Allen-Bradley PowerFlex 527 User manual

PowerFlex 527 Adjustable Frequency AC Drive
Catalog Number 25C
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 Software, Rockwell Automation, PowerFlex, CompactLogix, Connected Components Workbench, ControlLogix, GuardLogix, Logix5000, RSLinx, Studio 5000, Studio 5000 Logix Designer, and
TechConnect 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.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 3
Summary of Changes
This manual contains new and updated information. Changes throughout this
revision are marked by change bars, as shown to the right of this paragraph.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Added footnotes to indicate the overload capacity of catalogs. 12, 21...24
Updated Motor Phase Connection description in Power Terminal Block. 32
Added wiring information about Terminals 01 and 11. 33, 34
Updated descriptions for several terminals in the Control I/O Terminal Designations table. 35
Updated Network Configuration section. 47
Updated Real-time Information Display section. 49
Updated Configure the PowerFlex 527 Drive section with additional controllers. 59
Updated Test the Axes section. 83
Updated Tune the Axes section. 85
Updated PHF Data section. 89
Updated Operation of Hardwired Safe Torque-Off section. 97
Updated Compatible Safety Controllers section. 103
Updated Network Safe Torque-off Specifications section. 104
Added INIT FLT M22 – ILLEGAL ADDRESS to INIT FLT Fault Codes table. 125
Updated INHIBIT Fault Codes table. 125
Updated information on configurable stopping actions in Logix5000 Controller and Drive Behavior. 129
Updated Drive Behavior, FLT Sxx Fault Codes table. 131
Updated Control table in Technical Specifications. 135
Removed Bandwidth specification from Control Inputs table in Technical Specifications. 137
UpdatedMotion Group Base Update Rate graphic. 165
Updated Encoder Signal – Single-Ended, Dual Channel connection example graphic. 170

4Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Summary of Changes
Notes:

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 5
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Summary of Changes New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table of Contents
Preface
Overview
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Product Environmental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 1
Installation/Wiring
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 2
Start Up
Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Understanding the PowerFlex 527 Display and Indicators . . . . . . . . . . . 44
Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Using the Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chapter 3
Configuring the PowerFlex 527 Drive
with Integrated Motion
Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Configure the Logix Designer Application Project . . . . . . . . . . . . . . . . . . 52
Add a PowerFlex 527 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Configure the PowerFlex 527 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Apply Power to the PowerFlex 527 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Test and Tune the Axes – Velocity and Position Control Modes . . . . . 83

6Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Table of Contents
Chapter 4
PowerFlex 527 Integrated Safe
Torque-Off
Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Probability of Dangerous Failure Per Hour (PFH) . . . . . . . . . . . . . . . . . . 89
Safe Torque-Off (STO) Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Out-of-Box (OOB) Safety State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Safe Torque-Off Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Explicit Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Chapter 5
Hardwired Control of Safe Torque-Off
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Safe Torque-Off Connector Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Wire the Safe Torque-Off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Safe Torque-Off Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Chapter 6
Network Control of Safe Torque-Off
Understanding Integrated Safety Drive Replacement. . . . . . . . . . . . . . . 107
Replacing an Integrated Safety Drive in a GuardLogix System . . . . . . . 107
Motion Direct Commands in Motion Control Systems . . . . . . . . . . . . 114
Functional Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Chapter 7
Troubleshooting
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Logix5000 Controller and Drive Behavior. . . . . . . . . . . . . . . . . . . . . . . . . 129
Appendix A
Supplemental Drive Information
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Appendix B
Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Appendix C
Out-of-Box Configuration
Recommended Out-of-Box Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Setting the ACO/AVO Attribute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Appendix D
Encoder Option Card Usage
Installing the Encoder Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 7
Table of Contents
Removing the Encoder Option Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Encoder Option Card Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Index

8Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Table of Contents
Notes:

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 9
Preface
Overview
The purpose of this manual is to provide you with the basic information needed
to install, start-up and troubleshoot the PowerFlex® 527 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
a working knowledge and understanding of ControlLogix®/Studio 5000® and
CIP Motion.
If you do not have a basic understanding of the PowerFlex 527 drives, contact
your local Rockwell Automation sales representative for information on available
training courses.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at
http://www.rockwellautomation.com/literature. To order paper copies of
For information on… See page…
Who Should Use this Manual 9
Additional Resources 9
Manual Conventions 10
Drive Frame Sizes 10
General Precautions 11
Catalog Number Explanation 12
Title Publication
GuardLogix 5570 Controllers User Manual 1756-UM022
GuardLogix 5570 Controller Systems Safety Reference Manual 1756-RM099
CompactLogix 5370 Controllers User Manual 1769-UM021
ControlLogix 5580 Controllers User Manual 1756-UM543
Compact GuardLogix 5370 Controllers User Manual 1769-UM022
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001
Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001
Integrated Motion on the EtherNet/IP Network Configuration and Startup User Manual MOTION-UM003
Integrated Motion on the EtherNet/IP Network MOTION-RM003
PowerFlex DB (Dynamic Braking) Resistor Calculator PFLEX-AT001
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1
Guarding Against Electrostatic Damage 8000-4.5.2

10 Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Preface Overview
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
Manual Conventions •In this manual we refer to PowerFlex 527 Adjustable Frequency AC Drive
as: drive, PowerFlex 527, PowerFlex 527 drive or PowerFlex 527 AC drive.
•Specific drives within the PowerFlex 520-series may be referred to as:
– PowerFlex 523, PowerFlex 523 drive or PowerFlex 523 AC drive.
– PowerFlex 525, PowerFlex 525 drive or PowerFlex 525 AC drive.
– PowerFlex 527, PowerFlex 527 drive or PowerFlex 527 AC drive
•The following words are used throughout the manual to describe an
action:
•The Studio 5000 Automation Engineering and Design Environment™
(formerly RSLogix 5000) combines engineering and design elements into
one standard framework that enables optimized productivity and reduced
time to commission. As part of the Studio 5000 environment, Logix
Designer™ is the tool used to program Logix programmable automation
controllers for process, batch, discrete, drives, safety and motion-based
systems. The Studio 5000 environment is the foundation for system
engineering design tools and capabilities — it is the one tool for engineers
to design and develop all the elements of their control system.
These conventions are used throughout this manual:
•Bulleted lists such as this one provide information, not procedural steps.
•Numbered lists provide sequential steps or hierarchical information.
Drive Frame Sizes The PowerFlex 527 AC drive belongs to the new generation of PowerFlex 520-
series drives which also consist of PowerFlex 523 and PowerFlex 525 drives.
Similar PowerFlex 520-series 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.
Product Environmental
Information
Rockwell Automation maintains current product environmental information on
its website at
http://www.rockwellautomation.com/rockwellautomation/about-us/
sustainability-ethics/product-environmentalcompliance.page
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-UM002B-EN-E - December 2017 11
Overview Preface
General Precautions
At the end of its life, this equipment should be collected separately from any
unsorted municipal waste
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 (DC Bus voltage is less
than 50V DC). 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 input voltage or imbalanced input voltages can cause
uncommanded positive speed changes.
2. Actual deceleration times can be longer than commanded deceleration times.
However, a “Decel Override” fault is generated if the drive remains in this state for
one minute. If this condition is unacceptable, the bus regulator must be disabled by
setting the Bus Regulator Action in Logix Designer. In addition, installing a properly
sized dynamic brake resistor will provide equal or better performance in most
cases.See Dynamic Brake Resistors on page 142 to select an appropriate resistor for
your drive rating.
ATTENTION: Risk of injury or equipment damage exists. Drive does not contain
user-serviceable components. Do not disassemble drive chassis.

12 Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Preface Overview
Catalog Number Explanation
Code Type
25C PowerFlex 527
1-3 4 5 6-8 9 10 11 12 13 14
25C – B 2P3 N 1 1 4 – –
Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash
Output Current @ 1 Phase, 100...120V Input
Code Amps Frame ND HD
HP kW HP kW
2P5(1) 2.5 A 0.5 0.4 0.5 0.4
4P8(1) 4.8 B 1.0 0.75 1.0 0.75
6P0(1) 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(1) 2.5 A 0.5 0.4 0.5 0.4
4P8(1) 4.8 A 1.0 0.75 1.0 0.75
8P0(1) 8.0 B 2.0 1.5 2.0 1.5
011(1) 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(1) 2.5 A 0.5 0.4 0.5 0.4
5P0(1) 5.0 A 1.0 0.75 1.0 0.75
8P0(1) 8.0 A 2.0 1.5 2.0 1.5
011(1) 11.0 A 3.0 2.2 3.0 2.2
017(1) 17.5 B 5.0 4.0 5.0 4.0
024(1) 24.0 C 7.5 5.5 7.5 5.5
032(1) 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
Output Current @ 3 Phase, 380...480V Input
Code Amps Frame ND HD
HP kW HP kW
1P4(1) 1.4 A 0.5 0.4 0.5 0.4
2P3(1) 2.3 A 1.0 0.75 1.0 0.75
4P0(1) 4.0 A 2.0 1.5 2.0 1.5
6P0(1) 6.0 A 3.0 2.2 3.0 2.2
010(1) 10.5 B 5.0 4.0 5.0 4.0
013(1) 13.0 C 7.5 5.5 7.5 5.5
017(1) 17.0 C 10.0 7.5 10.0 7.5
024(1) 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 Frame ND HD
HP kW HP kW
0P9(1) 0.9 A 0.5 0.4 0.5 0.4
1P7(1) 1.7 A 1.0 0.75 1.0 0.75
3P0(1) 3.0 A 2.0 1.5 2.0 1.5
4P2(1) 4.2 A 3.0 2.2 3.0 2.2
6P6(1) 6.6 B 5.0 4.0 5.0 4.0
9P9(1) 9.9 C 7.5 5.5 7.5 5.5
012(1) 12.0 C 10.0 7.5 10.0 7.5
019(1) 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
V120VAC1
A240VAC1
B240VAC3
D480VAC3
E600VAC3
Code Enclosure
N IP20 NEMA / Open
Code Interface Module
1Standard
Code EMC Filter
0 No Filter
1Filter
Code Braking
4Standard
(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.
(2) 110% Overload capability for up to 60 s, 150% for up to 3 s.

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 13
Chapter 1
Installation/Wiring
This chapter provides information on mounting and wiring the PowerFlex® 527
drives.
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.
•Do not expose to a corrosive atmosphere.
•Protect from moisture and direct sunlight.
For information on... See page...
Mounting Considerations 13
AC Supply Source Considerations 17
General Grounding Requirements 18
Fuses and Circuit Breakers 20
Power and Control Module 25
Control Module Cover 28
Power Module Terminal Guard 28
Power Wiring 29
Power Terminal Block 32
I/O Wiring 32
Control I/O Terminal Block 34
CE Conformity 36
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.)

14 Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Chapter 1 Installation/Wiring
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.
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
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.)
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.)
50 mm
(2.0 in.)
50 mm
(2.0 in.) 50 mm
(2.0 in.)
50 mm
(2.0 in.)(1)

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 15
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) – 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) – 65 C (149 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 requires installation of the PowerFlex 520-Series IP 30/NEMA 1/UL Type 1 option kit, catalog number 25-JBAx.
(2) For catalogs 25C-D1P4N104 and 25C-E0P9N104, the temperature listed under the Maximum (Derate) column is reduced by 5 °C (9 °F) for all mounting methods.
(3) For catalogs 25C-D1P4N104 and 25C-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 25C-D1P4N104 and 25C-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.
Single Drive Zero Stacking
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 (%)
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

16 Rockwell Automation Publication 520-UM002B-EN-E - December 2017
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 (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),
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-UM002B-EN-E - December 2017 17
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 527 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.
IMPORTANT
Tighten screw after jumper removal.
Power module
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper

18 Rockwell Automation Publication 520-UM002B-EN-E - December 2017
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 Technical Specifications on page 135). 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 147 for specific line reactor part numbers.
•Install Line Reactor(2)
SHLD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 19
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.

20 Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Chapter 1 Installation/Wiring
Fuses and Circuit Breakers The PowerFlex 527 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.
The tables under Fuses and Circuit Breakers for PowerFlex 527 on page 21
provide recommended AC line input fuse and circuit breaker information. See
Fusing and Circuit Breakers below for UL and IEC requirements. Sizes listed are
the recommended sizes based on 40 °C (104 °F) and the U.S. N.E.C. Other
country, state or local codes may require different ratings.
Fusing
The recommended fuse types are listed in the tables found on Fuses and Circuit
Breakers for PowerFlex 527 on page 21. If available current ratings do not match
those listed in the tables provided, choose the next higher fuse rating.
•IEC – BS88 (British Standard) Parts 1 & 2(1), EN60269-1, Parts 1 & 2,
type GG or equivalent should be used.
•UL – UL Class CC, T, RK1, or J should be used.
Circuit Breakers
The “non-fuse” listings in the tables Fuses and Circuit Breakers for PowerFlex
527 on page 21 include inverse time circuit breakers, instantaneous trip circuit
breakers (motor circuit protectors) and 140M self-protected combination motor
controllers. If one of these is chosen as the desired protection method, the
following requirements apply:
•IEC – Both types of circuit breakers and 140M self-protected
combination motor controllers are acceptable for IEC installations.
•UL – Only inverse time circuit breakers and the specified 140M self-
protected combination motor controllers are acceptable for UL
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 motor applications.
•Bulletin 140M can be used up stream from the drive without the need for
fuses.
If the DC Bus terminals or the Dynamic Brake terminals are used, the drive must
be installed in an enclosure and fuses must be used for input protection (for CE
applications only). The ventilated enclosure needs to be IP 20 rating or higher
and at least 1.5x size larger than the drive.
(1) Typicaldesignations include, but may not belimited tothe following;
Parts 1 & 2: AC,AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.