Allen-Bradley PowerFlex 527 User manual

Technical Data

PowerFlex 527 AC Drive Specifications

Original Instructions

Topic Page

Product Overview 2

Catalog Number Explanation 7

Technical Specifications 8

Environmental Specifications 11

Certifications 12

Dimensions and Weights 13

Design Considerations 15

Fuses and Circuit Breaker Ratings 26

Accessories and Dimensions 31

Safe Torque-Off Function 40

Additional Resources 41

2Rockwell Automation Publication 520-TD002A-EN-E - May 2015

PowerFlex 527 AC Drive Specifications

Product Overview

PowerFlex® 527 AC drives are designed to be used with an Allen-Bradley® Logix Programmable Automation Controller

(PAC). Ideal for machines that can benefit from the same drive configuration experience for both servo and AC drives, the

PowerFlex 527 drive features a built-in dual port for EtherNet/IP™ and safety over the network. The PowerFlex 527 drive

provides maximum flexibility and performance ranging up to 30 HP and 22 kW.

Designed to connect and operate only with the ControlLogix® 1756-L7x, GuardLogix® 1756-L7xS, and CompactLogix™

5370 controllers and Studio 5000 Logix Designer™ application. The PowerFlex 527 is programmed with the embedded

motion instructions within Studio 5000, these are the same instructions that are used for Allen-Bradley Kinetix® servo

drives. This streamlined approach provides a common user experience and just one software package to learn and use. The

commonality and use of consolidated integration tools helps save valuable engineering time.

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

PowerFlex 527 drive.

PowerFlex 527 AC Drives Feature

Design

•Designed to be used exclusively with Allen-Bradley Logix controllers.

•Designed for machine applications – such as pumps, fans, and in-feed and out-feed conveyors – that need speed

control for induction motors.

•Logix integration helps deliver a high level of motor coordination.

•Built-in dual-port EtherNet/IP supports multiple network topologies and Device Level Ring functionality.

•Built-in hardwired Safe Torque-off. SIL 3 / PLe Cat 3.

•Integrated Safety – controller-based safety delivered via EtherNet/IP. SIL 3 / PLe Cat 3.

•Reduce your spare parts with a standard control module that can be used across the entire power range.

•Support for an incremental encoder accessory card without affecting footprint.

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.

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

•Integral filtering is 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

•Removable MOV to 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.

Rockwell Automation Publication 520-TD002A-EN-E - May 2015 3

PowerFlex 527 AC Drive Specifications

•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 8 kHz ensures quiet operation.

PowerFlex 527 AC Drive Advanced Features

Control Performance

• Frequency Control with the following options:

•Volts per Hertz (V/Hz)

•Sensorless Vector Control (SVC)

•Sensorless Vector Control (SVC) Economizer

• Position Loop, including:

•Closed Loop Position Vector Control (with optional encoder card)

• Velocity Loop, including:

•Closed Loop Velocity Vector Control (with optional encoder card)

I/O Wiring

•Two (2) Analog Inputs (one current and one voltage)

are independently isolated from the rest of the drive

I/O.

•Four (4) Digital Inputs provide application versatility.

•One (1) Analog Output 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 for

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.

Communications

•Built-in dual port for EtherNet/IP allows easy

configuration, control, and collection of drive data over

the network. It also supports Device Level Ring (DLR)

topologies, providing fault-tolerant connectivity for

optimum drive availability.

•Online EDS file creation with RSNetWorx™ providing

ease of set-up on a network.

PowerFlex 527 Control I/O Wiring Block Diagram

11 12 13 14 15 16 17

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

Digital Common

Digital In 1

Digital In 2

Digital In 3

Digital In 4

S+

Relay 1 N.O.

Relay 1 Common

+24V DC

+10V DC

±10V Input

Analog Common

4-20mA Input

Analog Output

Opto Output 1

Opto Output 2

Ethernet

Comm Common

Opto Common

+24V

+10V

Safety 1

Safety 2

Safety +24V

Typical

SNK wiring

Typical

SRC wiring

Pot must be

1...10 k ohm

2 W min.

0-10V

0/4-20 mA

SNK

Digital In

Analog Out

SRC

ACO

AVO

SRC

SNK

Relay 2 Common

Relay 2 N.C.

Common

24V

(1)

4Rockwell Automation Publication 520-TD002A-EN-E - May 2015

PowerFlex 527 AC Drive Specifications

Common DC Bus Installations

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 527 drive has been optimized for use in Common

DC Bus or Shared DC Bus installations.

•Direct DC Bus connection to power terminal blocks.

Improved Ride Through

Operation Down to 1/2 Line Voltage

The PowerFlex 527 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 527 drive also supports

enhanced inertia ride through for additional low voltage mitigation.

•Selectable 1/2 line voltage operation.

•Increased power loss ride through.

Basic Position Control

Closed loop position control using Logix motion instructions such as MAM (Motion Axis Move). For more information

on Logix motion instructions, see the Logix5000 Motion Controllers Instructions Reference Manual, publication

MOTION-RM002.

Closed Loop Feedback

Encoder Option Card

The PowerFlex 527 drive allows for configurable closed loop control with an optional encoder card for either speed or

position feedback for improved speed regulation or basic position control.

•Improved speed regulation

•Basic position control

Feedback Details

Line Driver Type Incremental Encoder Option Card

•Quadrature (dual channel)

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

•Single Ended or Differential (A, B, and Z

Channel)

•Duty Cycle of 50%, +10%

•Input Frequency up to 250 kHz

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-

Z-

to SHLD

Common

External

Power

Supply

SHLD

Marker Z

Marker

Z NOT

to SHLD

to Power Supply

Common

A-

B-

Z-

to SHLD

A NOT

B NOT

Marker

Z NOT

Marker Z

A-

B-

Z-

Encoder Wiring Examples

Rockwell Automation Publication 520-TD002A-EN-E - May 2015 5

PowerFlex 527 AC Drive Specifications

Safety Inside using Safe Torque-Off Function

Safe Torque-off is a standard feature that can be applied through either hardwired safety or Integrated Safety via an

EtherNet/IP network. 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.

•Built-in safety reduces wiring and saves on installation space.

•Meets ISO 13849-1 standards and provides safety ratings up to and including SIL 3/PLe.

Communications and Software

Versatile Programming and Network Solutions

•A network can be configured using

PowerFlex 527 drives for flexible configuration

capabilities.

•Built-in dual port for EtherNet/IP

EtherNet/IP is an established, broadly adopted

network that helps simplify and enhance machine

design and operation. Dual-port EtherNet/IP

connectivity supports linear and ring topologies as well

as device level ring (DLR) functionality.

The application of the CIP Safety protocol enables the

simultaneous transmission of safety and standard

control data and diagnostics information through

EtherNet/IP.

PC Programming Software

Studio 5000 Logix Designer

•PowerFlex 527 drives are designed to be used exclusively with Allen Bradley Logix controllers.

•Drives are programmed using the motion instructions in Studio 5000 Logix Designer(1).

•PowerFlex 527 drives feature drive configuration that is stored in the Logix controller, supporting fast, automatic

device replacement.

(1) Studio 5000 Logix Designer (formerly RSLogix 5000) version 24 or greater is required.

Linear Topology

Star Topology

Ring Topology Only Rockwell Automation supports

rings at the device level (DLR)

6Rockwell Automation Publication 520-TD002A-EN-E - May 2015

PowerFlex 527 AC Drive Specifications

PowerFlex 527 Drive Family

Frame A Frame B Frame C Frame D Frame E

Rockwell Automation Publication 520-TD002A-EN-E - May 2015 7

PowerFlex 527 AC Drive Specifications

Catalog Number Explanation

Code Type

25C PowerFlex 527

(1) Normal and Heavy Duty ratings are available for drives above 15 HP / 11 kW.

1-3 4 5 6-8 9 10 11 12 13 14

25C – 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(1) 30.0 D20.0 15.0 15.0 11.0

037(1) 37.0 E25.0 18.5 20.0 15.0

043(1) 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(1) 22.0 D20.0 15.0 15.0 11.0

027(1) 27.0 E25.0 18.5 20.0 15.0

032(1) 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

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

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

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(1) 48.3 E15.0 11.0 15.0 11.0

062(1) 62.1 E20.0 15.0 15.0 11.0

8Rockwell Automation Publication 520-TD002A-EN-E - May 2015

PowerFlex 527 AC Drive Specifications

Technical Specifications

Protection

Electrical

Specifications PowerFlex 527

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

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)

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 527

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

Rockwell Automation Publication 520-TD002A-EN-E - May 2015 9

PowerFlex 527 AC Drive Specifications

Control

Control Inputs

Specifications PowerFlex 527

Method •Frequency Control:

–Volts per Hertz (V/Hz)

–Sensorless Vector Control (SVC)

–Sensorless Vector Control (SVC) Economizer

•Position Loop:

–Closed Loop Position Vector Control (with optional encoder card)

•Velocity Loop:

–Closed Loop Velocity Vector Control (with optional encoder card)

Carrier Frequency 2...8 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

Performance

V/Hz (Volts per Hertz):

SVC (Sensorless Vector):

SVC Economizer:

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

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

Performance with Encoder

Closed Loop Velocity Vector Control: ±0.1% of base speed across a 100:1 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 – Disable & Coast, Current Decel & Disable, and Ramp Decel & Hold

Accel/Decel: “REAL” tag programmable with Studio 5000 motion instructions.

For more information see the Logix5000 Motion Controllers Instructions Reference Manual, publication MOTION-RM002.

Intermittent Overload

Normal Duty:

Heavy 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.

150% Overload capability for up to 60 s, 180% for up to 3 s (200% programmable)

Specifications PowerFlex 527

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

Quantity: (4) Programmable

Current: 6 mA

Type

Source Mode (SRC):

Sink Mode (SNK):

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

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

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

Specification

Resolution:

±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

10 Rockwell Automation Publication 520-TD002A-EN-E - May 2015

PowerFlex 527 AC Drive Specifications

Control Outputs

Encoder

Safety

(per

channel)

Input Current: <10 mA

Input ON Voltage, max: 18...26.4V DC

Input OFF Voltage, max: 5V DC

Input ON Current: 10 mA

Input OFF Current: 500 µA

Pulse Rejection Width: 700 µs

External Power Supply: SELV/PELV

Input Type: Optically isolated and reverse voltage protected

Specifications PowerFlex 527

Relay Quantity: (2) 1 Programmable Form A and 1 Programmable Form B

Specification

Resistive Rating:

Inductive Rating:

3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC

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

Specification

Resolution:

0-10V DC Analog:

4-20 mA Analog:

10-bit

1 k ohm minimum

525 ohm maximum

Specifications PowerFlex 527

Type: Incremental, dual channel

Supply: 5V, 12V, 250 mA

Quadrature: 90°, ±27°@ 25 °C

Duty Cycle: 50%, +10%

Requirements: Encoders must be line driver type, quadrature (dual channel), 3.5...26V DC output, single-ended or differential andcapable 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.

Specifications PowerFlex 527

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