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.
04
05
06
07
01
02
03
08
11
12
13
14
15
16
17
18
19
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
R1
R2
S1
S2
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
R1
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
R5
R6
Relay 2 Common
Relay 2 N.C.
C1
C2
Safe-Torque-O
PowerFlex525
Control I/O
Wiring Block
Diagram
04
05
06
01
02
03
11
12
13
14
15
C1
C2
Digital Common
DigIn TermBlk 05/Pulse
DigIn TermBlk 06
Stop (1)
DigIn TermBlk 02/
Start/Run FWD (2)
DigIn TermBlk 03/
Direction/Run REV
R1
R2
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
R1
11 12 13 14 15 C1 C2
R2
R3
01 02 03 04 05 06
Pot must be (4)
1...10 k ohm
2 W min.
4-20 mA
source
13
14
SNK
Digital In
DigIn TermBlk 05 Sel
J7J8
Pulse In
SRC Digital
Input
SRCSNK
R3
Relay N.C.
0/4-20 mA
Analog Out
J13
0-10V
4-20 mA
Analog In
J4
0-10V
81
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
A-
B
B-
Cm
+V
to SHLD
+
Common
External
Power
Supply
to
SHLD
A NOT
A
B
B NOT
to SHLD
to Power Supply
Common
A
A-
B
B-
Cm
+V
to SHLD
A NOT
B
A
B NOT
A
A-
B
B-
Cm
+V
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
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
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
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
e
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
e
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
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
±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 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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