Rockwell Automation B Series User manual

PowerFlex 520-Series Adjustable Frequency AC Drive
PowerFlex 523 Catalog Number 25A, Series B
PowerFlex 525 Catalog Number 25B
User Manual
Original Instructions

Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, Studio 5000 Logix Designer, DriveTools SP, AppView, CustomView, QuickView, MainsFree
Programming, PointStop, 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-UM001I-EN-E - July 2016 3
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Summary of Changes New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preface
Overview
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 1
Installation/Wiring
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 2
Start Up
Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Display and Control Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Smart Start-Up with Basic Program Group Parameters . . . . . . . . . . . . . . 65
LCD Display with QuickView Technology. . . . . . . . . . . . . . . . . . . . . . . . . 67
Using the USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Table of Contents
Chapter 3
Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Basic Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Network Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Fault and Diagnostic Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Parameter Cross Reference by Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Chapter 4
Troubleshooting
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 162
Appendix A
Supplemental Drive Information
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Appendix B
Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Appendix C
RS485 (DSI) Protocol
Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 205
Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 208
Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 5
Table of Contents
Appendix D
Velocity StepLogic, Basic Logic and
Timer/Counter Functions
Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 210
Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Counter Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Appendix E
Encoder/Pulse Train Usage and
Position StepLogic Application
Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Determine Encoder Pulse Per Revolution (PPR) Specification Based on
Speed Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 218
Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Setup Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Appendix F
PID Set Up
PID Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Appendix G
Safe-Torque-Off Function
PowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . . 235
EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 239
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
PowerFlex 525 Safe-Torque-Off Operation . . . . . . . . . . . . . . . . . . . . . . . 239
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
PowerFlex 525 Certification for Safe-Torque-Off. . . . . . . . . . . . . . . . . . 245
Appendix H
EtherNet/IP
Establishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . 247
Ground Connections for EtherNet/IP Networks . . . . . . . . . . . . . . . . . . 248

6Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Table of Contents
Appendix I
Control Diagrams
Induction Motor Tuning Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Appendix J
PowerFlex 525 PM Motor
Configuration
Download Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Automatic Configuration Using Drive Startup Wizard. . . . . . . . . . . . . 254
Manual Configuration Using Drive Keypad . . . . . . . . . . . . . . . . . . . . . . . 261
Additional PM Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Optional Parameter Adjustments for Optimum Performance . . . . . . . 266
Index

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 7
Summary of Changes
This manual contains new and updated information.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Added footnote to indicate that circuit breaker selection is not available for certain drive
ratings. 24...27
Added PowerFlex 523 series B to Control I/O Wiring Block Diagram. 38
Added PowerFlex 523 series B to Control I/O Terminal Designations. 40
Added PowerFlex 523 series B I/O wiring examples for analog input and analog output. 45
Added note to PowerFlex 525 I/O wiring example for pulse train input. 46
Added footnote to enum “4” for P053 [Reset to Defalts] under Smart Start-Up with Basic
Program Group Parameters. 67
Added new sub topic for 32-bit parameters. 72
Added footnotes to parameters that are available in PowerFlex 523 FRN 3.xxx and later. Chapter 3
Updated descriptions for parameters that are available in PowerFlex 523 FRN 3.xxx and later.
Added formula for calculating scaled process value to parameter b010 [Process Display]. 79
Added recommendation to perform rotate tune when using VVC mode to parameter P040
[Autotune]. 85
Added footnote to indicate which settings are PowerFlex 525 only for parameter d394 [Dig
Out Status]. 114
Updated descriptions for parameters A465 [PID 1 Deadband] and A477 [PID 2 Deadband]. 123
Added corrective action to fault F114 (uC Failure). 162
Added analog output to PowerFlex 523 drives. 171
Added new topic “Determine Encoder Pulse Per Revolution (PPR) Specification Based on
Speed Resolution” to Appendix E. 217
Updated information to verify operation of the safety inputs in Appendix G. 240
General maintenance updates. Throughout manual

8Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Summary of Changes
Notes:

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 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® 520-Series Adjustable
Frequency AC Drive.
Who Should Use this Manual This manual is intended for qualified personnel. You must be able to program
and operate Adjustable Frequency AC Drive devices. In addition, you must have
an understanding of the parameter settings and functions.
Recommended
Documentation
All the recommended documentation listed in this section is available online at
http://www.rockwellautomation.com/literature/.
The following publications provide general drive information:
The following publications provide specific PowerFlex 520-Series information on
drive installation, features, specifications, and service:
For information on… See page…
Who Should Use this Manual 9
Recommended Documentation 9
Manual Conventions 10
Drive Frame Sizes 11
General Precautions 12
Catalog Number Explanation 13
Title Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001
Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1
A Global Reference Guide for Reading Schematic Diagrams 100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
Title Publication
PowerFlex 520-Series AC Drive Specifications 520-TD001
PowerFlex Dynamic Braking Resistor Calculator PFLEX-AT001
PowerFlex AC Drives in Common Bus Configurations DRIVES-AT002

10 Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Preface Overview
The following publications provide specific Network Communications
information:
Manual Conventions •In this manual we refer to PowerFlex 520-Series Adjustable Frequency AC
Drive as; drive, PowerFlex 520-series, PowerFlex 520-series drive or
PowerFlex 520-series 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.
•Parameter numbers and names are shown in this format:
•The following words are used throughout the manual to describe an
action:
Title Publication
PowerFlex 525 Embedded EtherNet/IP Adapter 520COM-UM001
PowerFlex 25-COMM-D DeviceNet Adapter 520COM-UM002
PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter 520COM-UM003
PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter 520COM-UM004
P 031 [Motor NP Volts]
Name
Number
Group
b
P
t
C
L
d
A
N
M
f
G
= Basic Display
= Basic Program
= Terminal Blocks
= Communications
= Logic
= Advanced Display
= Advanced Program
= Network
= Modified
= Fault and Diagnostic
= AppView and CustomView
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-UM001I-EN-E - July 2016 11
Overview Preface
•The Studio 5000® Engineering and Design Environment combines
engineering and design elements into a common environment. The first
element in the Studio 5000 environment is the Logix Designer
application. The Studio 5000 Logix Designer™ application is the
rebranding of RSLogix™ 5000 software and will continue to be the product
to program Logix 5000 controllers for discrete, process, batch, motion,
safety, and drive-based solutions. The Studio 5000 environment is the
foundation for the future of Rockwell Automation engineering design
tools and capabilities. It is the one place for design engineers to develop all
the elements of their control system.
Drive Frame Sizes 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.

12 Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Preface Overview
General Precautions ATTENTION: The drive contains high voltage capacitors which take time to
discharge after removal of mains supply. After power has been removed from
the drive, wait three minutes to make sure DC bus capacitors are discharged.
After three minutes, verify AC voltage L1, L2, L3 (Line to Line and Line to
Ground) to ensure mains power has been disconnected. Measure DC voltage
across DC- and DC+ bus terminals to verify DC Bus has discharged to zero volts.
Measure DC voltage from L1, L2, L3, T1, T2, T3 DC – and DC+ terminals to
ground and keep the meter on the terminals until the voltage discharges to zero
volts. The discharge process may take several minutes to reach zero volts.
Darkened display LEDs is not an indication that capacitors have discharged to
safe voltage levels.
ATTENTION: Only qualified personnel familiar with adjustable frequency AC
drives and associated machinery should plan or implement the installation,
start-up and subsequent maintenance of the system. Failure to comply may
result in personal injury and/or equipment damage.
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts
and assemblies. Staticcontrol precautions are required when installing, testing,
servicing or repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with static control
procedures, reference A-B publication 8000-4.5.2, “Guarding Against
Electrostatic Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in component
damage or a reduction in product life. Wiring or application errors, such as
undersizing the motor, incorrect or inadequate AC supply, or excessive ambient
temperatures may result in malfunction of the system.
ATTENTION: The bus regulator function is extremely useful for preventing
nuisance overvoltage faults resulting from aggressive decelerations,
overhauling loads, and eccentric loads. However, it can also cause either of the
following two conditions to occur.
1. Fast positive changes in inputvoltage or imbalanced input voltages can cause
uncommanded positive speed changes;
2. Actual deceleration times can be longer than commanded deceleration times
However, a “Stall Fault” is generated if the drive remains in this state for 1
minute. If this condition is unacceptable, the bus regulator must be disabled
(see parameter A550 [Bus Reg Enable]). In addition, installing a properly sized
dynamic brake resistor will provide proper stopping requirements based on
braking resistor sizing.
ATTENTION: Risk of injury or equipment damage exists. Drive does not contain
user-serviceable components. Do not disassemble drive chassis.

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 13
Overview Preface
Catalog Number Explanation
Code Type
25A PowerFlex 523
25B PowerFlex 525
1-3 4 5 6-8 9 10 11 12 13 14
25B – B 2P3 N 1 1 4 – –
Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash
Output Current @ 1 Phase, 100...120V Input
Code Amps Frame ND HD
HP kW HP kW
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
Output Current @ 3 Phase, 380...480V Input
Code Amps Frame ND HD
HP kW HP kW
1P4 1.4 A 0.5 0.4 0.5 0.4
2P3 2.3 A 1.0 0.75 1.0 0.75
4P0 4.0 A 2.0 1.5 2.0 1.5
6P0 6.0 A 3.0 2.2 3.0 2.2
010 10.5 B 5.0 4.0 5.0 4.0
013 13.0 C 7.5 5.5 7.5 5.5
017 17.0 C 10.0 7.5 10.0 7.5
024 24.0 D 15.0 11.0 15.0 11.0
030(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 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
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) This rating is only available for PowerFlex 523 drives.
(2) Normal and Heavy Duty ratings are available for this drive.

14 Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Preface Overview
Notes:

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 15
Chapter 1
Installation/Wiring
This chapter provides information on mounting and wiring the PowerFlex 520-
series 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.
For information on... See page...
Mounting Considerations 15
AC Supply Source Considerations 19
General Grounding Requirements 20
Fuses and Circuit Breakers 23
Power and Control Module 28
Control Module Cover 31
Power Module Terminal Guard 31
Power Wiring 32
Power Terminal Block 35
Common Bus/Precharge Notes 36
I/O Wiring 36
Control I/O Terminal Block 37
Start and Speed Reference Control 49
CE Conformity 52
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.)

16 Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Chapter 1 Installation/Wiring
•Do not expose to a corrosive atmosphere.
•Protect from moisture and direct sunlight.
Minimum Mounting Clearances
See Appendix B for mounting dimensions.
(1) For Frame E with Control Module Fan Kit only, clearance of 95 mm (3.7 in.) is required.
(2) For Frame E with Control Module Fan Kit only, clearance of 12 mm (0.5 in.) is required.
25 mm
(1.0 in.)
25 mm
(1.0 in.) (2)
(2)
25 mm
(1.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)(1) 50 mm (2.0 in.)(1)
50 mm
(2.0 in.)(1)
50 mm
(2.0 in.)
50 mm
(2.0 in.) 50 mm
(2.0 in.)
Esc
Sel
Esc
Sel
Esc
Sel
Esc
Sel
50 mm
(2.0 in.) 50 mm
(2.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
Esc
Sel
Esc
Sel
50 mm
(2.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.) 50 mm
(2.0 in.)
50 mm
(2.0 in.)(1)
Esc
Sel
Esc
Sel
Esc
Sel
Esc
Sel
Esc
Sel
Esc
Sel
Vertical, Zero Stacking
No clearance between drives.
Horizontal, Zero Stacking with
Control Module Fan Kit
No clearance between drives.
Vertical Vertical, Zero Stacking with
Control Module Fan Kit
No clearance between drives.
Vertical with Control Module Fan Kit
Horizontal with Control Module Fan Kit

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 17
Installation/Wiring Chapter 1
Ambient Operating Temperatures
See Appendix B for option kits.
Current Derating Curves
Vertical Mounting
Horizontal/Floor Mounting
Mounting Enclosure Rating(1) Ambient Temperature
Minimum Maximum (No Derate) Maximum (Derate)(2) Maximum with
Control Module Fan Kit (Derate)(3)(5)
Vertical IP 20/Open Type
-20 °C (-4 °F)
50 °C (122 °F) 60 °C (140 °F) 70 °C (158 °F)
IP 30/NEMA 1/UL Type 1 45 °C (113 °F) 55 °C (131 °F) –
Vertical, Zero Stacking IP 20/Open Type 45 °C (113 °F) 55 °C (131 °F) 65 °C (149 °F)
IP 30/NEMA 1/UL Type 1 40 °C (104 °F) 50 °C (122 °F) –
Horizontal with
Control Module Fan Kit(4)(5) IP 20/Open Type 50 °C (122 °F) – 70 °C (158 °F)
Horizontal, Zero Stacking
with Control Module Fan Kit(4)(5) IP 20/Open Type 45 °C (113 °F) – 65 °C (149 °F)
(1) IP 30/NEMA 1/UL Type 1 ratingrequires 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 Maximum (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 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 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.
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

18 Rockwell Automation Publication 520-UM001I-EN-E - July 2016
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-UM001I-EN-E - July 2016 19
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 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.
IMPORTANT
Tighten screw after jumper removal.
Power Module
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper

20 Rockwell Automation Publication 520-UM001I-EN-E - July 2016
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 page 169). 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 noisespikes 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)
(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 183 for specific line reactor part numbers.
•Install Line Reactor(2)
SHLD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
Esc
Sel