Allen-Bradley PowerFlex 525 User manual

PowerFlex 525 Adjustable Frequency AC Drive
User Manual
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.
Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, DriveTools SP, AppView, CustomView, MainsFree Programming, and PointStop are trademarks of
Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
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.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 3
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Preface
Overview
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Installation/Wiring
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter 2
Start Up
Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Display and Control Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Smart Start-Up with Basic Program Group Parameters . . . . . . . . . . . . . . 52
LCD & Scrolling Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 3
Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Basic Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

4Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Table of Contents
Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Network Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Fault and Diagnostic Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Parameter Cross Reference by Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Chapter 4
Troubleshooting
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 138
Appendix A
Supplemental Drive Information
Drives, Fuse & Circuit Breaker Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Appendix B
Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Appendix C
RS485 (DSI) Protocol
Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 177
Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 180
Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Appendix D
Velocity StepLogic, Basic Logic and
Timer/Counter Functions
Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 182
Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Counter Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 5
Table of Contents
Appendix E
Encoder/Pulse Train Usage and
Position StepLogic Application
Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 189
Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Setup Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Appendix F
PID Set Up
PID Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Appendix G
Safe-Torque-Off Function
PowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . . 207
EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 211
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
PowerFlex 525 Safe-Torque-Off Operation . . . . . . . . . . . . . . . . . . . . . . . 211
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
PowerFlex 525 Certification for Safe-Torque-Off. . . . . . . . . . . . . . . . . . 217
Appendix H
EtherNet/IP
Establishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . 219
Appendix I
Control Diagrams
Induction Motor Tuning Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Index

6Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Table of Contents
Notes:

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 7
Preface
Overview
The purpose of this manual is to provide you with the basic information needed
to install, start-up and troubleshoot the PowerFlex® 525 Adjustable Frequency
AC Drive.
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
Documentation
All the recommended documentation listed in this section is available online at
http://www.rockwellautomation.com/literature.
The following publications provide general drive information:
The following publications provide specific PowerFlex 520-Series information on
drive installation, features, specifications, and service:
For information on… See page…
Who Should Use this Manual 7
Recommended Documentation 7
Manual Conventions 8
Drive Frame Sizes 9
General Precautions 9
Catalog Number Explanation 10
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
Title Publication
PowerFlex 525 AC Drive Specifications 520-TD001
PowerFlex Dynamic Braking Resistor Calculator PFLEX-AT001
PowerFlex AC Drives in Common Bus Configurations DRIVES-AT002

8Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Preface Overview
The following publications provide specific Network Communications
information:
Manual Conventions •In this manual we refer to PowerFlex 520-Series Adjustable Frequency AC
Drive as; drive, PowerFlex 520, PowerFlex 520 Drive or PowerFlex 520 AC
drive.
•Specific drives within the PowerFlex 520-Series may be referred to as:
– PowerFlex 525, PowerFlex 525 drive or PowerFlex 525 AC drive.
•Parameter numbers and names are shown in this format:
•The following words are used throughout the manual to describe an
action:
•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 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.
Title Publication
PowerFlex 525 Embedded EtherNet/IP Adapter (including dual port Ethernet) 520COM-UM001
PowerFlex 525 DeviceNet Adapter 520COM-UM002
PowerFlex 525 PROFIBUS DP Adapter 520COM-UM003
P 031 [Motor NP Volts]
Name
Number
Group
b
P
t
C
L
d
A
M
N
G
F
= Basic Display
= Basic Program
= Terminal Blocks
= Communications
= Logic
= Advanced Display
= Advanced Program
= Modified
= Network
= AppView and CustomView
= Fault and Diagnostic
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

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 9
Overview Preface
Drive Frame Sizes Similar PowerFlex 525 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.
General Precautions ATTENTION: The drive contains high voltage capacitors which take time to
discharge after removal of mains supply. Before working on drive, ensure
isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three
minutes for capacitors to discharge to safe voltage levels. Failure to do so may
result in personal injury or death.
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. Staticcontrol 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 inputvoltage 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 equal or better performance in most cases.
ATTENTION: Risk of injury or equipment damage exists. Drive does not contain
user-serviceable components. Do not disassemble drive chassis.

10 Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Preface Overview
Catalog Number Explanation
Code Braking
4Standard
Code EMC Filter
0NoFilter
1Filter
Code Interface Module
1Standard
Code Enclosure
N IP 20 NEMA/Open
Code Voltage Phase
V120VAC1
A240VAC1
B240VAC3
D480VAC3
E600VAC3
Code Type
25B PowerFlex 525
* 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
25B - B 2P3 N 1 1 4 – –
Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash
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 3.7 5.0 3.7
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 48.3 E 15.0 11.0 15.0 11.0
062 62.1 E20.0 15.0 15.0 11.0
Output Current @ 3 Phase, 380...480V Input
Code Amps Frame 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 30.0 D20.0 15.0 15.0 11.0
037 37.0 E25.0 18.5 20.0 15.0
043 43.0 E30.0 22.0 25.0 18.5
Output Current @ 3 Phase, 525...600V Input
Code Amps Frame 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 3.7 5.0 3.7
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 22.0 D20.0 15.0 15.0 11.0
027 27.0 E25.0 18.5 20.0 15.0
032 32.0 E30.0 22.0 25.0 18.5

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 11
Chapter 1
Installation/Wiring
This chapter provides information on mounting and wiring the PowerFlex 525
drive.
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.
Mounting Considerations •Mount the drive upright on a flat, vertical and level surface.
•Protect the cooling fan by avoiding dust or metallic particles.
For information on... See page...
Mounting Considerations 11
AC Supply Source Considerations 15
General Grounding Requirements 16
Fuses and Circuit Breakers 18
Power and Control Module 22
Control Module Cover 25
Power Module Terminal Guard 25
Power Wiring 26
Power Terminal Block 29
Common Bus/Precharge Notes 30
I/O Wiring 30
Control I/O Terminal Block 32
Start and Speed Reference Control 39
CE Conformity 41
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.
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.)

12 Rockwell Automation Publication 520-UM001A-EN-E - February 2013
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.
(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.
25 mm
(1.0 in.)
25 mm
(1.0 in.) (2)
(2)
25 mm
(1.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)(1) 50 mm (2.0 in.)(1)
50 mm
(2.0 in.)(1)
50 mm
(2.0 in.)
50 mm
(2.0 in.) 50 mm
(2.0 in.)
Esc
Sel
Esc
Sel
Esc
Sel
Esc
Sel
50 mm
(2.0 in.) 50 mm
(2.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
Esc
Sel
Esc
Sel
50 mm
(2.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.) 50 mm
(2.0 in.)
50 mm
(2.0 in.)(1)
Esc
Sel
Esc
Sel
Esc
Sel
Esc
Sel
Esc
Sel
Esc
Sel
Vertical, Zero Stacking
No clearance between drives.
Horizontal, Zero Stacking with
Control Module Fan Kit
No clearance between drives.
Vertical Vertical, Zero Stacking with
Control Module Fan Kit
No clearance between drives.
Vertical with Control Module Fan Kit
Horizontal with Control Module Fan Kit

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 13
Installation/Wiring Chapter 1
Ambient Operating Temperatures
See Appendix B for option kits.
Current Derating Curves
Vertical Mounting
Horizontal/Floor Mounting
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
-20 °C (-4 °F)
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 40 °C (104 °F) 50 °C (122 °F) –
Horizontal with
Control Module Fan Kit(4)(5) IP 20/Open Type 50 °C (122 °F) – 70 °C (158 °F)
Horizontal, Zero Stacking
with Control Module Fan Kit(4)(5) IP 20/Open Type 45 °C (113 °F) – 65 °C (149 °F)
(1) IP 30/NEMA 1/UL Type 1 rating requiresinstallation of the PowerFlex 520-Series IP 30/NEMA 1/UL Type 1 option kit, catalog number 25-JBAx.
(2) For catalogs 25B-D1P4N104 and 25B-E0P9N104, the temperature listed under the Maximum (Derate) column is reduced by 5 °C (9 °F) for all mounting methods.
(3) For catalogs 25B-D1P4N104 and 25B-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 25B-D1P4N104 and 25B-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.
Ambient Temperature (°C)
40
100
90
110
120
80
70
60
50
45403530 60 65 70 75 80 5550
Percentage of Rated Current (%)
IP 30/NEMA 1 with Control
Module Fan Kit
IP 20/Open Type
Ambient Temperature (°C)
40
100
90
110
120
80
70
60
50
45403530 60 65 70 75 80 5550
Percentage of Rated Current (%)
IP 30/NEMA 1 with Control
Module Fan Kit
IP 20/Open Type
Single Drive Zero Stacking
Ambient Temperature (°C)
40
100
90
120
110
80
70
60
50
30 35 70 75 80 60 6550 5540 45
Percentage of Rated Current (%)
with Control
Module Fan Kit
IP 20/Open Type
Ambient Temperature (°C)
40
100
90
120
110
80
70
60
50
30 35 70 75 80 60 6550 5540 45
Percentage of Rated Current (%)
with Control
Module Fan Kit
IP 20/Open Type
Single Drive Zero Stacking

14 Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Chapter 1 Installation/Wiring
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 (41 °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.
High Altitude
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.
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
Altitude (m)
Percentage of Rated Current (%)
40
90
100
110
120
80
70
60
50
04000 300020001000
Altitude (m)
Ambient Temperature (°C)
20
50
60
40
30
04000 300020001000

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 15
Installation/Wiring Chapter 1
AC Supply Source
Considerations
Ungrounded Distribution Systems
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)
Phase to Ground MOV Removal
ATTENTION: PowerFlex 525 contains 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.
IMPORTANT
Tighten screw after jumper removal.
Power Module
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper

16 Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Chapter 1 Installation/Wiring
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated
voltage of the drive (see Appendix A). 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.
General Grounding
Requirements
The drive Safety Ground - (PE) must be connected to system ground. Ground
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
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)
•or Isolation Transformer
(2) See Appendix B for accessory ordering information.
Greater than 120 kVA supply transformer
Line has power factor correction capacitors •Install Line Reactor(2)
•or Isolation Transformer
Line has frequent power interruptions
Line has intermittent noisespikesin excess of 6000V (lightning)
Phase to ground voltage exceeds 125% of normal line to line voltage •Remove MOV jumper to ground.
•or Install Isolation Transformer with
grounded secondary if necessary.
Ungrounded distribution system
240V open delta configuration (stinger leg)(1)
(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 156 for specific line reactor part numbers.
•Install Line Reactor(2)
SHLD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
Esc
Sel

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 17
Installation/Wiring Chapter 1
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.
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.

18 Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Chapter 1 Installation/Wiring
Fuses and Circuit Breakers The PowerFlex 525 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.
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 and group motor applications.
•Bulletin 140M can be used up stream from the drive without the need for
fuses.
Fusing
The ratings in the tables that follow are the recommended values for use with
each drive rating. The devices listed in this table are provided to serve as a guide.

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 19
Installation/Wiring Chapter 1
100...120V 1-Phase Input Protection Devices – Frames A...B 200...240V 1-Phase Input Protection Devices – Frames A...B 200...240V 3-Phase Input Protection Devices – Frames A...E (1) Normal and Heavy duty ratings are available for drives above 15 HP / 11 kW.
Catalog No.
Output Ratings Input Ratings
Frame Size
Contactor Catalog No.
IEC (Non-UL Applications) UL Applications
Normal Duty Heavy Duty
Amps kVA Amps
Fuses Circuit Breakers Fuses (Max. Rating) Circuit Breakers
HP kW HP kW Min. Rating Max. Rating 140U 140M Class / Catalog No. UL 489 (140U) UL 140 (140M)
25B-V2P5N104 0.5 0.4 0.5 0.4 2.5 1.3 9.6 A 100-C12 15 20 140U-D6D2-C12 140M-C2E-C10 CLASS RK5, J or T / DLS-R-20 140U-D6C2-C12 140M-C2E-C10 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, J or T / DLS-R-40 140U-D6D2-C25 140M-D8E-C20 25B-V6P0N104 1.5 1.1 1.5 1.1 6.0 3.2 24.0 B 100-C23 30 50 140U-D6D2-C30 140M-F8E-C25 CLASS RK5, J or T / DLS-R-50 140U-D6D2-C30 140M-F8E-C25
Catalog No.
Output Ratings Input Ratings
Frame Size
Contactor Catalog No.
IEC (Non-UL Applications) UL Applications
Normal Duty Heavy Duty
Amps kVA Amps
Fuses Circuit Breakers Fuses (Max. Rating) Circuit Breakers
HP kW HP kW Min. Rating Max. Rating 140U 140M Class / Catalog No. UL 489 (140U) UL 140 (140M)
25B-A2P5N104 0.5 0.4 0.5 0.4 2.5 1.7 6.5 A 100-C09 10 15 140U-D6D2-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-15 140U-D6D2-C10 140M-C2E-C10 25B-A2P5N114 0.5 0.4 0.5 0.4 2.5 1.7 6.5 A 100-C09 10 15 140U-D6D2-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-15 140U-D6D2-C10 140M-C2E-C10 25B-A4P8N104 1.0 0.75 1.0 0.75 4.8 2.8 10.7 A 100-C12 15 25 140U-D6D2-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-25 140U-D6D2-C15 140M-C2E-C16 25B-A4P8N114 1.0 0.75 1.0 0.75 4.8 2.8 10.7 A 100-C12 15 25 140U-D6D2-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-25 140U-D6D2-C15 140M-C2E-C16 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 J or T / 40 140U-D6D2-C25 140M-F8E-C25 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 J or T / 40 140U-D6D2-C25 140M-F8E-C25 25B-A011N104 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 30 50 140U-H6C2-C35 140M-F8E-C25 CLASS J or T / 50 140U-H6C2-C35 140M-F8E-C25 25B-A011N114 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 30 50 140U-H6C2-C35 140M-F8E-C25 CLASS J or T / 50 140U-H6C2-C35 140M-F8E-C25
Catalog No.(1)
Output Ratings Input Ratings
Frame Size
Contactor Catalog No.
IEC (Non-UL Applications) UL Applications
Normal Duty Heavy Duty
Amps kVA Amps
Fuses Circuit Breakers Fuses (Max. Rating) Circuit Breakers
HP kW HP kW Min. Rating Max. Rating 140U 140M Class / Catalog No. UL 489 (140U) UL 140 (140M)
25B-B2P5N104 0.5 0.4 0.5 0.4 2.5 1.2 2.7 A 100-C07 6 6 140U-D6D3-B40 140M-C2E-B40 CLASS RK5, J or T / DLS-R-6 140U-D6D3-B40 140M-C2E-B40 25B-B5P0N104 1.0 0.75 1.0 0.75 5.0 2.7 5.8 A 100-C09 10 15 140U-D6D3-B80 140M-C2E-B63 CLASS RK5, J or T / DLS-R-15 140U-D6D3-B80 140M-C2E-B63 25B-B8P0N104 2.0 1.5 2.0 1.5 8.0 4.3 9.5 A 100-C12 15 20 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-20 140U-D6D3-C10 140M-C2E-C10 25B-B011N104 3.0 2.2 3.0 2.2 11.0 6.3 13.8 A 100-C23 20 30 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-30 140U-D6D3-C15 140M-C2E-C16 25B-B017N104 5.0 3.7 5.0 3.7 17.5 9.6 21.1 B 100-C23 30 45 140U-D6D3-C25 140M-F8E-C25 CLASS J or T / 45 140U-D6D3-C25 140M-F8E-C25 25B-B024N104 7.5 5.5 7.5 5.5 24.0 12.2 26.6 C 100-C37 35 60 140U-H6C3-C35 140M-F8E-C32 CLASS J or T / 60 140U-H6C3-C35 140M-F8E-C32 25B-B032N104 10.0 7.5 10.0 7.5 32.2 15.9 34.8 D 100-C43 45 70 140U-H6C3-C60 140M-F8E-C45 CLASS RK5, J or T / DLS-R-70 – 140M-F8E-C45 25B-B048N104 15.0 11.0 15.0 11.0 48.3 20.1 44.0 E 100-C60 60 90 140U-H6C3-C70 140M-F8E-C45 CLASS J or T / 90 – –
25B-B062N104 20.0 15.0 15.0 11.0 62.1 25.6 56.0 E100-C72 70 125 140U-H6C3-C90 140M-H8P-C70 CLASS J or T / 125 – –

20 Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Chapter 1 Installation/Wiring
380...480V 3-Phase Input Protection Devices – Frames A...E (1) Normal and Heavy duty ratings are available for drives above 15 HP / 11 kW.
Catalog No.(1)
Output Ratings Input Ratings
Frame Size
Contactor Catalog No.
IEC (Non-UL Applications) UL Applications
Normal Duty Heavy Duty
Amps kVA Amps
Fuses Circuit Breakers Fuses (Max. Rating) Circuit Breakers
HP kW HP kW Min. Rating Max. Rating 140U 140M Class / Catalog No. UL 489 (140U) UL 140 (140M)
25B-D1P4N104 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C07 3 6 140U-D6D3-B30 140M-C2E-B25 CLASS RK5, J or T / DLS-R-6 – 140M-C2E-B25 25B-D1P4N114 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C07 3 6 140U-D6D3-B30 140M-C2E-B25 CLASS RK5, J or T / DLS-R-6 – 140M-C2E-B25 25B-D2P3N104 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C07 6 10 140U-D6D3-B60 140M-C2E-B40 CLASS RK5, J or T / DLS-R-10 – 140M-C2E-B40 25B-D2P3N114 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C07 6 10 140U-D6D3-B60 140M-C2E-B40 CLASS RK5, J or T / DLS-R-10 – 140M-C2E-B40 25B-D4P0N104 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 15 140U-D6D3-B60 140M-C2E-B63 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-B63 25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 15 140U-D6D3-B60 140M-C2E-B63 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-B63 25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 15 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-C10 25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 15 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-C10 25B-D010N104 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 30 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-30 – 140M-C2E-C16 25B-D010N114 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 30 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-30 – 140M-C2E-C16 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 J or T / 35 – 140M-D8E-C20 25B-D013N114 7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 20 35 140U-D6D3-C15 140M-D8E-C20 CLASS J or T / 35 – 140M-D8E-C20 25B-D017N104 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40 140U-D6D3-C25 140M-D8E-C20 CLASS J or T / 40 – 140M-D8E-C20 25B-D017N114 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40 140U-D6D3-C25 140M-D8E-C20 CLASS J or T / 40 – 140M-F8E-C20 25B-D024N104 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 60 140U-H6C3-C40 140M-F8E-C32 CLASS J or T / 60 – – 25B-D024N114 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 60 140U-H6C3-C40 140M-F8E-C32 CLASS J or T / 60 – –
25B-D030N104 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D100-C43 45 70 140U-H6C3-C50 140M-F8E-C45 CLASS J or T / 70 – – 25B-D030N114 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D100-C43 45 70 140U-H6C3-C50 140M-F8E-C45 CLASS J or T / 70 – – 25B-D037N114 25.0 18.5 20.0 15.0 37.0 30.8 33.7 E100-C43 45 70 140U-H6C3-C50 140M-F8E-C45 CLASS J or T / 70 –140M-F8E-C45 25B-D043N114 30.0 22.0 25.0 18.5 43.0 35.6 38.9 E100-C60 50 80 140U-H6C3-C60 140M-F8E-C45 CLASS J or T / 80 –140M-F8E-C45