Run.
PV 000.0 Tph
cntrl 000.0 %
>+++
EDIT ADV
Here is a description of the functions available in this screen.

l Edit Button—The Edit key is only displayed when the variable in
line 2 of the screen is enterable.
l Advance Button—Pressing the Advance button accesses the

following functions.
l Control Output %—Controller output can be manually changed
from 0 to 100%, when the Auto/Manual selection is Manual.
l Setpoint—Setpoint can be entered from the controller front panel
when Local/Remote selection is Local.
l Error %—Indicates error in percentage between setpoint and
process variable.
l Bar Graph—The bar graph on line 3 displays process variable
and setpoint deviation. The bar’s resolution is 2%.

Chapter 3
Maintenance and
Troubleshooting
The maintenance information in this manual should meet your service

needs. If problems occur requiring technical assistance, please call 1-
800-445-3503 or the local Thermo contact listed in Chapter 4. Thermo
Scientific has a repair center located at our plant in Minneapolis,
Minnesota. Contact one of our technical representatives at
1-800-445-3503 for assistance or the local Thermo contact listed in
Chapter 4. To expedite your service request, please have your Micro-
Tech model, serial number, and belt-scale code available.
The Micro-Tech Integrator is a solid-state device and should require

Critical very little maintenance. The front panel can be wiped clean with a damp
Checkpoints cloth, and if necessary, a mild detergent (never use abrasive cleaners,
especially on the display window). As a preventative measure, check to
ensure all wires, plugs, and integrated circuits are tight in their
connectors. Also, keep the enclosure door tightly closed to prevent dirt
infiltration. More often than not, a quick visual inspection leads to the
source of trouble. If a problem develops, check the following before
proceeding to more specific troubleshooting procedures.
l Check Power
l Check the fuse.
l Check that the power switch is ON and that power is supplied to
the unit.
l Check Connections
l Check that all terminations are secure.
l Check to ensure the display, module, and keypad connectors are
firmly seated in their connectors.
l Check that all jumpers are in their correct position.

Maintenance and Troubleshooting
Frequently Asked Questions
Here is a list of frequently-asked questions (FAQs) to help you resolve

Frequently common problems and concerns about operating, calibrating, and
Asked maintaining your scale.
Questions
Question Answer
What is the best way to calibrate my The best way to calibrate your scale is to use the “Material Calibration”
scale? method. (For details, see the 9105/9205 Reference manual.) If, for
whatever reason, you cannot perform a Material Calibration on your scale,
you can run a number of “simulated-calibration” tests. For example, all
Micro-Techs can be calibrated using the “R-Cal” procedure, but you must
have purchased the optional equipment allowing you to run these simulated
tests.
How often should the zero and span As a general rule, if you make or receive payments based upon the weight
be calibrated? readings from your scale, the scale should be zeroed daily and the span
checked weekly.
• Your scale is only as good as the repeatability of your error on repeated
zero calibrations.
• The span should never change drastically, if the zero is properly
maintained.
If an external contractor is responsible for maintaining your scale, he or she

will establish an appropriate schedule for testing your scale’s zero and
span.
How often should I check the The scale should only need daily preventive-maintenance checks for
mechanical installation of the scale? material build up in critical areas, such as under the weigh idlers. The
exception to this is, when changes are made to the scale area—for
example, when the belt or idlers are replaced. The scale area includes not
only the weighbridge, but also the idlers that are shimmed with scale.
• A 10-20-1 scale system’s scale area includes +3 to -3 of scale.
• A 10-14-4 scale area includes +5 to –5. Any maintenance in this area
should be realigned, shimmed, and spaced to the proper specifications.
If in doubt, please contact Thermo Fisher Scientific for the correct
specifications.
Why do I need to see repeatability The repeatability of a scale is important for the accuracy of the scale. If the
during calibrations? scale cannot repeat tests within the scale’s percentage of accuracy, then
you should investigate why the scale is not repeating within the appropriate
tolerances.
Every time I complete a zero or span The only time you should change zero or span is on the initial, start-up test.
test and get a percentage of error, do I Press the “Yes” button to change the span. In any subsequent test, even
say “Yes” each time to change the when there is an error, press the “No” button—as any additional tests are
zero or span? for repeatability, which is a maintenance feature of calibrations.

Maintenance and Troubleshooting
Frequently Asked Questions
Question Answer
Can I put a 100 lb. weight on the The short answer is “No,” because a weight is not a rate.
weighbridge and see a reading of
100 lbs. in the Run screen?
The signal delivered by the load cell or cells, which represents the weight
per unit length of the belt (lbs./ft), is multiplied by the signal delivered by the
speed sensor, which represents the belt speed (ft/min). The result of this
operation is the instantaneous flow rate (lbs./ft x ft/min = lbs./min), which is
then multiplied by a suitable constant to obtain the value in the required
engineering units (kg/h, Tph, and so on). An adjustable damping filter is
provided separately for the displayed rate and current outputs.
What kind of information is available The programmable outputs are as follows.

from the digital output?
• Alarm cumulative • Low speed
• Shutdown cumulative • Totalization pulse (remote
• Ready counter)
• High load • Print ready
• Low load • Load weights
• High rate • Out of range
• Low rate • Deviation alarms
• High speed

Chapter 4
Service, Repair, and
Replacement Parts
Listed below is information about how to get help servicing, repairing,
and obtaining replacement parts for your Micro-Tech. In addition,
Thermo Fisher Scientific provides experienced, on-site service
technicians who can assist you with installing, setting up, calibrating,
maintaining, and repairing your Micro-Tech. They can also help you
train your operators and solve virtually any Micro-Tech-related problem.
For a detailed list of the spare parts available for your Micro-Tech,
Overview please see the Parts List in table 4–1 on page 4-4.
Before returning the Micro-Tech or any other equipment to Thermo

Fisher Scientific, you must contact your nearest Thermo Fisher
Scientific office for a Return Material Authorization (RMA) number,
which will authorize you to make the return. In addition, you will need
to complete the appropriate RMA Form, Product Information Sheet, and
Hazard Declaration Form before returning anything to Thermo Fisher
Scientific.
For more information about contacting Thermo Fisher Scientific, see

page 4-3.
The Return Material Authorization (RMA) form you will need before
RMA returning your Micro-Tech to Thermo Fisher.

Service, Repair, and Replacement Parts
Getting Ready to Order
The quickest way to get the parts you need for your Micro-Tech is to do
Getting Ready the following.
to Order
1. Identify the broken or faulty parts.
2. See whether the part is shown in table 4–1, which lists parts that may
need to be replaced. Note the part number from the table. If the part
is not listed in the table, contact Thermo Fisher Scientific directly (as
described in the following pages).
3. Before you contact Thermo Fisher Scientific for commonly needed

parts, make sure you have the following information ready.
l Your Micro-Tech serial number and belt-scale code.
l Your company’s purchase order (PO) number. Please note that a
hard copy of your PO is required before parts can be sent. In
addition, your PO must reflect the current and correct prices for all
parts ordered. So, please email or fax us your PO to expedite the
process.
l The date the parts are needed.
l Your preferred shipping method.
l A list of all the part numbers—together with descriptions and the
quantities needed.
4. Then contact Thermo Fisher Scientific by email, fax, or telephone—

as described on the following page.
WARNING. Major repairs and/or modifications to your Micro-Tech

must be performed by Thermo Fisher Scientific personnel. 

Contacting Thermo Fisher Scientific
Please verify and write down your Micro-Tech model number and serial
Contacting number before contacting us. Things will go a lot more quickly and
Thermo Fisher efficiently once we know this information.
Scientific
North America Brazil
1-800-445-3503 +55-11-2367-2192
1-763-783-2525 +55-11-2367-2192 fax
Service.bulk.us@thermofisher.com
parts.bulk.us@thermofisher.com
Germany Chile
+49 (0) 208-824930 +56 2 2378 5080
+49 (0) 208-852310 fax +56 2 2370 1082 fax
service.oberhausen@thermofisher.com
Italy China
+39 02-959514-1 +86 10-8419-3588
+39 02-953200-15 fax +86 10-8419-3580 fax
service.bulk.emea@thermofisher.com
Spain India
+34 91-484-5965 +91-22-4157-8800
+34 91-484-3597 fax +91-22-4157-8801 fax
United Kingdom Mexico

+44 (0) 1452-337800 +52 55 1253 9410
+44 (0) 1452-415156 fax +52 55 1253 9424 fax
Australia South Africa

+61 (0) 8 8208-8200 +27 (0) 11-609-3101
+61 (0) 8 8234-3772 fax +27 (0) 11-609-3110 fax
service.auadl@thermofisher.com

Parts List
Here is the parts list for your Micro-Tech.

Parts List
Table 4–1. Micro-Tech Parts List
Description Part Number
PCBA,MOTHERBOARD,MT9105 127654
DISPLAY,LCD,6 DIGIT,QVGA,MT9000 100775
PCBA,HMI BOARD,MT9000 100802
CONN,PWR,3POS,3.81MM,HDR,M 100781
POWER SUPPLY,SGL, 24V, 3.2A 100755
CABLE,USB,M/F,2.0,1.6FT,PNL MT 100792
PCBA, ANALOG I/O BOARD, MT9000 102949
PCBA, 4-20MA OUTPUT BD, 1 CH, MT9000 100744
PCBA, DC INPUT BD, MT9K 100785
PCBA, PLANT A/D BD, MT9000 102450
PCBA, OPTO-22 INPUT, MT9000 102999
PCBA, OPTO-22 OUTPUT BD, MT9000 103003
PCBA, RELAY OUTPUT BD, MT9000 102479
PCBA, COMM BOARD, MT2K/9K 102942
PCBA,PREMIUM A/D BD,MT-9000 100766
PCBA,PROFIBUS BD,MT2000/MT9000 102936
PCBA, DIO, 8IN / 8OUT 103017
MODULE,POWER,IN,140VAC, G4- 5 038014
MODULE,POWER,IN,280VAC, G4- 5 050480
MODULE,POWER,IN, 32VDC, G4- 5 044551
MODULE,POWER,OUT,240VAC, G4- 5 037289
MODULE,POWER,OUT, 60VDC, G4- 5 039669
MODULE,POWER,OUT,DRY,N/O,G4- 5 044552
FUSE, FAST-BLOW, 2A, 250V, 5X20MM 103190
DRIVE,FLASH,USB 2,4GB,BRANDED 112183

Appendix A
Additional Installation
Information
The following page shows a copy of a typical System Data Sheet for the
System Data Micro-Tech.
Sheet
Thermo Fisher Scientific Micro-Tech 9105/9205 User Manual, Rev E A-1

A-2 Micro-Tech 9105/9205 User Manual, Rev E Thermo Fisher Scientific
Here is a copy of a typical Door Label for the Micro-Tech.
Door Label

Here are the belt-scale codes for all Thermo Fisher Scientific scales (also
Belt-Scale known as “weigh-bridges”) manufactured by Thermo Fisher Scientific
Codes as of May 2012.
Table A–1. List of Belt-Scale Codes

An explanation of the abbreviations used in the table’s header (such as LA, LB, and so on, which relate to the
conveyor measurements you made in the “Acquiring Basic System Data” section of the manual on page 2-5)
are shown at the end of the table. Also listed at the end of the table are the units of measure for the numbers
shown in the table below.
# Load Cells
# Idlers
Belt
LB1
LB2
LB3
LB4
LB5
LB6
LA
Scale Scale Belt Calibr. mV/

Code Model Width Kit LC LD LE LF LG V
1 10-20-1 18-36 50-34 1 1 32 24 0 0 0 0 0 24 36 0 6.5 6.5 3
2 10-20-1 42-72 50-34 1 1 32 22.75 0 0 0 0 0 22.75 36 0 6.5 7 3
3 10-20-1 24-36 50-34 2 1 32 24 0 0 0 0 0 24 36 0 6.5 6.5 3
4 10-20-1 42-84 50-34 2 1 32 22.75 0 0 0 0 0 22.75 36 0 6.5 7 3
5 10-20-2 50-34 1 2 36 18 18 0 0 0 0 18 36 0 6.5 7 3
6 10-20-2 50-34 1 2 48 24 24 0 0 0 0 24 48 0 6.5 7 3
7 10-20-1 18-36 50-30 1 1 32 24 0 0 0 0 0 38 36 4.5 6.5 6.5 3
8 10-20-1 42-72 50-30 1 1 32 22.75 0 0 0 0 0 38 36 4.5 6.5 7 3
9 10-20-2LC 24-36 50-30 2 1 32 24 0 0 0 0 0 42.5 36 4.5 6.5 6.5 3
10 10-20-2LC 42-84 50-30 2 1 32 22.75 0 0 0 0 0 42.5 36 4.5 6.5 7 3
11 10-22 18-36 50-30 1 2 62 54 18 0 0 0 0 38 36 4.75 6.5 6.5 3
12 10-22 18-36 50-30 1 2 71 63 21 0 0 0 0 42 42 4.75 6.5 6.5 3
13 10-22 18-36 50-30 1 2 80 72 24 0 0 0 0 48 48 4.75 6.5 6.5 3
14 10-22 42-48 50-30 1 2 62 52.75 16.75 0 0 0 0 36 36 4.75 6.5 7 3
15 10-22 42-48 50-30 1 2 71 61.75 19.75 0 0 0 0 42 42 4.75 6.5 7 3
16 10-22 42-48 50-30 1 2 80 70.75 22.75 0 0 0 0 48 48 4.75 6.5 7 3
17 10-22 18-36 50-30 1 2 62 54 18 0 0 0 0 68 36 4.5 6.5 6.5 3
18 10-22 18-36 50-30 1 2 71 63 21 0 0 0 0 77 42 4.5 6.5 6.5 3
19 10-22 18-36 50-30 1 2 80 72 24 0 0 0 0 86 48 4.5 6.5 6.5 3
20 10-22 42-48 50-30 1 2 62 52.75 16.75 0 0 0 0 68 36 4.5 6.5 7 3
21 10-22 42-48 50-30 1 2 71 61.75 19.75 0 0 0 0 77 42 4.5 6.5 7 3
22 10-22 42-48 50-30 1 2 80 70.75 22.75 0 0 0 0 86 48 4.5 6.5 7 3
23 10-22 18-36 50-34 1 2 62 64 18 0 0 0 0 54 36 0 6.5 6.5 3
24 10-22 18-36 50-34 1 2 71 63 21 0 0 0 0 63 42 0 6.5 6.5 3
25 10-22 18-36 50-34 1 2 80 72 24 0 0 0 0 84 48 0 6.5 6.5 3
26 10-22 42-48 50-34 1 2 62 52.75 16.75 0 0 0 0 66 36 0 6.5 7 3
27 10-22 42-48 50-34 1 2 71 61.75 19.75 0 0 0 0 75 42 0 6.5 7 3
28 10-22 42-48 50-34 1 2 80 70.75 22.75 0 0 0 0 84 48 0 6.5 7 3
29 10-20-WF BAR 1 1 32 24 0 0 0 0 0 24 30 -2 4 4 3
30 10-20-WF BAR 1 1 32 22.75 0 0 0 0 0 22.75 30 -2 4 4 3
31 10-20-WF BAR 1 1 32 24 0 0 0 0 0 36 30 2 4 4 3
32 10-20-WF BAR 1 1 32 22.75 0 0 0 0 0 36 30 2 4 4 3
33 10-17-2 50-17 2 2 64 54 18 0 0 0 0 36 36 -4.75 6.5 7 3
34 10-17-2 50-17 2 2 76 63 21 0 0 0 0 42 42 -4.75 6.5 7 3

# Load Cells
# Idlers
Belt
LB1
LB2
LB3
LB4
LB5
LB6
LA
35 10-17-2 50-17 2 2 88 72 24 0 0 0 0 48 48 -4.75 6.5 7 3
36 10-17-2 50-17 2 2 76 63 23.62 0 0 0 0 43.31 39.37 -4.75 6.5 7 3
37 10-17-2 50-17 2 2 88 72 24.75 0 0 0 0 48.38 47.24 -4.75 6.5 7 3
38 10-17-4 50-17 2 4 64 54 18 54 18 0 0 36 36 0 0 0 3
39 10-17-4 50-17 2 4 76 63 21 63 21 0 0 42 42 0 0 0 3
40 10-17-4 50-17 2 4 88 72 24 72 24 0 0 48 48 0 0 0 3
41 10-17-4 50-17 2 4 66 63 23.62 63 23.62 0 0 43.31 39.37 0 0 0 3
42 10-17-4 50-17 2 4 88 72 24.75 72 24.75 0 0 48.31 47.24 0 0 0 3
43 10-14-3 50-14 4 3 0 0 0 0 0 0 0 0 36 0 0 0 3
44 10-14-3 50-14 4 3 0 0 0 0 0 0 0 0 42 0 0 0 3
45 10-14-3 50-14 4 3 0 0 0 0 0 0 0 0 48 0 0 0 3
46
47 10-14-4 50-14 4 4 0 0 0 0 0 0 0 0 36 0 0 0 3
48 10-14-4 50-14 4 4 0 0 0 0 0 0 0 0 42 0 0 0 3
49 10-14-4 50-14 4 4 0 0 0 0 0 0 0 0 48 0 0 0 3
50 10-14-4 50-14 4 4 0 0 0 0 0 0 0 0 54 0 0 0 3
51 10-14-4 50-14 4 4 0 0 0 0 0 0 0 0 39.37 0 0 0 3
52 10-14-4 50-14 4 4 0 0 0 0 0 0 0 0 47.24 0 0 0 3
53 10-30 50-30 1 1 0 0 0 0 0 0 0 0 36 0 0 0 1.8
54 10-11 18-42 WTS 1 1 55.50 48 0 0 0 0 0 40 36 6.5 6.5 6.5 3
55 10-11 48-72 WTS 1 1 56.50 48 0 0 0 0 0 40 36 7 7 7 3
56 10-12 WTS 1 2 66 48 48 0 0 0 0 40 36 7 7 7 3
57 10-17-2D 50-17 2 2 40 24 24 0 0 0 0 24 48 0 6.5 7 3
58 10-17-2D 50-17 2 2 34 21 21 0 0 0 0 21 42 0 6.5 7 3
59 10-17-2D 50-17 2 2 28 18 18 0 0 0 0 18 36 0 6.5 7 3
60
101 1 1 32 24 0 0 0 0 0 40 36 -4.5 6.5 7 3

102 1 2 68 24 60 0 0 0 0 76 36 -4.5 6.5 7 3
103 1 1 32 24 0 0 0 0 0 24 36 1.5 3.5 4.3 3
104
105 1 2 56 18 48 0 0 0 0 64 30 -4.5 6.5 7 3
106 1 2 68 24 60 0 0 0 0 76 36 -4.5 6.5 7 3
107 1 2 74 24 66 0 0 0 0 82 42 -4.5 6.5 7 3
108 1 2 80 24 72 0 0 0 0 88 48 -4.5 6.5 7 3
109
110 1 2 70.87 23.62 62.99 0 0 0 0 78.74 39.37 -4.5 6.5 7 3
111 1 2 78.74 23.62 70.87 0 0 0 0 86.61 47.24 -4.5 6.5 7 3
112 1 2 90.55 23.62 82.68 0 0 0 0 98.43 59.06 -4.5 6.5 7 3
113
114 2 2 60.5 16.5 49.5 0 0 0 0 71.5 33 -4.5 6.5 7 3
115 2 2 66 18 54 0 0 0 0 78 36 -4.5 6.5 7 3
116 2 2 73.31 20 60 0 0 0 0 86.62 40 -4.5 6.5 7 3
117 2 2 77 21 63 0 0 0 0 91 42 -4.5 6.5 7 3
118 2 2 88 24 72 0 0 0 0 104 48 -4.5 6.5 7 3
119 2 2 99 27 81 0 0 0 0 117 54 -4.5 6.5 7 3

# Load Cells
# Idlers
Belt
LB1
LB2
LB3
LB4
LB5
LB6
LA
120 2 2 110 30 90 0 0 0 0 130 60 -4.5 6.5 7 3
121
122
123 2 2 72.17 19.69 59.06 0 0 0 0 85.28 39.37 -4.5 6.5 7 3
124 2 2 86.61 23.62 70.87 0 0 0 0 102.36 47.24 -4.5 6.5 7 3
125
126
127
128
129
130 2 4 58.12 16.5 49.5 16.5 49.5 0 0 58.12 33 -4.5 6.5 7 3
131 2 4 64.12 18 54 18 54 0 0 64.12 36 -4.5 6.5 7 3
132 2 4 72.12 20 60 20 60 0 0 72.12 40 -4.5 6.5 7 3
133 2 4 76.12 21 63 21 63 0 0 76.12 42 -4.5 6.5 7 3
134 2 4 88.12 24 72 24 72 0 0 88.12 48 -4.5 6.5 7 3
135 2 4 100.12 27 81 27 81 0 0 100.1 54 -4.5 6.5 7 3
136 2 4 112.12 30 90 30 90 0 0 112.1 60 -4.5 6.5 7 3
137
138
139 2 4 70.87 19.69 59.06 19.69 59.06 0 0 70.87 39.37 -4.5 6.5 7 3
140 2 4 86.61 23.62 70.87 23.62 70.87 0 0 86.61 47.24 -4.5 6.5 7 3
201 1 1 31.89 24.02 0 0 0 0 0 24.02 39.37 - 6.38 4.92 3

16.81
202 1 1 31.89 24.02 0 0 0 0 0 24.02 39.37 - 4.41 4.92 3
16.81
203 1 1 31.89 24.02 0 0 0 0 0 24.02 19.69 - 6.38 4.92 3
16.81
204 1 1 31.89 24.02 0 0 0 0 0 24.02 19.69 - 4.41 4.92 3
16.81
205 2 1 31.89 24.02 0 0 0 0 0 24.02 39.37 - 6.38 4.92 3
16.81
206 2 1 31.89 24.02 0 0 0 0 0 24.02 39.37 - 4.41 4.92 3
16.81
207 1 2 31.89 24.02 24.02 0 0 0 0 24.02 39.37 - 6.38 4.92 3
16.81
208 2 2 31.89 24.02 24.02 0 0 0 0 24.02 39.37 - 6.38 4.92 3
16.81
209 1 1 0 0 0 0 0 0 0 0 39.37 0 0 0 2
210 1 1 0 0 0 0 0 0 0 0 23.62 0 0 0 2
211 2 1 0 0 0 0 0 0 0 0 47.24 0 0 0 2
212 4 4 0 0 0 0 0 0 0 0 39.37 0 0 0 2
213 4 3 0 0 0 0 0 0 0 0 39.37 0 0 0 2
214 10-101R-1 50-30 1 1 0 0 0 0 0 0 0 0 39.37 0 0 0 2
215 10-101R-2 50-30 2 1 0 0 0 0 0 0 0 0 39.37 0 0 0 2
301 1 1 39.37 31.50 0 0 0 0 0 25.59 39.37 -6.42 5.43 5.31 3

302 1 1 39.37 31.50 0 0 0 0 0 25.59 47.24 -6.42 5.43 5.31 3
303 1 1 39.37 31.50 0 0 0 0 0 25.59 39.37 -8.39 7.40 6.30 3

# Load Cells
# Idlers
Belt
LB1
LB2
LB3
LB4
LB5
LB6
LA
304 1 1 39.37 31.50 0 0 0 0 0 25.59 47.24 -8.39 7.40 6.30 3
305 2 1 39.37 31.50 0 0 0 0 0 25.59 39.37 -8.39 7.40 7.72 3
306 2 1 39.37 31.50 0 0 0 0 0 25.59 47.24 -8.39 7.40 7.72 3
307 1 2 39.37 31.50 31.50 0 0 0 0 46.46 39.37 0 0 0 3
308 1 2 39.37 31.50 31.50 0 0 0 0 46.46 47.24 0 0 0 3
309 1 2 39.37 31.50 31.50 0 0 0 0 46.46 39.37 0 0 0 3
310 1 2 39.37 31.50 31.50 0 0 0 0 46.46 47.24 0 0 0 3
311 2 2 39.37 31.50 31.50 0 0 0 0 46.46 39.37 0 0 0 3
312 2 2 39.37 31.50 31.50 0 0 0 0 46.46 47.24 0 0 0 3
313 4 4 0 0 0 0 0 0 0 0 39.37 0 0 0 3
314 1 1 0 0 0 0 0 0 0 0 39.37 0 0 0 2
315 2 1 0 0 0 0 0 0 0 0 39.37 0 0 0 2
401 1 2 49.21 29.53 68.90 0 0 0 0 49.21 39.37 4.06 4.17 4.72 3

402 2 2 49.21 29.53 68.90 0 0 0 0 49.21 39.37 4.06 4.17 4.72 3
403 1 1 39.37 29.53 29.53 0 0 0 0 29.53 39.37 4.06 4.17 4.72 3
404
405 2 1 0 0 0 0 0 0 0 0 39.37 0 0 0 2
406 4 2 0 0 0 0 0 0 0 0 39.37 0 0 0 3
407 4 3 0 0 0 0 0 0 0 0 47.24 0 0 0 3
408 4 4 0 0 0 0 0 0 0 0 39.37 0 0 0 3
409 4 6 0 0 0 0 0 0 0 0 39.37 0 0 0 3
410 1 1 0 0 0 0 0 0 0 0 39.37 0 0 0 2
501 1 1 31.50 23.62 0 0 0 0 0 23.62 39.37 0 0 0 3

502 1 1 31.50 22.64 0 0 0 0 0 22.64 39.37 0 0 0 3
503 1 2 43.31 23.62 23.62 0 0 0 0 23.62 39.37 0 0 0 3
504 2 4 70.87 19.69 59.06 19.69 59.06 0 0 0 39.37 0 0 0 3
505 4 4 0 0 0 0 0 0 0 0 39.37 0 0 0 3
601 1 1 0 0 0 0 0 0 0 0 39.37 0 0 0 2
602 1 1 31.89 24.02 0 0 0 0 0 24.02 39.37 0 0 0 3
603 2 1 31.89 24.02 0 0 0 0 0 24.02 39.37 0 0 0 3
604 1 1 23.62 17.72 0 0 0 0 0 17.72 39.37 0 0 0 3
605 1 2 39.37 19.69 19.69 0 0 0 0 19.69 39.37 0 0 0 3
606 2 2 39.37 19.69 19.69 0 0 0 0 19.69 39.37 0 0 0 3
607 1 2 39.37 19.69 19.69 0 0 0 0 19.69 39.37 0 0 0 3
608 2 4 66.93 59.06 19.69 59.06 19.69 0 0 72.83 39.37 0 0 0 3
609 4 4 0 0 0 0 0 0 0 0 39.37 0 0 0 3
610 4 5 0 0 0 0 0 0 0 0 39.37 0 0 0 3
611 4 6 0 0 0 0 0 0 0 0 39.37 0 0 0 3
See next page for additional information

List of Abbreviations and Units of Measure Used in the Table
Unit of For more information, see

Abbreviation Explanation Measure the following figures
Belt width — inches —
LA Pivot-to-load-cell distance inches Figure 2–1
LB Pivot-to-n-idler distance inches Figure 2–3
(where n = 1st, 2nd, 3rd, ...n idler)
LC Pivot-to-test-weight length inches Figure 2–5
LD Idler spacing inches Figure 2–8
LE Pivot-to-test-weight height inches Figure 2–4
LF Pivot-to-carriage height inches Figure 2–6
LG Roller-to-stringer height inches Figure 2–7
mV/V Load-cell sensitivity millivolts/volt Figure 2–10
This procedure calibrates the belt to the system and establishes a test
Establishing duration for all the simulated calibrations. A test duration can be
Belt-Length- acquired or entered manually. Acquiring a test duration is described
below. Manual entry of the test duration is described on page 2-37.
Test Duration
Acquire Test There are two methods to acquire the test duration—the Full and Partial
methods. The Partial (belt-length measurement) method allows you to
Duration acquire the test duration without measuring the entire length of the belt.
This method, however, should only be used when the belt length exceeds
1,000 feet. In addition, using the Partial method may be less accurate
than using the Full method. Zero and span calibrations are the most
accurate when using complete passes of the belt.

Partial Belt- The partial belt-length method should only be used if the belt is longer
than 1,000 feet.
Length Method
Pressing the Abort button at anytime returns you to the “Cal Data
Scroll 12” screen shown below.

Establish test
duration
ACQ MANUAL
To use the partial belt-length method, do the following.
1. Press the Acquire button and the following screen appears.
ACQUIRE TEST DUR

Choose belt length
measuring method
FULL PARTIAL
2. Mark and measure a section of the belt. The section you mark must
be longer than 200 feet.

3. Press the Partial button and the following screen appears.
Ent. len. between

two marks on belt.
Length 200.0 ft
EDIT ABORT
4. Press the Edit button and use the keypad to enter the actual length of
the section you marked. (The default value is 200 feet.)
5. Press the Enter button. (We entered 300 feet.)
Ent. len. between

two marks on belt.
Length 300 ft
EDIT ABORT
6. Press the Start button.
Start belt. Press

START when 1st mark
passes reference.
START ABORT

7. Press the Count button each time a reference mark passes.
Press COUNT each

time a mark passes.
1 sec 0 rev
COUNT ABORT DONE
8. Continue to press the Count button when a mark passes, until the
following two conditions are met.
l The belt has made at least three complete revolutions.
l The total running time of the test exceeds six minutes.
Press COUNT each

time a mark passes.
120 sec 1 rev
COUNT ABORT DONE
9. After the last revolution has been counted, press the Done button.
TEST DURATION
Length = 600.0 ft
Time = 360 sec
EXIT

Full Belt-Length Use this method for belts that are shorter than 1,000 feet. In addition,
note that pressing the Abort button at anytime returns you to the “Cal
Method Data Scroll 12” screen shown below.

Establish test
duration
ACQ MANUAL
To use the full belt-length method, do the following.
1. Make a chalk mark on the belt.
2. Press the Acquire button and the following screen appears.
ACQUIRE TEST DUR

Choose belt length
measurement method
FULL PARTIAL

3. Press the Full button.
Ent. len. of
one belt revolution.
Length 1000.0 ft
EDIT ABORT
4. Press the Edit button and use the keypad to enter the entire length of
the belt. Then press the Enter button.
Ent. len. of
one belt revolution.
Length ft
ENTER ABORT CLEAR
5. Press the Start button.
Start belt. Press

START when 1st mark
passes reference.
START ABORT
6. Press the Count button each time the reference mark passes.

Press COUNT each

time a mark passes.
1 sec 0 rev
COUNT ABORT DONE
7. Continue to press the Count button when the mark passes, until the
following two conditions are met.
l The belt has made at least three complete revolutions.
l The total running time of the test exceeds six minutes.
Press COUNT each

time a mark passes.
120 sec 1 rev
COUNT ABORT DONE
8. After the last revolution is counted, press the Done button.
TEST DURATION
Length = 1000 ft
Time = 360 sec
EXIT

When the possibility exists that multiple calibration methods are
Material available, one must be selected to achieve a span number. All other
Factoring calibration methods should be material factored to the proven span
number.
Calibration Method Availability

R-Cal Built-in
Static weights Optional item
Test chain Optional item
Other Material Factoring—pre- or post-
weighed material. (User supplied.)
Since all Micro-Tech models are equipped with R-Cal, this example will
assume an R-Cal span #. It then will factor the static weights to the R-
Cal span number. Other factoring is similar and not shown.
Reset Weight To reset the existing weight material factor, do the following.
Factor
1. Press the Menu button twice to bring up “Main Menu 2.”
- MAIN MENU 2 -
Press MENU for more
SCALE CALIB
DISPLAY DATA DATA

2. Press the Calibration Data button and the following screen appears.
- START OF SCROLL -
Use SCROLL keys to view
selections.
3. Press the down-arrow button repeatedly until the “Cal Data Scroll
10” screen appears.

Material FACTOR
R-Cal x.xx %
EDIT NEXT
4. Press the Next button and the Weights screen appears.

Material FACTOR
Weights x.xx %
EDIT NEXT

5. Press the Edit button.

Material FACTOR
Weights x.xx %
EDIT +/– . CLEAR
6. Use the keypad to enter a zero value (0) for Weights. Then press the
Enter button. Your screen will now look like this.

Material FACTOR
Weights 0 %
EDIT +/– . CLEAR
Static Weight The auto-span procedure determines the percent static-weight span-
error.
1. Press the Menu button to bring up the “Main Menu 1” screen.
- MAIN MENU 1 -
Press MENU for more
ZERO SPAN MATL

CAL CAL CAL

2. Press Span button and the following screen appears.
AUTO SPAN Weights

Press START to begin
Weight calibration
START EXIT MANUAL
Auto Span The auto-span procedure determines the percent of scale weight span
error.
1. Add your test weight to the conveyor.
AUTO SPAN Weights

Apply weights then
press START
START EXIT

2. Press the Start button and the following screen appears.
AUTO SPAN Weights

Run belt, then
press START
START EXIT
3. Make sure the belt is running empty, then press the Start button. The
following Auto Spanning screen appears.
AUTO SPANNING
Time remaining 360
Rate xxx.x Tph
Tot xx.xx Tons
ABORT
4. When the Auto Span procedure is completed, the span percent-error

is displayed.
Record Results Record the results and note whether the error is positive or negative.
AUTO SPAN COMPLETE

Change Span?
Error x.xx %
YES NO ADV

1. Press the No button (meaning you do not want to change the span),
and the following screen appears.
SPAN UNCHANGED
New span # xxxxxx
Old span # xxxxxx
RUN REPEAT ADV
2. Press the Run button and the following screen appears.
Remove weight
before returning to
normal operation ! !
RUN NO ADV
3. Press the Run button and the Micro-Tech Run screen reappears, as
shown below.
xxxxx.x Tons
xxx.x Tph
TOTALS

4. Press the Menu button twice to bring up the “Main Menu 2” screen.
- MAIN MENU 2 -
Press MENU for more
SCALE CALIB
DISPLAY DATA DATA
5. Press the down-arrow button and the Material Factor screen appears.

Material FACTOR
R-Cal x.xx %
EDIT NEXT
6. Press the Next button and the Weights screen appears.

Material FACTOR
Weights x.xx %
EDIT NEXT

7. Press the Edit button and use the keypad to enter the weight error.
Then press the Edit button. The error you entered is displayed in the
screen below.

Material FACTOR
Weights x.xx %
ENTER +/– CLEAR
8. Press the Run button and the Micro-Tech Run screen reappears, as
shown below.
xxxxx.x Tons
xxx.x Tph
TOTALS

The terminal-block definitions for the motherboard are shown below.
Motherboard
Terminal Block
Definitions
J16 J21 J45 J37 J29

1 2 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 31 32 33 34 35 36 37 38 41 42 43 44 45 46 47 48
LOADCELL 1 LOADCELL 2 COMM B COMM A SPU and

PULSE OUT
J16 Load Cell 1

1 SHIELD (EARTH)
2 + EXCITATION
3 – EXCITATION
4 + SENSE
5 – SENSE
6 + SIGNAL
7 – SIGNAL
J21 Load Cell 2

11 SHIELD (EARTH)
12 + EXCITATION
13 – EXCITATION
14 + SENSE
15 – SENSE
16 + SIGNAL
17 – SIGNAL

J45 COMM B (Non-isolated RS-485)
21 RS-485 Z TX -
22 RS-485 Y TX +
23 RS-485 A RX +
24 RS-485 B RX -
25 COMMON
26 SHIELD (EARTH)
J37 COMM A (Isolated RS-485/232)

31 RTS/-485 OUT
32 TXD/+485 OUT
33 RXD
34 +485 IN
35 –485 IN
36 CTS/DCO
37 UART GND (ISOLATED)
38 SHIELD (EARTH)
J29 Speed signal (SPU) input and Output #5

41 +24VDC
42 SIGNAL 1 (SPU)
43 COMMON
44 SHEILD (EARTH)
45 SIGNAL 2 (SPU)
46 24VDC POWER
47 OUTPUT #5 (24V) (OPEN-DRAIN)
48 COMMON

Premium A/D The terminal block definitions for the Premium A/D Board are shown
below. (Model 9205 Micro-Tech only.)
Terminal Block
Definitions
J9 Premium A/D Load Cell
1 Shield (Earth GND)
2 Signal COM
3 + Excitation (+5v)
4 - Excitation (-5v)
5 + Excitation Sense
6 - Excitation Sense
7 + Load Cell Signal
8 - Load Cell Signal

Here are the jumper locations the Micro-Tech motherboard.
Motherboard
Jumper
Locations

Premium A/D Here are the Load Cell jumper locations of the Premium A/D board
(Model 9205 Micro-Tech only.)
Jumper
Locations

Here are the jumper settings for the Micro-Tech Motherboard.
Motherboard
Jumper
Settings
Load-Cell Interrupt Selection Jumper
Jumper Jumper Settings Default
Jumper Setting Description

Pins 1-2 Load Cell IRQ 1
J8 J8 Not Installed
Load-Cell Sense Selection Jumpers


J14 J14 1-2 Installed
Pins 1-2 Local Sense Channel 1
Pins 2-3 Remote Sense Channel 1
Not Installed Remote Sense Channel 1
J17 Optional R-CAL resistor Channel 1 Not Installed

Pins 1-2 Local Sense Channel 2
Pins 2-3 Remote Sense Channel 2
Not Installed Remote Sense Channel 2
J22 Optional R-CAL resistor Channel 2 J22 Not Installed

Speed-Input and Output #5 Jumpers
Speed input 1
J24
Jumper Setting Description J24 Installed
J25
Installed Local 24V Power J25 Installed
Not Installed Remote Power

Speed input 2 & Output #5
J26 Jumper Setting Description J26 Installed

J27 Installed Local 24V Power J27 Installed
Not Installed Remote Power

J28 Speed input 1 cutoff, J30 Speed input 2 cutoff
J28 J28 Installed 1-2
Pins 1-2 Speed Input Cut-off 13kHz
Pins 2-3 Speed Input Cut-off 425 Hz
Not Installed Speed Input Cut-off 13kHz
UART Configuration Jumpers

COMM A, (UART 0)
J34 Jumper Setting Description J34 Installed 1-2

Pins 1-2 RS-485 Normal Operation
Pins 2-3 RS-485 Multi-Drop Operation
COMM A, (UART 0)
J35 Jumper Setting Description J35 Installed Pins 1-2

J36 Pins 1-2 RS-232 Mode J36 Installed Pins 1-2
J39 Pins 2-3 RS-485 Mode J39 Installed Pins 1-2
Not Installed RS-232 Mode

COMM A, (UART 0)
Pins 1-2 RS-485 Receive  U0RXD
Pins 2-3 RS-485 Receive  U0CTS

COMM A Termination, (UART 0)
J40 Pins 1-2 Enable RS-485 Termination J40 Installed 3-4
Pins 3-4 Disable RS-485 Termination
Not Installed Disable RS-485 Termination
Jumper Setting Description J41 Installed
J41
Pins1-2 Enable RS-485 Termination

Pins1-2 1.2kΩ termination enable
Pins 2-3 600Ω Bias Enabled
Not Installed No additional termination
UART Configuration Jumpers (continued)

COMM B Termination, (UART 2)
J46 Jumper Setting Description J46 Not Installed
Installed 120Ω term nation

Premium A/D Here are the jumper settings for the Premium A/D board. (Model 9205
Micro-Tech only.)
Jumper
Settings
Premium A/D Board Load-Cell Excitation Sense


J2 J2 1-2 Installed
Pins 1-2 Local sensing (4-wire LC)
J3 J3 1-2 Installed
Pins 2-3 Remote sensing (6-wire LC)
Not Installed Remote sensing (6-wire LC)
Load-cell sense is controlled by selectable jumpers (J14 and J15 for

A/D Jumpers— channel 1, and J19 and J20 for channel 2) located on the motherboard
Load-Cell Sense and by jumpers (J2 and J3) on the Premium A/D Board. The jumpers
should be in position “1-2” local sense, if the distance is less than 200
feet between the load cell and the Micro-Tech. For distances greater than
200 feet and less than 3,000 feet, the jumper should be in position “2-3”
and a special 6-wire cable is required. Refer to the field wiring diagram
that is appended to this manual, for jumper requirement in the scale
junction box.

Load-Cell Table A–2. Motherboard Load-Cell Technical Specifications
(Model 9105)
Specifications
Load Cell Excitation Power Supply 5 VDC ±10%, 90 mA, minimum load impedance (58 ohms).
Output short circuit, 0.5 A maximum.
Load Cell Number: Up to six (6) 350-ohm load cells in parallel. Cable
distance: 200ft [61m] or less without sense, or 3000ft [914m]
with sense.
Load cell input circuits
Sensitivity: 0.5mV/V to 3.5 mV/V (keypad selectable).
(2 each)
Input Impedance: 1M-ohm minimum.
Maximum Usable Signal: 114% of 3mV/V.
Internal A/D counts: (3mV/V): 6,440,000.
Isolation: Non-isolated.
Max non-destructive input voltage: ± 6 V relative to ground.
Load Cell Cable Shield: Connected to earth ground.
Load Cell 4 wire system: cable distance not exceed 200ft [61m].
6 wire system: cable distance not to exceed 3000ft [914m].
Excitation-Sense Circuitry Nominal input voltage: 5 VDC.
(2 each) Input impedance: 100 k-ohm minimum.
Jumper selectable: Local or remote sense.
Table A–3. Premium A/D Board Load-Cell Technical

Specifications (Model 9205)
Load Cell Excitation Power Supply ±5 VDC ±5%, 180 mA, minimum load impedance (58 ohms).
Output short circuit, 0.5 A maximum.
Load Cell Number: Up to six (6) 350-ohm load cells in parallel. Cable
distance: 200ft [61m] or less without sense, or 3000ft [914m]
with sense.
Sensitivity: 0.5mV/V to 3.5 mV/V (keypad selectable).
Load cell input circuit Input Impedance: 1M-ohm minimum.
Maximum Usable Signal: 114% of 3mV/V.
Internal A/D counts: (3mV/V): 7,341,000.
Isolation: Non-isolated.
Max non-destructive input voltage: ± 6 V relative to ground.
Load Cell Cable Shield: Connected to earth ground.
Load Cell 4 wire system: cable distance not exceed 200ft [61m].
6 wire system: cable distance not to exceed 3000ft [914m].
Excitation-Sense Circuitry Nominal input voltage: ±5 VDC.
Input impedance: 100 k-ohm minimum.
Jumper selectable: Local or remote sense.

Table A–4. Speed Sensor Specifications
Speed Sensor
Specifications
Minimum required for scale use 1000 pulse/minute at nominal belt speed.

The Micro-Tech has provision for up to 21 programmable digital inputs
Programmable and 21 programmable digital outputs. Motherboard I/O includes two
Digital speed inputs and one digital pulse output. Optional I/O includes three
Inputs/Outputs programmable inputs and four programmable outputs. Optional DIO
boards can be added, if additional I/O is required.
l Digital Inputs
l Two (2) speed (DC) inputs on the motherboard. (See the
Specifications in chapter 1.)
l Three (3) programmable dry-contact inputs on the optional DC
Input Board, or three (3) programmable opto-22 inputs modules
on the optional Opto22 Input Board.
l Eight (8) programmable inputs on the optional Digital I/O
8in/8out Board. Two of these boards may be installed for a total
of sixteen (16) inputs.
l Digital Outputs
l One (1) Digital Pulse Output on the motherboard. (See the
Specifications in chapter 1.)
l Four (4) programmable relay outputs on the optional Relay
Output Board, or four (4) programmable opto-22 output modules
on the optional Opto22 Output Board.
l Eight (8) programmable outputs on the optional Digital I/O
8in/8out Board. Two of these boards may be installed for a total
of sixteen (16) outputs.

Digital Input The board options are as follows.
Expansion l DC Input Board
Boards or
l Opto-22 Input Board
Install in expansion slot J6 on the motherboard. Use UL 1015 wire,

16AWG / 1 sq.mm or smaller
DC Input Board This is an optional board with three inputs (inputs #3–5).
Type: Current sourcing to common ground. Designed for dry-contact
input. Rated: 24VDC, 5mA typical. Input function is assigned by user.
Part number = 100785

Opto22 Input This is an optional board with three inputs (inputs #3–5). The module
options are as follows.
Board
l 240VAC In Module (G4IAC5A)

l Input voltage range: 180-280 VAC or VDC.
l Input current at maximum line: 5mA.
l 120VAC In Module (G4IAC5)

l Input voltage range: 90-140 VAC or VDC.
l 32VDC In Module (G4IDC5)

l Input voltage range: 10-32VDC; 12-32VAC.
Install in slots U1–U3 on the input board.

The board options are as follows.
Digital Output
Relay Output Board
Expansion l
or
Boards
l Opto-22 Output Board
Install in expansion slot J7 on the motherboard. Use UL 1015 wire,

16AWG / 1 sq.mm or smaller.
Relay Output This is an optional board.

Board l Four (4) outputs (outputs #1–4)
l Panel version
l Rated: 33 VAC at 2A. Fusing requirement: 3A.
l Rated: 70 VDC at 0.5A. Fusing requirement: 1A.
l Field version
l Rated: 240 VAC at 3A. Fusing requirement:5A.
l Rated: 70 VDC at 0.5A. Fusing requirement 1A.

Opto22 Output This is an optional board. There are four (4) outputs (outputs #1–4).
Modules are installed in slots U2–U5 on the output board. One spare
Board fuse is located on the output board. The module options are as follows.
l 240VAC Out Module, G4OAC5A.

l Output voltage range: 24-280 VAC.
l 2A at 50°C ambient.
l Replaceable 250V 4A fuse.
l 60VDC Out Module, G4ODC5.
l Output voltage range: 5-60 VDC.
l 2A at 50°C ambient.
l Dry (Reed) Out Module, G4ODC5R.
l Contact rating: 10 VA.
l Maximum switching voltage: 100VDC, 130VAC.
l Maximum switching current: 0.5A.

This is an optional board with eight (8) inputs (inputs #6–13) and eight
DIO 8in/8out (8) outputs (outputs #6–13). Install in one of the motherboard expansion
Board slots J10–J13. Up to two boards may be installed for a total of 16
inputs/16 outputs.
The DIO board provides isolated contact closure inputs and 24-volt
current sinking or current sourcing isolated outputs. Output current must
be limited to 80 mA maximum, continuous.
The inputs and outputs are powered by an external 24 VDC power

source.
The isolated contact closure inputs are activated by completing the
circuit from the input to the negative side of the 24 VDC supply.
Approximately 12 mA of current flows out of each input during contact
closure.
Output current sinking or sourcing is selectable thru a menu screen.

Inputs are always current sourcing.
Board Diagram

The analog I/O board is available in two configurations described below.
Analog I/O Type A has one current output only, whereas, Type B has two voltage
Boards inputs and two current outputs. The Micro-Tech can support up to four
analog inputs and four analog outputs.
Type A: 4–20mA This is an optional board. Install in one of the motherboard expansion
slots J10–J13. Single channel high-level current output.
Output Board
l Outputs
l Rate
l Speed
l Load
l Optically isolated
l Isolated power source
l Voltage output by adding an internal dropping resistor
l Output range (mA)

l 0 to 20 mA
l +4 to 20 mA
l +20 to 4 mA
l +20 to 0 mA
l Resistive load: 800 ohms max.

l Capacitive load: No limit
l Field wiring: Connections are made to the terminal strip on end of
the 4-20mA Output Board. Note that connector is removable for ease
of termination.

Board Diagram
Type B: Analog This is an optional board. Install in one of the motherboard expansion
slots J10–J13.
I/O Board
l Inputs
l Incline compensation
l Moisture compensation
l Outputs
l Rate
l Speed
l Load

High-Level Inputs (Two Channels)
Differential voltage.
l Input Range (Volts)
l 0 to +5 V
l +1 to +5 V
l -5 to +5 V
Current (Requires Jumper Selection)

l Input Range (mA)
l 0 to +20 mA
l +4 to 20 mA
l Converted Display (Volts)
l 0 to +5 V
l +1 to +5 V
l Jumpers J1 and/or J2 are used to select 250 ohm resistance for the
Current inputs.
l Input impedance: 100 k nominal (differential)
l Maximum usable input voltage: 106% of full scale
l Non-isolated voltage
l Max. non-destructive input voltage: 12V peak
Current Outputs (Two Channels)

Here are the specifications.
l Optically isolated
l Isolated power source
l Output Range (mA)
l 0 to 20 mA
l +4 to 20 mA
l Voltage output by adding an internal dropping resistor.

l Resistive load: 800 ohms max.
l Capacitive load: No limit
l Field wiring: Connections are made to the terminal strip on end of
the Analog I/O Board. Note that connector is removable for ease of
termination.
Board Diagram
This is an optional board. Install in one of the motherboard expansion

Dual-Plant slots J10–J13. For use with Model 9105 only.
Load-Cell A/D
Board Each load-cell channel provides its own buffer amplifiers for driving the
A/D converter IC’s differential reference voltage from the excitation
sense voltage resistive divider. The load-cell signals are individually
filtered then connected directly to the differential signal input of the A/D
converter. Each load-cell also has an individual R-Cal relay and
individual R-Cal resistor.
“Channel 1,” top connector has jumpers J14 and J15 that allow selection
of either external excitation sense (6-wire LC hook-up) or internal
excitation sense (4-wire LC hook-up).

“Channel 2,” bottom connector has jumpers J19 and J20 that allow
selection of either external excitation sense (6-wire LC hook-up) or
internal excitation sense (4-wire LC hook-up).
One of four different interrupt channels can be selected from J1 jumper.
J1 is board interrupt 1-2 this is a factory installed jumper, do not move.
Load-Cell Sense Jumper Defaults

Four-Wire Load-Cell Six-Wire Load-Cell
Jumper (internal sense) (external sense)
J14 1-2 2-3
J15 1-2 2-3
J19 1-2 2-3
J20 1-2 2-3
Factory option jumpers W2 and W3 allow the A/D converters to operate

at either 10 conversions per second or at 80 conversions per second,
which may be useful for “loss-in-weight” applications. The standard
board is hard-wired for 10 conversions per second. Altering the W2/W3
option jumpers allows software selection of the desired conversion rate,
so do not change.
Jumper Locations

Board Diagram
This is an optional board. Installed in one of the motherboard expansion

Communication slots J10–J13.
Board
Serial Interface
l Type: Conforms to RS-232C, RS-485/422, and 20 mA standards;
supports 2 and 4 wire multi-drop in RS-485. 20 mA loop is passive
ONLY.
l Interfacing: RS-485 supports 2-wire or 4-wire multi-drop
networking; RS-232C provides support for modem.
l Data rate: 300 to 19200, operator selectable from the keypad.
l Data format: Asynchronous, bit-serial, selectable parity, data length,
and stop bits.
l Optical isolation, 250 Vrms max.
l Input voltage: ±30 Vdc max. (RS-232C)
l +15/-10 Vdc max. (RS-485)
l Cable length: 50 feet maximum (RS-232C)
l 4000 feet maximum (RS-485 and 20 mA)

For more information, see the 9105/9205 Reference manual.
Installation
To install the COMM board(s), do the following.
1. Select the jumper positions on the COMM board for the desired
communication standard. Below is a table which summarizes the
jumper positions for selection of the electrical interface. The jumper
locations are shown below.
Jumpers
Mode OP1 OP2 OP3 OP4 OP5 OP6
RS-232 “A” “A” “A” “A” “A” “B”
RS-485* “B” “A” “B” “B” “MDP” “TRM”
20 mA “B” “B” “A” “A” “A” “C”
* Default
“MDP” “TRM”
For RS-485 only For RS-485 only
OP5 OP6
“A” Normal “A” Terminated
“B” Multi-drop “B” Not terminated
2. Open the Micro-Tech wall mount enclosure and turn power off at the
mains, or remove panel mount enclosure from the panel and remove
top cover allowing access to the motherboard.
3. Remove the field mating connector. Wire the connector per the
supplied field-wiring diagram at the end of the manual.
4. Remove the hex head mounting screw from the connector end of the
COMM board.

5. Insert the COMM board in any available expansion slot on the
motherboard.
Board Diagram
This is an optional board. Install in one of the motherboard expansion

Profibus-DP slots J10–J13. No hardware configuration jumpers or switches are
Board present on the Profibus-DP board.
Profibus is a typical master/slave communication where the main PLC is

the master or scanner, and the Micro-Tech device is a slave. The
connection is EIA RS 485 through a 2-wire twinax Siemens cable.
Profibus-DP is the performance-optimized version specifically dedicated

to time-critical communication between automation systems and
distributed peripherals. It is typically used to transfer I/O images
between a main PLC and remote devices (sensors, actuators,
transmitters, etc.). In this case, it will be used to transfer (read and write)
blocks of data.

The Profibus-DP interface board contains the Siemens SPC3 Profibus-
DP controller ASIC. The SPC3 controller is an integrated circuit
provided by Siemens that handles the interface between the Micro-Tech
slave and the master.
See REC 4372 for details about the Profibus-DP option card.
Board Diagram

Glossary
A/D channel Analog/Digital channel. An pcba Printed-circuit board assembly.
electronic sub-unit on the Micro-Tech PEIC Periodic-error-integrating control.
motherboard that handles the load-cell(s) input.
Your Micro-Tech motherboard is equipped with PID Proportional, integral, derivative control.
two A/D channels, but the dual A/D printed- Scroll When used as a noun (for example, when
circuit-board assembly can be ordered as an the word appears in the Micro-Tech display), it
option. means “menu.” When used as a verb (for example,
AZT Auto zero-tracking. “Scroll down to...”), it means press the up- or
down-arrow button to move to one of the Micro-
Belt-scale code This code describes your exact Tech menus.
belt-scale set-up and allows the Micro-Tech to
set the relevant menu defaults for you. Please Soft key One of the four buttons at the bottom of
write down your belt-scale code before the Micro-Tech display that allows you to
contacting Thermo Fisher Scientific for help. access various context-sensitive Micro-Tech
commands—such as Edit, Enter, Continue, and
Console The main operating panel of the Micro- so forth.
Tech including the display, keypad, arrow
buttons, and soft keys. Standard (US) ton Equivalent to 2,000 lbs.
DIO A digital-input/output board. t/hr Metric tons per hour.
display In the console, the small square screen that t/min Metric tons per minute.
displays Micro-Tech results, menus, and so T/mn Standard US tons/minute.
forth.
Ton Standard (2,000# or 2,000 lb.) tons per hour.
kg Kilogram.
tonne The “metric tonne” equivalent to 1,000 kg.
kg/h Kilograms per hour.
Tph Tons per hour.
kg/min Kilograms per minute.
Totalizer The Totalizer shows the total tons
Lb/hr Pounds per hour.
accumulated by the Micro-Tech.
Lb/mn Pounds per minute.
Weigh-bridge Another name for a scale.
Lt/min Long tons per minute.
LTons The “long ton,” equivalent to 2,240 lbs.
LTph Long tons per hour.
Mixed units A menu choice that allows the Micro-
Tech to display a mixture of English and metric
units.
mV/V Millivolts per volt. A measure of the
sensitivity of a load cell.
Thermo Fisher Scientific Micro-Tech 9105/9205 User Manual Rev E G-1

Attached Drawings
The following information is appended to the manual to help you install and maintain your Micro-Tech.
Description Document
Field-Wiring Diagrams
Micro-Tech 9105 D07392B-E033
Micro-Tech 9205 D07392B-E036
Analog I/O Board B07392B-E003
8-In/8-Out Digital Board B07392B-E005
Serial Communication C07392B-E008
Siemens Profibus Board C07392B-E011
Speed Sensors C07392B-E016
Communication Board C07392B-E017
Notes—Micro-Tech 9000 C07392B-E018
Digital Output Boards C07392B-E021
Anybus Comm for Device Net B07392B-E022
Digital Input Boards B07392B-E025
4–20mA Out Board B07392B-E026
Dual Plant LC A/D Board B07392B-E027
Premium A/D Board B07392B-E028
G-2 Micro-Tech 9105/9205 User Manual Rev E Thermo Fisher Scientific

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Intrinsic Safety Barrier
Operating and Service Manual
Ramsey
Pro-Line
Direct Coupled
Non-Hazardous
Location Motion Sensor
Hi Frequency 60-241-500P or 60-241-1000P
Rec 3824 Rev. E

Part No. 045138
Motion Sensor
****
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ii
Ramsey
Pro-Line
Direct Coupled
Non-Hazardous
Location Motion Sensor
Hi Frequency 60-241-500P or 60-241-1000P
This document is confidential and is the property of Thermo Electron. It may not be
copied or reproduced in any way without the express written consent of Thermo
Electron. This document also is an unpublished work of Thermo Electron. Thermo
Electron intends to, and is maintaining the work as confidential information. Thermo
Electron also may seek to protect this work as an unpublished copyright. In the event
of either inadvertent or deliberate publication, Thermo Electron intends to enforce its
rights to this work under the copyright laws as a published work. Those having
access to this work may not copy, use, or disclose the information in this work unless
expressly authorized by Thermo Electron.
All registered and unregistered trademarks are the property of their respective
owners.
Thermo Electron,
501 90th Avenue N.W.
Minneapolis, MN 55433 U.S.A.
Tel (763) 783-2500
Fax (763) 783-2525
http://www.thermoelectron.com
eng@thermo.com
2002 Thermo Electron
iii
Motion Sensor
Revision History
Revision A August 1993

Revision B March 1994
Revision C October 1994
Revision D September 1997
iv
Table of Contents
Table of Contents............................................................................................................. 1-1
List of Figures...................................................................................................................... iii
List of Tables....................................................................................................................... iii
About this Manual................................................................................................................ v
Who Should Use this Manual?......................................................................................... v
Organization of the Manual .............................................................................................. v
Unpacking and Inspection................................................................................................ v
Safety Messages ............................................................................................................. v
Occupational Safety and Health Act (OSHA) ...................................................................vi
Thermo Electron Warranty...............................................................................................vi
Disclaimer....................................................................................................................... vii
Chapter 1 Introduction ................................................................................................. 1-1
1.1 Specifications..................................................................................................... 1-1
Chapter 2 Installation................................................................................................... 2-1
2.1 Installation Procedures....................................................................................... 2-1
2.1.1 Installation of Bolt or Rigid Coupling............................................................ 2-1
Chapter 3 Theory of Operation .................................................................................... 3-1
Chapter 4 Operation and Maintenance ........................................................................ 4-1
4.1 Electrical Wiring ................................................................................................. 4-1
Chapter 5 Troubleshooting .......................................................................................... 5-1
Chapter 6 Replacement Parts...................................................................................... 6-1
6.1 Service and Repair Information .......................................................................... 6-1
6.2 Parts Ordering Information ................................................................................. 6-2
6.3 Replacement Parts............................................................................................. 6-2
6.4 Disposal of Hazardous Waste ............................................................................ 6-2
****
INTENTIONALLY
****
iiREC 3824
List of Figures
Figure 1-1: Dimensions ................................................................................................... 1-2
Figure 2-1: Installation Methods ...................................................................................... 2-2
Figure 2-2: Installation Methods ...................................................................................... 2-2
Figure 4-1: Conduit.......................................................................................................... 4-2
Figure 4-2: Circuit and Wiring Diagram............................................................................ 4-2
List of Tables
Table 6-1: Parts List ........................................................................................................ 6-2
REC 3824 iii

Motion Sensor
****
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****
iv REC 3824
About this Manual
This manual provides the information you need to install, operate, and maintain
the Direct Coupled Non-Hazardous Location Motion Sensor (Motion Sensor).
Read this manual before working with the product. For personal and system
safety, and for the best product performance, make sure you thoroughly
understand the manual before installing or using this product.
Who Should Use this Manual?
The Motion Sensor manual is a learning resource and reference for anyone
concerned with installing, operating, or maintaining the sensor in a variety of
environments.
Organization of the Manual
This manual is organized into five chapters.
Chapter 1: Introduction gives you an overview of the device’s capabilities,
describes its functions, and lists its technical specifications.
Chapter 2: Installation provides information about installing the Motion Sensor.
Chapter 3: Theory of Operation provides information about setting up,
calibrating, and operating the Motion Detector.
Chapter 4: Operation and Maintenance provides information about operation
and maintenance of the Motion Sensor.
Chapter 5: Troubleshooting provides troubleshooting advice for the Motion
Sensor.
Chapter 6: Replacement Parts
Appendix A: Engineering Drawings contains drawings associated with the
Motion Sensor.
Unpacking and Inspection
The Motion Sensor has been properly packaged for shipment and storage, when
necessary. Refer to the appropriate manual in the appendix section for
unpacking procedures for optional equipment.
Inspect all packages for damage before opening; sometimes the carrier may be
responsible for shipping damage. Refer to the appropriate manual in the
appendix for inspection procedures for optional equipment.
Safety Messages
Instructions in this manual may require special precautions to ensure the safety
of the personnel performing the operations.
Please read the safety information before performing any operation preceded by
this symbol.
There are two levels of safety messages: warnings and cautions. The distinction
REC 3824 v
Motion Sensor
between the two is as follows:
WARNING
Failure to observe could result in death or serious
injury.
CAUTION
Failure to observe may cause minor injury or
damage the equipment
Occupational Safety and Health Act (OSHA)

The Occupational Safety and Health Act clearly places the burden of com-
pliance on the user of the equipment and the act is generalized to the extent that
determination of compliance is a judgment decision on the part of the local
inspection. Hence, Thermo Electron will not be responsible for meeting the full
requirements of OSHA in respect to the equipment supplied or for any penalty
assessed for failure to meet the requirements, in respect to the equipment
supplied, of the Occupational Safety and Health Act, as interpreted by an
authorized inspector. Thermo Electron will use their best efforts to remedy such
violation at a reasonable cost to the buyer.
Thermo Electron Warranty
The seller agrees, represents, and warrants that the equipment delivered
hereunder shall be free from defects in material and workmanship. Such
warranty shall not apply to accessories, parts, or material purchased by the seller
unless they are manufactured pursuant to seller's design, but shall apply to the
workmanship incorporated in the installation of such items in the complete
equipment. To the extent purchased parts or accessories are covered by the
manufacturer's warranty, seller shall extend such warranty to buyer.
Seller's obligation under said warranty is conditioned upon the return of the
defective equipment, transportation charges prepaid, to the seller's factory in
Minneapolis, Minnesota, and the submission of reasonable proof to seller prior
to return of the equipment that the defect is due to a matter embraced within
seller's warranty hereunder. Any such defect in material and workmanship shall
be presented to seller as soon as such alleged errors or defects are discovered by
purchaser and seller is given opportunity to investigate and correct alleged errors
or defects and in all cases, buyer must have notified seller thereof within one (1)
year after delivery, or one (1) year after installation if the installation was
accomplished by the seller.
Said warranty shall not apply if the equipment shall not have been operated and
maintained in accordance with seller's written instructions applicable to such
equipment, or if such equipment shall have been repaired or altered or modified
without seller's approval; provided, however, that the foregoing limitation of
warranty insofar as it relates to repairs, alterations, or modifications, shall not be
applicable to routine preventive and corrective maintenance which normally
occur in the operation of the equipment.
“EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED
vi REC 3824
Motion Sensor
HEREIN, SELLER DISCLAIMS ANY AND ALL WARRANTIES WITH

RESPECT TO THE EQUIPMENT DELIVERED HEREUNDER, INCLUDING
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR USE. THE SOLE LIABILITY OF SELLER ARISING OUT OF THE
WARRANTY CONTAINED HEREIN SHALL BE EXCLUSIVELY LIMITED
TO BREACH OF THOSE WARRANTIES. THE SOLE AND EXCLUSIVE
REMEDY FOR BREACH OF THE WARRANTIES SET OUT ABOVE
SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF ANY
DEFECTIVE ACCESSORY, PART OR MATERIAL WITH A SIMILAR
ITEM FREE FROM DEFECT, AND THE CORRECTION OF ANY DEFECT
IN WORKMANSHIP. IN NO EVENT SHALL SELLER BE LIABLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.”
Purchaser agrees to underwrite the cost of any labor required for replacement;
including time, travel, and living expenses of a Thermo Electron Field Service
Engineer at closest factory base.
THERMO ELECTRON
TH
501 90 AVE. NW
MINNEAPOLIS, MN 55433
PHONE: (763) 783-2500
FAX: (763) 783-2525
Disclaimer
Though the information provided herein is believed to be accurate, be advised
that the information contained herein is not a guarantee for satisfactory results.
Specifically, this information is neither a warranty nor guarantee, expressed or
implied, regarding performance, merchantability, fitness, or any other matter
with respect to the products, and recommendation for use of the product/process
information in conflict with any patent. Please note that Thermo Electron
reserves the right to change and/or improve the product design and
specifications without notice.
REC 3824 vii

Motion Sensor
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viii REC 3824

Chapter 1
Introduction
The rotation of the sensor shaft produces 500 pulses per revolution at the output
of the sensor. All sensor outputs are NPN with an internal 2.2 K pull-up
resistor, which can sink up to 50 mA of current each. This allows connection in
a variety of applications.
1.1 Specifications
Supply Voltage
5-24 VDC
Output
2 NPN outputs (A & B) – with 2.2 K pull-up resistors – 50 mA current sinking
each
1 index pulse (Z) – 1 pulse per revolution – with 2.2 K pull-up resistor – 50 mA
current sinking
Environmental Conditions
Operating Temperature: 0° to 80° C
Storage Temperature: -25° to -85° C
Housing
Aluminum
Dimensions
See Figure 1-1
Speed
Up to 200 RPM
REC 3824 1-1

Motion Sensor
Figure 1-1: Dimensions
1-2 REC 3824

Chapter 2
Installation
This chapter outlines the installation procedures for the Motion Sensor. Refer to
Figure 1-1 for dimensional data.
Because a slight misalignment can occur between the motion sensor and driving
shaft, Thermo Electron recommends some degree of flexibility be used in
mounting or coupling the sensor.
Thermo Electron’s rigid mounting kit (042120) should be used with flexible
coupling kits’ 042117 or 042118. Rigid coupling kit 042119 has a flexible
mounting strap and is recommended for applications that do not exceed 200
RPM because of the increased vibration beyond that speed.
2.1 Installation Procedures
Refer to Figure 2-1 and Figure 2-2 as reference.
2.1.1 Installation of Bolt or Rigid Coupling
Use the following steps to install Bolt 005318 or Rigid Coupling 042220 into the
shaft.
1. Locate the exact center of the shaft and center punch it.
2. Use a 5/16” drill to drill a hole 1-3/4” deep
!Hint: A smaller pilot hole is helpful in assuring correct centering.
Use caution to assure parallelism between the axis of the shaft and axis of
the tapped hole being drilled. These precautions will minimize
misalignment and reduce vibration.
3. Tap the drilled hole with a 3/8-16 tap. Clean the hole with solvent to
remove any oil or chips.
4. After cleaning, apply a thread locking adhesive, such as Loctite
Threadlocker 262, to the threads and tapped hole.
5. After installing Bolt 005318 into the drive shaft, remove the bolt head and
grind two flat surfaces that are 90° apart on the full length of the unthreaded
portion of the bolt. These flat surfaces provide the setscrews with additional
holding power.
If Rigid Coupling 042220 is being used, thread coupling in so it bottoms out
against the driving shaft.
6. Once the shaft is in place, align the setscrews in the coupling perpendicular
to the flat surfaces on the shaft. Tighten all setscrews securely.
7. When assembling the motion sensor with rigid mounting brackets 041579,
ensure alignment between the sensor shaft, coupling, and drive shaft.
8. If mounting strap 042222 is being installed, allow enough slack in the end of
the strap for belt tensioning movement.
REC 3824 2-1

Motion Sensor
Figure 2-1: Installation Methods
Figure 2-2: Installation Methods
2-2 REC 3824

Chapter 3
Theory of Operation
The motion sensor is an electro-mechanical device that translates rotational
motion into an electrical signal. The shaft encoder employed in the 60-241-
500P will provide 500 pulses per revolution on each of two channels. The 60-
241-1000P will provide 1000 pulses per revolution on each of the two channels.
The encoder is also wired to provide an index pulse equal to one pulse per
revolution.
REC 3824 3-1

Motion Sensor
****
INTENTIONALLY
****
3-2 REC 3824

Chapter 4
Operation and Maintenance
The only adjustments needed during installation to ensure that the axis of
coupling is as straight as possible.
Flexible mounting should only be used for low speed applications due to the
proportional effect of increasing vibration.
4.1 Electrical Wiring
Reference Figure 4-1 and Figure 4-2 for wiring information. The motion sensor
has a ½ NPT pipefitting and 15 feet of 22 AWG wire.
During wiring installation, the method and materials used (such as conduit,
junction box, fittings, and sealants) must be according to the National Electrical
Code.
The unit should be sealed at fitting to ensure that no contamination is allowed
into the unit that might degrade performance.
After wiring has been completed, check the alignment between the motion
sensor and shaft. Make any necessary adjustments.
REC 3824 4-1

Motion Sensor
Figure 4-1: Conduit
Figure 4-2: Circuit and Wiring Diagram
4-2 REC 3824

Chapter 5
Troubleshooting
Unit operation can be verified by placing 5 to 24 VDC to the white wire and
ground to the black wire. A voltmeter connected from an output wire (brown,
red, orange) to the black wire will show variations of AC voltage as the shaft is
rotated.
Shaft rotation speed for the Model 60-241-500P and 60-241-1000P should not
be excessive as pulses might be missed and appear as a defective output.
Maximum mechanical shaft speed per design is 7500 RM. Maximum user shaft
speed is dependent on the speed-monitoring device.
Shaft rotation should be smooth and free from binding or other obstruction.
REC 3824 5-1

Motion Sensor
****
INTENTIONALLY
****
5-2 REC 3824

Chapter 6
Replacement Parts
This chapter provides information about service, repair, and replacement parts
for your Thermo Electron product. It includes the telephone numbers for
various departments at Thermo Electron, the procedure for ordering replacement
parts, a Return Material Authorization Form, and the parts list for the product
are also included in this chapter.
6.1 Service and Repair Information
The maintenance information in this manual is designed to meet your service
needs. If you should encounter a problem that requires technical assistance, you
may call Thermo Electron Product Service at (763) 783-2605.
Thermo Electron also provides on-site service technicians to assist customers
with installation, setup, initial calibration, customer training, maintenance, and
repair. Contact the Thermo Electron Field Service department at the number
given below for current rates and scheduling.
Thermo Electron has repair centers located at the plant in Minneapolis,
Minnesota. Products that need system checkout or repair can be returned to the
plant with the Return Material Authorization (RMA) Form. Contact our Repair
and Return department (763) 783-2728 to get an RMA number to use on the
form.
Note: Have your machine model number and serial number available when you
call.
Main Switchboard (763) 783-2500
FAX (763) 783-1537
Service (763) 783-2605
(763) 783-2605
Return Material Authorization & Repair (763) 783-2728
REC 3824 6-1

Motion Sensor
6.2 Parts Ordering Information

For the fastest service when ordering parts, telephone or FAX the Thermo
Electron Parts Department at the numbers given below. Your regional field
service representative can also assist you with parts orders.
The recommended procedure for ordering parts is:
1. Determine the broken or faulty part.
2. Locate the part in the Parts List.
3. Find the part number(s) for the item(s) you need.
4. Before you contact Thermo Electron for your parts, make sure you have the
following information:
! Machine model and serial number
! Purchase Order number
! Date Required
! Preferred shipping method
! Part number(s), descripto9in, and quantity needed.
5. Telephone or FAX:
Thermo Electron
Customer Service Department
501 90th Ave. NW
Minneapolis, MN 55433
FAX: (763) 780-2525
Phone: (763) 783-2500
Return Material Authorization and Repair: (763) 783-2774
6-2 REC 3824

REC 3824 6-1
Motion Sensor
6.3 Replacement Parts
A multiple character model number that precisely identifies a particular type of
unit identifies the Ramsey Motion Sensor. An explanation of the alphanumeric
model number is shown below. It will enable the owner to define the model
number, pulse rate, and voltage of the sensor.
A B C
60 - XXX - XXX - XXX
• A = Model Number
241 – Conduit Connection Type
• B = Pulse Rate
500 P – 500 Pulses per Revolution
1000P – 1000 Pulses per Revolution
• C = Voltage
5/24 – 5 to 24 VDC
Table 6-1: Parts List
DESCRIPTON PART NUMBER
Flex Coupling Kit #1 042117
Coupling, Flexible 042165
3/8-16 Screw 005318
Flex Coupling Kit #2 042118
Coupling, Extra Flexible 042166
3/8-16 Screw 005318
Rigid Coupling Kit 042119
Rigid Mounting Kit 042120
Speed Sensor, 60-241-500P-5/24 045056
Speed Sensor, 60-241-1000P-5/24 046135
6.4 Disposal of Hazardous Waste

Disposal of lithium batteries and soldered printed circuit boards must be in
accordance with your local Hazardous Waste Policy.
As an alternative product supplied by Thermo Electron may be returned freight
pre-paid, for disposal. Contact the Repair Department for a Return Material
Authorization Number before shipping any product for disposal.
6-2 REC 3824

SECTION 2
SPARE PARTS LIST

RECOMMENDED SPARE PARTS LIST
Item Description Supplier Part Number OEM Name/ Lead Time Equipment Item Installed Qty Recommended Commissioning 2x Years Spares 2x Years
Supplier (Weeks) Estimate Weight Critical On Equipment Commissioning Spares Spares Qty Y/N Spares Qty Comments
(kg) Y/N Y/N
900mm Weigh Feeder
1 Motor / Gearbox, 2.2Kw-440VAC-60Hz, 5RPM, Ratio 364, 90mm Hollow Shaft, IE3 KA107/TR77DRN100LM4 SEW/SEW 4 332 Y 1 N 0 Y 1
Complete Flange Bearing for 90mm Shaft UCT218 ASAHI 2 11.3 Y 2 N 0 Y 1
2 Complete Take Up Bearing for 85mm Shaft UCT217 ASAHI 2 11.2 Y 2 N 0 Y 1
3 Head Pulley, 381mm Dia x 965mm Face, 90mm Shaft Fabrication Parts UMP 4 890 Y 1 N 0 N 0 Fabrication Parts
4 Tail Pulley, 356mm Dia x 965mm Face, 85mm Shaft Fabrication Parts UMP 4 730 Y 1 N 0 N 0 Fabrication Parts
5 Carry Idler, Single Roll Flat, Diameter 102, Face Length 978, Bare Fabrication Parts Belt Brokers 3 24 Y 12 N 0 N 0 Fabrication Parts
6 Scale Idler, Single Roll Flat, Diameter 102, Face Length 689, Bare Fabrication Parts Belt Brokers 3 20 Y 1 N 0 N 0 Fabrication Parts
7 Impact Return Idler, Diameter 127, Face Length 978 Fabrication Parts Belt Brokers 3 25 Y 2 N 0 N 0 Fabrication Parts
8 11,973m Endless Belt, XE-TB 315/2+2 4.0 X2.0 Cross Stabilised, Belt Width 900 mm Conveyor Belt DUNLOP 4 200 Y 1 N 0 N 0
9 Primary scaper, complete with 150mm Polyurethane Blades (E905-0900) 1-E905-900 Brelko 5 45 N 1 N 0 N 0
10 SPS-2D-3 Safety Pull Switches XR395101 Thermo 2 3 Y 1 Y 1 Y 1
11 60-33A Run-Off Switches XR395042 Thermo 2 3 Y 2 Y 1 Y 1
12 DB-100 Belt Rip Detector 050089 Thermo 3 8 N 1 N 0 N 0
13 Electrical Local Control Panel 16523BE002 PCS 3 10 Y 1 Y 0 N 0 Fabrication Parts
14 Variable Speed Drive PowerFlex 525, 480 VAC, 3 Phase, 10.5A 25B-D010N114 Allen-Bradley 2 3 Y 1 Y 0 N 0
15 Bar, Cal-weight 16523BF037 UMP 3 40 Y 1 N 0 N 0 Fabrication Parts
16 Loadcell 10-101R-100KG IDEA Module XR463161 Thermo 2 2 Y 2 N 0 Y 2
17 MT9105F Integrator XR136041 Thermo 3 10 Y 1 N 0 N 0

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O & M Manual

900mm Weigh Feeder

PRECISION PERU S.A.

• SEW MOTOR MANUAL

• SEW MOTOR MANUAL

Edition 08/2016 22760253/EN

2 Safety notes ............................................................................................................................ 10

3 Motor structure ....................................................................................................................... 17

4 Mechanical installation .......................................................................................................... 29

5 Electrical installation.............................................................................................................. 49

Operating Instructions – AC Motors 3

5.4 Special aspects for operation with a frequency inverter ............................................... 51

6 Startup ..................................................................................................................................... 99

8 Technical data....................................................................................................................... 164

8.11 S1 duty cycle DRK.. single-phase motor .................................................................... 192

4 Operating Instructions – AC Motors

9.5 Disposal ...................................................................................................................... 198

10 Appendix ............................................................................................................................... 199

11 Address list ........................................................................................................................... 215

Index ...................................................................................................................................... 226

Operating Instructions – AC Motors 5

1.2 Structure of the safety notes

Signal word Meaning Consequences if disregarded

1.2.2 Structure of section-related safety notes

6 Operating Instructions – AC Motors

Hazard symbol Meaning

Warning of dangerous electrical voltage

Warning of hot surfaces

Warning of risk of crushing

Warning of suspended load

Warning of automatic restart

1.2.3 Structure of embedded safety notes

Operating Instructions – AC Motors 7

1.3 Rights to claim under limited warranty

1.4 Exclusion of liability

1.5 Product names and trademarks

1.6 Copyright notice

1.7 Other applicable documentation

1.7.1 DR..71 – 315, DRN80 – 315 AC motors

• Addendum to the operating instructions "Safety-Rated Encoders – DR..71 – 315,

8 Operating Instructions – AC Motors

Operating Instructions – AC Motors 9

2.2 General information

Removing required covers without authorization, improper use or incorrect installation

10 Operating Instructions – AC Motors

Operating Instructions – AC Motors 11

2.4 Target group

2.5 Designated use

12 Operating Instructions – AC Motors

Functional Brake Encoder

Operating Instructions – AC Motors 13

14 Operating Instructions – AC Motors

2.9 Electrical connection

Nominal voltage VN Distance

Operating Instructions – AC Motors 15

2.10.1 Surface temperature during operation

16 Operating Instructions – AC Motors

3.1 Basic structure DR..71 – 132/DRN80 – 132S motors

Operating Instructions – AC Motors 17

3.2 Basic structure DR..160 – 180, DRN132M – 180 motors

18 Operating Instructions – AC Motors

Operating Instructions – AC Motors 19

3.4 Basic structure DR..250 – 280, DRN250 – 280 motors

20 Operating Instructions – AC Motors