Allen-Bradley PowerFlex 525 User manual

Technical Data

PowerFlex 520-Series AC Drive Specifications

Original Instructions

Drive Features: AppView™, CustomView™, QuickView™, and MainsFree™ configuration and programming tools.

Topic Page

Product Overview 2

Catalog Number Explanation 8

Technical Specifications 9

Environmental Specifications 12

Certifications 13

Dimensions and Weights 14

Design Considerations 16

Fuses and Circuit Breaker Ratings 27

Accessories and Dimensions 32

Safe-Torque-Off Function 42

Additional Resources 47

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2Rockwell Automation Publication 520-TD001E-EN-E - July 2016

PowerFlex 520-Series AC Drive Specifications

Product Overview

The PowerFlex® 520-Series AC drive delivers an innovative design that is remarkably versatile and can accommodate

systems ranging from standalone machines to simple system integration. The PowerFlex 523 drive provides general purpose

control for applications ranging up to 30 HP and 22 kW. The PowerFlex 525 drive provides maximum flexibility and

performance ranging up to 30 HP and 22 kW.

By combining a variety of motor control options, communications, energy savings and standard safety features in a cost-

effective drive, the PowerFlex 520-Series drive is suitable for a wide array of applications.

Maximize your system performance and productivity by taking advantage of the following key features offered in a

PowerFlex 520-Series drive.

PowerFlex 520-Series AC Drives Feature

Modular Design

•Detachable control module and power module allow simultaneous configuration and installation.

•Each drive has a standard control module used across the entire power range.

• MainsFree™ configuration allows you to simply connect your control module to a PC with a standard USB cable

and quickly upload, download, and flash the drive with new settings.

• Support for accessory cards without affecting footprint.

(PowerFlex 523 drives support one, PowerFlex 525 drives support two)

Packaging and Mounting

•Installation can be quick and easy using the DIN rail mounting feature on A, B, and C frame drives. Panel mounting

is also available, providing added flexibility.

•ZeroStacking™ is allowed for ambient temperatures up to 45 °C, saving valuable panel space.

•Integralfilteringis available on all 200V and 400V ratings, providing a cost-effective means of meeting EN61800-3

Category C2 and C3 EMC requirements. External filters provide compliance to EN61800-3 Category C1, C2, and

C3 EMC requirements for all PowerFlex 520-Series ratings.

•An optional IP 30, NEMA/UL Type 1 conduit box is easily adapted to the standard IP 20 (NEMA Type Open)

product, providing increased environmental ratings.

Optimized Performance

•RemovableMOVto ground provides trouble-free operation when used on ungrounded distribution systems.

•A relay pre-charge limits inrush current.

• Integral brake transistor, available on all ratings, provides dynamic braking capability with simple low cost brake

resistors.

•A jumper to switch between 24V DC sink or source control for control wiring flexibility.

• Dual Overload Rating available for drives above 15 HP/11 kW. Normal duty: 110% overload for 60 seconds or

150% for 3 seconds. Heavy duty: 150% overload for 60 seconds or 180% overload (200% programmable) for

3 seconds provides robust overload protection.

• Adjustable PWM frequency up to 16 kHz ensures quiet operation.

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Rockwell Automation Publication 520-TD001E-EN-E - July 2016 3

PowerFlex 520-Series AC Drive Specifications

PowerFlex 520-Series AC Drive Advanced Features

Control Performance

• Variety of motor control options, including:

•Volts per hertz (V/Hz)

•Sensorless Vector Control (SVC)

•Closed loop velocity vector control (PowerFlex 525 drives only)

•Permanent Magnet motor control (PowerFlex 525 drives only)

• Variety of Positioning Control, including:

•PointStop™ stops motor load in a consistent position without encoder feedback

•Closed loop feedback with an optional encoder card (PowerFlex 525 drives only)

•Point-to-point positioning mode (PowerFlex 525 drives only)

•IntegralPIDfunctionality enhances application flexibility

(PowerFlex 523 drives have one PID loop, PowerFlex 525 drives have two PID loops)

I/O Wiring

PowerFlex 523

• One (1) Analog Input (unipolar voltage or current)

independently isolated from the rest of the drive I/O.

•Five(5)DigitalInputs(four programmable)provide

application versatility.

• One (1) Analog Output(1) which is jumper selectable

between either 0-10V or 0-20 mA. This scalable, 10-bit

output is suitable for metering or as a speed reference to

another device.

• One (1) Relay Output (form C) can be used to

indicate various drive, motor or logic conditions.

(1) 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.

PowerFlex 525

• Two (2) Analog Inputs (one unipolar and one bipolar)

are independently isolated from the rest of the drive

I/O. These inputs can be toggled via a digital input.

•Seven(7)DigitalInputs(six programmable)provide

application versatility.

• One (1) Analog Output which is jumper selectable

between either 0-10V or 0-20 mA. This scalable, 10-bit

output is suitable for metering or as a speed reference to

another drive.

• Two (2) Opto Outputs and two (2) Relay Outputs

(one form A and one form B) can be used to indicate

various drive, motor or logic conditions.

Digital Common

DigIn TermBlk 05

DigIn TermBlk 06

DigIn TermBlk 07/Pulse

Stop (1)

DigIn TermBlk 02/

Start/Run FWD (2)

DigIn TermBlk 03/

Direction/Run REV

DigIn TermBlk 08

S+

Relay 1 N.O.

Relay 1 Common

+24V DC

+10V DC

0-10V (or ±10V) Input

Analog Common

4-20mA Input

Analog Output

Opto Output 1

Opto Output 2

RJ45 Shield

Comm Common

Opto Common

+24V

+10V

Safety 1

Safety 2

Safety +24V

Typical

SNK wiring

Typical

SRC wiring

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

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

30V DC

50 mA

Non-inductive

Common

24V (3)

Pot must be

1...10 k ohm

2 W min.

0-10V

0/4-20 mA

SNK

Digital In

DigIn TermBlk 07 Sel

Analog Out

J10 J9 J5

Pulse In

SRCDigital

Input

0/4-20mA

0-10V

SRCSNK

Relay 2 Common

Relay 2 N.C.

Safe-Torque-O

PowerFlex525

Control I/O

Wiring Block

Diagram

Digital Common

DigIn TermBlk 05/Pulse

DigIn TermBlk 06

Stop (1)

DigIn TermBlk 02/

Start/Run FWD (2)

DigIn TermBlk 03/

Direction/Run REV

Relay N.O.

Relay Common +24V DC

+10V DC

Analog Input

Analog Common

Analog Output (3)

RJ45 Shield

Comm Common

+24V

+10V

Typical

SNK wiring

Typical

SRC wiring

11 12 13 14 15 C1 C2

01 02 03 04 05 06

Pot must be (4)

1...10 k ohm

2 W min.

4-20 mA

source

SNK

Digital In

DigIn TermBlk 05 Sel

J7J8

Pulse In

SRC Digital

Input

SRCSNK

Relay N.C.

0/4-20 mA

Analog Out

J13

0-10V

4-20 mA

Analog In

0-10V

RS485

(DSI)

0-10V

4-20 mA

0-10V

0/4-20 mA

PowerFlex523

Series B

Control I/O

Wiring Block

Diagram

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4Rockwell Automation Publication 520-TD001E-EN-E - July 2016

PowerFlex 520-Series AC Drive Specifications

Communications

•EmbeddedEtherNet/IP™portallows easy configuration, control, and collection of drive data over the network.

(PowerFlex 525 drives only)

•DualportEtherNet/IPoptioncardsupports Device Level Ring (DLR) topologies, providing fault-tolerant

connectivity for optimum drive availability.

• Integral RS485/DSI communications enable the drives to be used in a multi-drop network configuration.

•Optional communication cards such as DeviceNet™, and PROFIBUS DP™ can improve machine performance.

• Online EDS file creation with RSNetWorx™ providing ease of set-up on a network.

Optimized for Common DC Bus Installations

Enhanced Control of Internal Pre-charge

Common DC Bus offers additional inherent breaking capabilities by utilizing all the drives/loads on the bus for energy

absorption offering higher efficiency and cost savings. The PowerFlex 520-Series drive has been optimized for use in

Common DC Bus or Shared DC Bus installations.

•Configurable pre-charge control using digital inputs.

•Direct DC Bus connection to power terminal blocks.

Improved Ride Through

Operation Down to 1/2 Line Voltage

The PowerFlex 520-Series drive allows for the selection of 1/2 DC Bus operation, for use in critical applications where

continued drive output is desired even in the event of brown out or low voltage conditions. The PowerFlex 520-Series drive

also supports enhanced inertia ride through for additional low voltage mitigation.

•Selectable 1/2 line voltage operation.

•Increased power loss ride through.

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Rockwell Automation Publication 520-TD001E-EN-E - July 2016 5

PowerFlex 520-Series AC Drive Specifications

Additional Features of PowerFlex 525 Drives

Closed Loop Feedback

Encoder/Pulse Train Input

The PowerFlex 525 drive allows for configurable closed loop control with an optional encoder card for either speed or

position feedback for improved speed regulation, basic position control, or other pulse inputs for motor control.

•Improved speed regulation

•Basic position control

Basic Position Control

Local Position Control

•Position regulator with StepLogic™

•8 positions (local logic)

Outer Position Control Loop

• Analog input bipolar mode offers improved zero-cross performance.

• Simple motion control applications with more complex position profiles.

• Speed reference supplied to drive via Analog Input or multiple field bus network options.

•Speedratioavailable for simple draw applications.

Feedback Details

Line Driver Type Incremental Encoder Option Card

•Quadrature (dual channel) or Single Channel

•5V/12V DC supply, 10 mA min per channel

•Single Ended or Differential (A, B Channel)

•Duty Cycle of 50%, +10%

•Input Frequency up to 250 kHz

Pulse Train Input

•Configurable Input Voltage 5V/12V/24V DC

autodetect

•Input Frequency up to 100 kHz

Safety Inside using Safe-Torque-Off Function

Safe Torque-Off is a standard safety feature of the PowerFlex 525 drive to help protect personnel and equipment. Safe

Torque-off allows you to restart your application faster after a safety-related situation.

•Safe Torque-Off functionality removes rotational power without powering down the drive.

•Embedded safety reduces wiring and saves on installation space.

•Meets ISO 13849-1 standards and provides safety ratings up to and including SIL 2/PLd.

I/O Connection Example I/O Connection Example

Encoder

Power –

Internal Drive

Power

Internal (drive)

12V DC, 250 mA

Encoder

Power –

External

Power

Source

Encoder

Signal –

Single-Ended,

Dual Channel

Encoder

Signal –

Differential,

Dual Channel

Common

+12V DC

(250 mA)

A-

B-

to SHLD

Common

External

Power

Supply

SHLD

A NOT

B NOT

to SHLD

to Power Supply

Common

A-

B-

to SHLD

A NOT

B NOT

A-

B-

Encoder Wiring Examples

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6Rockwell Automation Publication 520-TD001E-EN-E - July 2016

PowerFlex 520-Series AC Drive Specifications

Communications and Software

Versatile Programming and Network Solutions

•PowerFlex 520-Series drives are compatible with

any device that acts as a RTU Master and

supports standard 03 and 06 RTU commands.

•A network can be configured using

PowerFlex 520-Series drives for high

performance and flexible configuration

capabilities.

•Embedded port for EtherNet/IP

(PowerFlex 525 drives only)

•EtherNet/IP dual-port option card

•DeviceNet option card

•PROFIBUS DP option card

•A multi-drive solution can be reached using a

single PowerFlex 520-Series drive, with the

ability for up to five (5) drives to reside on one

(1) node.

• Integral RS485 communications enable the

drives to be used in a multi-drop network

configuration. A serial converter module (SCM)

provides connectivity to any controller with a

DF1 port. The SCM can be eliminated if the

controller acts as a RTU Master.

PC Programming Software

Connected Components Workbench™

•Supports plug-and-play connectivity through a standard USB connection.

•AppView™ tool provides parameter groups for several of the most common applications.

•Create and save custom parameter groups using the CustomView™ tool.

•Supports PowerFlex drives, Micro800™ controllers and PanelView™ component graphic terminals.

Studio 5000™ Logix Designer

•Add-on profiles (AOPs) for PowerFlex 520-seriers AC drives provide seamless integration into the Logix

environment.

•Configuration files from Studio 5000 Logix Designer(1) can be transferred directly to the PowerFlex 520-Series drive

over EtherNet/IP.

•Automatic Device Configuration (ADC) uploads configuration parameters to a replaced drive, minimizing the need

for a manual reconfiguration.

(1) The Logix Designer application is the rebranding of RSLogix 5000 software. You can also use RSLogix 5000 version 17 or greater.

DeviceNet to EtherNet/IP

RTU

Network Communication

Node 1 Node 2 Node 3

up to 4 PowerFlex 520-Series, PowerFlex 4, or PowerFlex 40 drives

up to 31 PowerFlex 520-Series, PowerFlex 4, or PowerFlex 40 drives

RTU

SCM

DF1

PowerFlex 520-Series

with Comms card

PowerFlex 520-Series

with Comms card

PowerFlex 520-Series

with Comms card

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Rockwell Automation Publication 520-TD001E-EN-E - July 2016 7

PowerFlex 520-Series AC Drive Specifications

PowerFlex 523 Drive Family

PowerFlex 525 Drive Family

Frame A Frame B Frame C Frame D Frame E

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8Rockwell Automation Publication 520-TD001E-EN-E - July 2016

PowerFlex 520-Series AC Drive Specifications

Catalog Number Explanation

Code Type

25A PowerFlex 523

25B PowerFlex 525

(1) This rating is only available for PowerFlex 523 drives.

(2) Normal and Heavy Duty ratings are available for this drive.

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

Output Current @ 3 Phase, 380...480V Input

Code Amps Fram

ND HD

HP kW HP kW

1P4 1.4 A 0.5 0.4 0.5 0.4

2P3 2.3 A 1.0 0.75 1.0 0.75

4P0 4.0 A 2.0 1.5 2.0 1.5

6P0 6.0 A 3.0 2.2 3.0 2.2

010 10.5 B 5.0 4.0 5.0 4.0

013 13.0 C 7.5 5.5 7.5 5.5

017 17.0 C 10.0 7.5 10.0 7.5

024 24.0 D 15.0 11.0 15.0 11.0

030(2) 30.0 D20.0 15.0 15.0 11.0

037(2) 37.0 E25.0 18.5 20.0 15.0

043(2) 43.0 E30.0 22.0 25.0 18.5

Output Current @ 3 Phase, 525...600V Input

Code Amps Fram

ND HD

HP kW HP kW

0P9 0.9 A 0.5 0.4 0.5 0.4

1P7 1.7 A 1.0 0.75 1.0 0.75

3P0 3.0 A 2.0 1.5 2.0 1.5

4P2 4.2 A 3.0 2.2 3.0 2.2

6P6 6.6 B 5.0 4.0 5.0 4.0

9P9 9.9 C 7.5 5.5 7.5 5.5

012 12.0 C 10.0 7.5 10.0 7.5

019 19.0 D 15.0 11.0 15.0 11.0

022(2) 22.0 D20.0 15.0 15.0 11.0

027(2) 27.0 E25.0 18.5 20.0 15.0

032(2) 32.0 E30.0 22.0 25.0 18.5

Code Voltage Phase

V 120V AC 1

A 240V AC 1

B 240V AC 3

D 480V AC 3

E 600V AC 3

Code Enclosure

N IP20 NEMA / Open

Code Interface Module

1Standard

Code EMC Filter

0 No Filter

1Filter

Code Braking

4Standard

Output Current @ 1 Phase, 100...120V Input

Code Amps Frame ND HD

HP kW HP kW

1P6(1) 1.6 A 0.25 0.2 0.25 0.2

2P5 2.5 A 0.5 0.4 0.5 0.4

4P8 4.8 B 1.0 0.75 1.0 0.75

6P0 6.0 B 1.5 1.1 1.5 1.1

Output Current @ 1 Phase, 200...240V Input

Code Amps Frame ND HD

HP kW HP kW

1P6(1) 1.6 A 0.25 0.2 0.25 0.2

2P5 2.5 A 0.5 0.4 0.5 0.4

4P8 4.8 A 1.0 0.75 1.0 0.75

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 @ 3Phase, 200...240V Input

Code Amps Frame ND HD

HP kW HP kW

1P6(1) 1.6 A 0.25 0.2 0.25 0.2

2P5 2.5 A 0.5 0.4 0.5 0.4

5P0 5.0 A 1.0 0.75 1.0 0.75

8P0 8.0 A 2.0 1.5 2.0 1.5

011 11.0 A 3.0 2.2 3.0 2.2

017 17.5 B 5.0 4.0 5.0 4.0

024 24.0 C 7.5 5.5 7.5 5.5

032 32.2 D 10.0 7.5 10.0 7.5

048(2) 48.3 E15.0 11.0 10.0 7.5

062(2) 62.1 E20.0 15.0 15.0 11.0

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Rockwell Automation Publication 520-TD001E-EN-E - July 2016 9

PowerFlex 520-Series AC Drive Specifications

Technical Specifications

Protection

Electrical

Control

Specifications PowerFlex 523 PowerFlex 525

Bus Overvoltage Trip

100...120V AC Input:

200...240V AC Input:

380...480V AC Input:

525...600V AC Input:

405V DC bus (equivalent to 150V AC incoming line)

405V DC bus (equivalent to 290V AC incoming line)

810V DC bus (equivalent to 575V AC incoming line)

1005V DC bus (equivalent to 711V AC incoming line)

Bus Undervoltage Trip

100...120V AC Input:

200...240V AC Input:

380...480V AC Input:

525...600V AC Input

P038 = 3 “600V”:

P038 = 2 “480V”:

190V DC bus (equivalent to 75V AC incoming line)

190V DC bus (equivalent to 150V AC incoming line)

390V DC bus (equivalent to 275V AC incoming line)

487V DC bus (equivalent to 344V AC incoming line)

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 Protection: Provides 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.

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

Specifications PowerFlex 523 PowerFlex 525

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

200...240V AC Input:

380...480V AC Input:

525...600V AC Input:

Only for Frame E drive ratings

11 kW (15 HP)

15...18.5 kW (20...25 HP) – Heavy Duty

Specifications PowerFlex 523 PowerFlex 525

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:

Analog Input:

Analog Output:

Within ±0.05% of set output frequency

Within 0.5% of maximum output frequency, 10-Bit resolution

±2% of full scale, 10-Bit resolution

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10 Rockwell Automation Publication 520-TD001E-EN-E - July 2016

PowerFlex 520-Series AC Drive Specifications

Control Inputs

Performance

V/Hz (Volts per Hertz):

SVC (Sensorless Vector):

SVC Economizer:

VVC (Velocity Vector Control):

PM Motor(1):

±1% of base speed across a 60:1 speed range

±0.5% of base speed across a 100:1 speed range

(Applicable to PowerFlex 525 drives only)

±0.5% of base speed across a 60:1 speed range

±0.5% of base speed, up to a 20:1 speed range

Performance with Encoder

SVC (Sensorless Vector):

SVC Economizer:

VVC (Velocity Vector Control):

PM Motor (iPM motor, 10 HP

rating and below)(1):

(Applicable to PowerFlex 525 drives only)

±0.1% of base speed across a 100:1 speed range(2)

±0.1% of base speed across a 1000:1 speed range(2)

±0.1% of base speed, up to a 60:1 speed range

Output Voltage Range: 0V to rated motor voltage

Output Frequency Range: 0...500 Hz (programmable)

Efficiency: 97.5% (typical)

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 the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001.

Specifications PowerFlex 523 PowerFlex 525

Digital Bandwidth: 10 Rad/s for open and closed loop

Quantity: (1) Dedicated for stop

(4) Programmable

(1) Dedicated for stop

(6) Programmable

Current: 6 mA

Type

Source Mode (SRC):

Sink Mode (SNK):

18...24V = ON, 0...6V = OFF

0...6V = ON, 18...24V = OFF

Pulse Train

Quantity:

Input Signal:

Input Frequency:

Current Consumption:

(1) Shared with one of the programmable digital input terminals.

Transistor contact (open collector)

0...100 kHz

7 mA @ 24V DC maximum

Analog Quantity: (1) Isolated, 0-10V and 4-20 mA (2) Isolated, -10-10V and 4-20 mA

Specification

Resolution:

0-10V DC Analog:

4-20 mA Analog:

External Pot:

10-bit

100k ohm input impedance

250 ohm input impedance

1...10k ohm, 2 W minimum

Specifications PowerFlex 523 PowerFlex 525

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