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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Rockwell Automation Publication 520-TD001E-EN-E - July 2016 11
PowerFlex 520-Series AC Drive Specifications
Control Outputs
Encoder
Specifications PowerFlex 523 PowerFlex 525
Relay Quantity: (1) Programmable Form C (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(1)
(1) Feature is not applicable to PowerFlex 523 series A drives.
Specification
Resolution:
0-10V DC Analog:
4-20 mA Analog:
10-bit
1 k ohm minimum
525 ohm maximum
Specifications PowerFlex 523 PowerFlex 525
Type: – Incremental, dual channel
Supply: 12V, 250 mA
Quadrature: 90°, ±27°@ 25 °C
Duty Cycle: 50%, +10%
Requirements: Encoders must be line driver type, quadrature (dual channel) or pulse (single channel), 3.5...26V DC
output, single-ended or differential and capable of supplying a minimum of 10 mA per channel.
Allowable input is DC up to a maximum frequency of 250 kHz. The encoder I/O automatically scales
to allow 5V, 12V and 24V DC nominal voltages.
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12 Rockwell Automation Publication 520-TD001E-EN-E - July 2016
PowerFlex 520-Series AC Drive Specifications
Environmental Specifications
Specifications PowerFlex 523 PowerFlex 525
Altitude
Without derating:
With derating:
See Current Derating Curves on page 18 for derating guidelines.
1000 m (3300 ft) max.
Up to 4000 m (13,200 ft) max., with the exception of 600V drives at 2000 m (6600 ft) max.
Surrounding Air Temperature, max.
Without derating:
With derating:
See Current Derating Curves on page 18 for derating guidelines.
-20...50 °C (-4...122 °F)
-20...60 °C (-4...140 °F) or -20...70 °C (-4...158 °F) with optional Control Module Fan kit.
Storage Temperature
Frame A...D:
Frame E:
-40...85 °C (-40...185 °F)
-40...70 °C (-40...158 °F)
Atmosphere:
Relative Humidity: 0...95% noncondensing
Shock:
Vibration:
Complies with IEC 60068-2-27
Complies with IEC 60068-2-6:1995
Conformal Coating: Complies with:
IEC 60721-3-3 to level 3C2 (chemical and gases only)
Surrounding Environment Pollution Degree
Pollution Degree 1 & 2: All enclosures acceptable.
Sound Pressure Level (A-weighted)
Frame A & B:
Frame C:
Frame D:
Frame E:
Measurements are taken 1 m from the drive.
Maximum 53 dBA
Maximum 57 dBA
Maximum 64 dBA
Maximum 68 dBA
IMPORTANT
Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors
or dust. If the drive is not going to be installed for a period of time, it must be stored in an area where it will not
be exposed to a corrosive atmosphere.
Frame
Size
Operating and Nonoperating Nonoperating (Transportation)
Force (Shock/Vibration) Mounting Type Force (Shock/Vibration) Mounting Type
A 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only
B 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only
C 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only
D 15 g / 2 g Screw only 30 g/ 2.5 g Screw only
E 15 g / 1.5 g Screw only 30 g/ 2.5 g Screw only
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Rockwell Automation Publication 520-TD001E-EN-E - July 2016 13
PowerFlex 520-Series AC Drive Specifications
Certifications
Certification PowerFlex 523 PowerFlex 525
c-UL-us Listed to UL508C and CAN/CSA-C22.2 No. 14-05.
RCM Australian Communications and Media Authority
In conformity with the following:
Radiocommunications Act: 1992
Radiocommunications Standard: 2008
Radiocommunications Labelling Notice: 2008
Standards applied:
EN 61800-3
CE In conformity with the following European Directives:
2014/35/EU Low Voltage Directive (LVD)
2014/30/EU EMC Directive (EMC)
2014/34/EU ATEX Directive (ATEX)
2006/42/EC Machinery Directive (MD)
Standards applied:
EN 61800-3
EN 61800-5-1
TUV (Applicable to PowerFlex 525 drives only)
TÜV Rheinland
Standards applied:
EN ISO 13849-1
EN 61800-5-2
EN 61508 PARTS 1-7
EN 62061
EN 60204-1
Certified to ISO 13849-1 SIL2/PLd with embedded Safe-Torque-Off function
Meets Functional Safety (FS) when used with embedded Safe-Torque-Off function
ATEX
II (2) G D
TUV 12 ATEX 7199 X
(Applicable to PowerFlex 525 drives only)
Certified to ATEX directive 2014/34/EU
Group II Category (2) GD Applications with ATEX Approved Motors
KCC Korean Registration of Broadcasting and Communications Equipment
Compliant with the following standards:
Article 58-2 of Radio Waves Act, Clause 3
EAC Standards applied:
Low Voltage TP TC 004/2011
EMC TP TC 020/2011
AC 156 Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification Testing of Nonstructural Componentsand 2003 International
Building Code for worst-case seismic level for USA excluding site class F
SEMI F47 Electric Power Research Institute
Certified compliant with the following standards:
SEMI F47
IEC 61000-4-11
IEC 61000-4-34
Lloyds Register (Applicable to PowerFlex 525 drives only)
Lloyd’s Register Type Approval Certificate 12/10068(E1)
RoHS Compliant with the European “Restriction of Hazardous Substances” Directive
The drive is also designed to meet the appropriate portions of the following specifications:
NFPA 70 - US National Electrical Code
NEMA ICS 7.1 - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable Speed Drive Systems.
Functional
Safety
Typ e
Approved
www.tuv.com
ID 0600000000
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14 Rockwell Automation Publication 520-TD001E-EN-E - July 2016
PowerFlex 520-Series AC Drive Specifications
Dimensions and Weights
Frame/Rating Cross-Reference
Catalog Number Description
PowerFlex 520-Series Drive Ratings
25B - V 2P5 N 1 0 4
Drive Voltage Rating Rating Enclosure HIM Emission Class Version
PowerFlex 523 PowerFlex 525
Output Ratings
Input
Voltage Range Total Watts Loss Frame Size
Normal Duty Heavy Duty Output
Current (A)Catalog No. Catalog No. HP kW HP kW
100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
25A-V1P6N104 – 0.25 0.2 0.25 0.2 1.6 85...132 20.0 A
25A-V2P5N104 25B-V2P5N104 0.5 0.4 0.5 0.4 2.5 85...132 27.0 A
25A-V4P8N104 25B-V4P8N104 1.0 0.75 1.0 0.75 4.8 85...132 53.0 B
25A-V6P0N104 25B-V6P0N104 1.5 1.1 1.5 1.1 6.0 85...132 67.0 B
200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
25A-A1P6N104 – 0.25 0.2 0.25 0.2 1.6 85...132 20.0 A
25A-A2P5N104 25B-A2P5N104 0.5 0.4 0.5 0.4 2.5 170...264 29.0 A
25A-A4P8N104 25B-A4P8N104 1.0 0.75 1.0 0.75 4.8 170...264 50.0 A
25A-A8P0N104 25B-A8P0N104 2.0 1.5 2.0 1.5 8.0 170...264 81.0 B
25A-A011N104 25B-A011N104 3.0 2.2 3.0 2.2 11.0 170...264 111.0 B
200...240V AC (-15%, +10%) – 1-Phase Input with EMC Filter, 0...230V 3-Phase Output
25A-A1P6N114 – 0.25 0.2 0.25 0.2 1.6 85...132 20.0 A
25A-A2P5N114 25B-A2P5N114 0.5 0.4 0.5 0.4 2.5 170...264 29.0 A
25A-A4P8N114 25B-A4P8N114 1.0 0.75 1.0 0.75 4.8 170...264 53.0 A
25A-A8P0N114 25B-A8P0N114 2.0 1.5 2.0 1.5 8.0 170...264 84.0 B
25A-A011N114 25B-A011N114 3.0 2.2 3.0 2.2 11.0 170...264 116.0 B
200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output
25A-B1P6N104 – 0.25 0.2 0.25 0.2 1.6 85...132 20.0 A
25A-B2P5N104 25B-B2P5N104 0.5 0.4 0.5 0.4 2.5 170...264 29.0 A
25A-B5P0N104 25B-B5P0N104 1.0 0.75 1.0 0.75 5.0 170...264 50.0 A
25A-B8P0N104 25B-B8P0N104 2.0 1.5 2.0 1.5 8.0 170...264 79.0 A
25A-B011N104 25B-B011N104 3.0 2.2 3.0 2.2 11.0 170...264 107.0 A
25A-B017N104 25B-B017N104 5.0 4.0 5.0 4.0 17.5 170...264 148.0 B
25A-B024N104 25B-B024N104 7.5 5.5 7.5 5.5 24.0 170...264 259.0 C
25A-B032N104 25B-B032N104 10.0 7.5 10.0 7.5 32.2 170...264 323.0 D
25A-B048N104 25B-B048N104 15.0 11.0 10.0 7.5 48.3 170...264 584.0 E
25A-B062N104 25B-B062N104 20.0 15.0 15.0 11.0 62.1 170...264 708.0 E
380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output(1)
25A-D1P4N104 25B-D1P4N104 0.5 0.4 0.5 0.4 1.4 323...528 27.0 A
25A-D2P3N104 25B-D2P3N104 1.0 0.75 1.0 0.75 2.3 323...528 37.0 A
25A-D4P0N104 25B-D4P0N104 2.0 1.5 2.0 1.5 4.0 323...528 62.0 A
25A-D6P0N104 25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 323...528 86.0 A
25A-D010N104 25B-D010N104 5.0 4.0 5.0 4.0 10.5 323...528 129.0 B
25A-D013N104 25B-D013N104 7.5 5.5 7.5 5.5 13.0 323...528 170.0 C
25A-D017N104 25B-D017N104 10.0 7.5 10.0 7.5 17.0 323...528 221.0 C
25A-D024N104 25B-D024N104 15.0 11.0 15.0 11.0 24.0 323...528 303.0 D
25A-D030N104 25B-D030N104 20.0 15.0 15.0 11.0 30.0 323...528 387.0 D
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Rockwell Automation Publication 520-TD001E-EN-E - July 2016 15
PowerFlex 520-Series AC Drive Specifications
(1) A non-filtered drive is not available for 380...480V AC 25 HP (18.5 kW) and 30 HP (22.0 kW) ratings. Filtered drives are available, however you must verify that the application will support a filtered drive.
380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output
25A-D1P4N114 25B-D1P4N114 0.5 0.4 0.5 0.4 1.4 323...528 27.0 A
25A-D2P3N114 25B-D2P3N114 1.0 0.75 1.0 0.75 2.3 323...528 37.0 A
25A-D4P0N114 25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 323...528 63.0 A
25A-D6P0N114 25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 323...528 88.0 A
25A-D010N114 25B-D010N114 5.0 4.0 5.0 4.0 10.5 323...528 133.0 B
25A-D013N114 25B-D013N114 7.5 5.5 7.5 5.5 13.0 323...528 175.0 C
25A-D017N114 25B-D017N114 10.0 7.5 10.0 7.5 17.0 323...528 230.0 C
25A-D024N114 25B-D024N114 15.0 11.0 15.0 11.0 24.0 323...528 313.0 D
25A-D030N114 25B-D030N114 20.0 15.0 15.0 11.0 30.0 323...528 402.0 D
25A-D037N114 25B-D037N114 25.0 18.5 20.0 15.0 37.0 323...528 602.0 E
25A-D043N114 25B-D043N114 30.0 22.0 25.0 18.5 43.0 323...528 697.0 E
525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output
25A-E0P9N104 25B-E0P9N104 0.5 0.4 0.5 0.4 0.9 446...660 22.0 A
25A-E1P7N104 25B-E1P7N104 1.0 0.75 1.0 0.75 1.7 446...660 32.0 A
25A-E3P0N104 25B-E3P0N104 2.0 1.5 2.0 1.5 3.0 446...660 50.0 A
25A-E4P2N104 25B-E4P2N104 3.0 2.2 3.0 2.2 4.2 446...660 65.0 A
25A-E6P6N104 25B-E6P6N104 5.0 4.0 5.0 4.0 6.6 446...660 95.0 B
25A-E9P9N104 25B-E9P9N104 7.5 5.5 7.5 5.5 9.9 446...660 138.0 C
25A-E012N104 25B-E012N104 10.0 7.5 10.0 7.5 12.0 446...660 164.0 C
25A-E019N104 25B-E019N104 15.0 11.0 15.0 11.0 19.0 446...660 290.0 D
25A-E022N104 25B-E022N104 20.0 15.0 15.0 11.0 22.0 446...660 336.0 D
25A-E027N104 25B-E027N104 25.0 18.5 20.0 15.0 27.0 446...660 466.0 E
25A-E032N104 25B-E032N104 30.0 22.0 25.0 18.5 32.0 446...660 562.0 E
PowerFlex 523 PowerFlex 525
Output Ratings
Input
Voltage Range Total Watts Loss Frame Size
Normal Duty Heavy Duty Output
Current (A)Catalog No. Catalog No. HP kW HP kW
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16 Rockwell Automation Publication 520-TD001E-EN-E - July 2016
PowerFlex 520-Series AC Drive Specifications
Drive Dimensions and Weight
Dimensions are in mm and (in.). Weights are in kg and (lb).
Design Considerations
Mounting Considerations
•Mount the drive upright on a flat, vertical and level surface.
•Protect the cooling fan by avoiding dust or metallic particles.
•Do not expose to a corrosive atmosphere.
•Protect from moisture and direct sunlight.
Frame Size A B C D E Weight
A 72.0 (2.83) 152.0 (5.98) 172.0 (6.77) 57.5 (2.26) 140.0 (5.51) 1.1 (2.4)
B 87.0 (3.43) 180.0 (7.09) 172.0 (6.77) 72.5 (2.85) 168.0 (6.61) 1.6 (3.5)
C 109.0 (4.29) 220.0 (8.66) 184.0 (7.24) 90.5 (3.56) 207.0 (8.15) 2.3 (5.0)
D 130.0 (5.12) 260.0 (10.24) 212.0 (8.35) 116.0 (4.57) 247.0 (9.72) 3.9 (8.6)
E 185.0 (7.28) 300.0 (11.81) 279.0 (10.98) 160.0 (6.30) 280.0 (11.02) 12.9 (28.4)
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.)
Esc
Sel
AC
B
E
D
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Rockwell Automation Publication 520-TD001E-EN-E - July 2016 17
PowerFlex 520-Series AC Drive Specifications
Minimum Mounting Clearances
See Dimensions and Weights on page 14 for mounting dimensions.
(1) For FrameE with Control ModuleFan Kit only, clearance of 95 mm (3.7 in.) is required.
(2) For FrameE with Control ModuleFan Kit only, clearance of 12 mm (0.5 in.) is required.
Ambient Operating Temperatures
See Accessories and Dimensions on page 32 for option kits.
(1) IP 30/NEMA1/UL Type 1 rating requires installation of the PowerFlex 520-Series IP 30/NEMA 1/UL Type 1 option kit,catalog number 25-JBAx.
(2) For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature listed under the Max. (Derate) column is reduced by 5 °C (9 °F) for all mounting methods.
(3) For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature listed under the Max. withControl Module Fan Kit (Derate) column is reduced by 10 °C (18 °F) for vertical and vertical with zero stacking
mounting methods only.
(4) Catalogs 25x-D1P4N104 and 25x-E0P9N104 cannot be mounted using either of the horizontal mounting methods.
(5) Requires installation of the PowerFlex 520-Series Control Module Fan Kit, catalog number 25-FANx-70C.
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)
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
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18 Rockwell Automation Publication 520-TD001E-EN-E - July 2016
PowerFlex 520-Series AC Drive Specifications
Current Derating Curves
Vertical Mounting
Horizontal Mounting/Floor
Derating Guidelines for High Altitude
The drive can be used without derating at a maximum altitude of 1000 m (3300 ft).
If the drive is used above 1000 m (3300 ft):
•Derate the maximum ambient temperature by 5 °C (9 °F) for every additional 1000 m (3300 ft), subject to limits
listed in the Altitude Limit (Based on Voltage) table below.
Or
•Derate the output current by 10% for every additional 1000 m (3300 ft), subject to limits listed in the Altitude Limit
(Based on Voltage) table below.
Altitude Limit (Based on Voltage)
Drive Rating Center Ground (Wye Neutral)
Corner Ground, Impedance
Ground, or Ungrounded
100...120V 1-Phase 6000 m 6000 m
200...240V 1-Phase 2000 m 2000 m
200...240V 3-Phase 6000 m 2000 m
380...480V 3-Phase 4000 m 2000 m
525...600V 3-Phase 2000 m 2000 m
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
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Rockwell Automation Publication 520-TD001E-EN-E - July 2016 19
PowerFlex 520-Series AC Drive Specifications
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.
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.
ATTENTION: PowerFlex 520-Series drives contain protective MOVs that are referenced to ground. These devices must be
disconnected if the drive is installed on an ungrounded or resistive grounded distribution system.
ATTENTION: Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground.
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
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20 Rockwell Automation Publication 520-TD001E-EN-E - July 2016
PowerFlex 520-Series AC Drive Specifications
Jumper Location (Typical)
Phase to Ground MOV Removal
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated voltage of the drive (see Input Power Conditions
on page 20). 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.
Input Power Conditions
IMPORTANT
Tighten screw after jumper removal.
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 Condition Corrective Action
Low Line Impedance (less than 1% line reactance) •Install Line Reactor(2)
•or Isolation Transformer
Greater than120 kVA supply transformer
Line has power factor correction capacitors •Install Line Reactor(2)
•or Isolation Transformer
Line has frequent power interruptions
Line has intermittent noise spikes in excess of 6000V (lightning)
Phase to ground voltage exceeds 125% of normal line to line voltage •Remove MOV jumper to ground.
•or Install Isolation Transformer with grounded secondary if necessary.
Ungrounded distribution system
B-phase grounded distribution system
240V open delta configuration (stinger leg)(1) •Install Line Reactor(2)
Power Module
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper
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