PowerFlex 523 Catalog Number 25A, Series B PowerFlex 525 .
User ManualPowerFlex 520-Series Adjustable Frequency AC DrivePowerFlex 523 Catalog Number 25A, Series BPowerFlex 525 Catalog Number 25BOriginal Instructions
Important User InformationSolid-state equipment has operational characteristics differing from those of electromechanical equipment. SafetyGuidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available fromyour local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes someimportant 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 equipmentmust 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 theuse or application of this equipment.The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables andrequirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility orliability 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, orsoftware 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.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, propertydamage, 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 dangerousvoltage may be present.BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces mayreach dangerous temperatures.ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people topotential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALLRegulatory requirements for safe work practices and for Personal Protective Equipment (PPE).IMPORTANTIdentifies information that is critical for successful application and understanding of the product.Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, Studio 5000 Logix Designer, DriveTools SP, AppView, CustomView, QuickView, MainsFreeProgramming, PointStop, and TechConnect are trademarks of Rockwell Automation, Inc.Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of ContentsImportant User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Summary of ChangesNew and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7PrefaceOverviewWho Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Chapter 1Installation/WiringMounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1519202328313132353636374952Chapter 2Start UpPrepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Display and Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Smart Start-Up with Basic Program Group Parameters . . . . . . . . . . . . . .LCD Display with QuickView Technology. . . . . . . . . . . . . . . . . . . . . . . . .Using the USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rockwell Automation Publication 520-UM001I-EN-E - July 201659626364646567673
Table of ContentsChapter 3Programming and ParametersAbout Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Basic Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Network Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Fault and Diagnostic Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Parameter Cross Reference by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Chapter 4TroubleshootingDrive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . .157157159162Appendix ASupplemental Drive InformationCertifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167168169172Appendix BAccessories and DimensionsProduct Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Appendix CRS485 (DSI) Protocol4Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . .Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . .Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . .Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rockwell Automation Publication 520-UM001I-EN-E - July 2016201202203203205205207208208208
Table of ContentsAppendix DVelocity StepLogic, Basic Logic andTimer/Counter FunctionsVelocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . .Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . .Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Counter Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210210211212213Appendix EEncoder/Pulse Train Usage andPosition StepLogic ApplicationEncoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Determine Encoder Pulse Per Revolution (PPR) Specification Based onSpeed Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 218Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225Setup Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226Appendix FPID Set UpPID Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230Appendix GSafe-Torque-Off FunctionPowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . .EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . .Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PowerFlex 525 Safe-Torque-Off Operation . . . . . . . . . . . . . . . . . . . . . . .Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PowerFlex 525 Certification for Safe-Torque-Off . . . . . . . . . . . . . . . . . .235236236236237239239239240241245Appendix HEtherNet/IPEstablishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . 247Ground Connections for EtherNet/IP Networks . . . . . . . . . . . . . . . . . . 248Rockwell Automation Publication 520-UM001I-EN-E - July 20165
Table of ContentsAppendix IControl DiagramsInduction Motor Tuning Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250Appendix JPowerFlex 525 PM MotorConfigurationDownload Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Configuration Using Drive Startup Wizard. . . . . . . . . . . . .Manual Configuration Using Drive Keypad . . . . . . . . . . . . . . . . . . . . . . .Additional PM Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Parameter Adjustments for Optimum Performance . . . . . . .Index6Rockwell Automation Publication 520-UM001I-EN-E - July 2016252254261262266
Summary of ChangesThis manual contains new and updated information.New and UpdatedInformationThis table contains the changes made to this revision.TopicPageAdded footnote to indicate that circuit breaker selection is not available for certain driveratings.24.27Added PowerFlex 523 series B to Control I/O Wiring Block Diagram.38Added PowerFlex 523 series B to Control I/O Terminal Designations.40Added PowerFlex 523 series B I/O wiring examples for analog input and analog output.45Added note to PowerFlex 525 I/O wiring example for pulse train input.46Added footnote to enum “4” for P053 [Reset to Defalts] under Smart Start-Up with BasicProgram Group Parameters.67Added new sub topic for 32-bit parameters.72Added footnotes to parameters that are available in PowerFlex 523 FRN 3.xxx and later.Chapter 3Updated 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].79Added recommendation to perform rotate tune when using VVC mode to parameter P040[Autotune].85Added footnote to indicate which settings are PowerFlex 525 only for parameter d394 [DigOut Status].114Updated descriptions for parameters A465 [PID 1 Deadband] and A477 [PID 2 Deadband].123Added corrective action to fault F114 (uC Failure).162Added analog output to PowerFlex 523 drives.171Added new topic “Determine Encoder Pulse Per Revolution (PPR) Specification Based onSpeed Resolution” to Appendix E.217Updated information to verify operation of the safety inputs in Appendix G.240General maintenance updates.Throughout manualRockwell Automation Publication 520-UM001I-EN-E - July 20167
Summary of ChangesNotes:8Rockwell Automation Publication 520-UM001I-EN-E - July 2016
PrefaceOverviewThe purpose of this manual is to provide you with the basic information neededto install, start-up and troubleshoot the PowerFlex 520-Series AdjustableFrequency AC Drive.For information on Who Should Use this ManualRecommended DocumentationManual ConventionsDrive Frame SizesGeneral PrecautionsCatalog Number ExplanationSee page 9910111213Who Should Use this ManualThis manual is intended for qualified personnel. You must be able to programand operate Adjustable Frequency AC Drive devices. In addition, you must havean understanding of the parameter settings and functions.RecommendedDocumentationAll the recommended documentation listed in this section is available online e following publications provide general drive information:TitleWiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC DrivesPreventive Maintenance of Industrial Control and Drive System EquipmentSafety Guidelines for the Application, Installation and Maintenance of Solid State ControlA Global Reference Guide for Reading Schematic DiagramsGuarding Against Electrostatic 0-2.108000-4.5.2The following publications provide specific PowerFlex 520-Series information ondrive installation, features, specifications, and service:TitlePowerFlex 520-Series AC Drive SpecificationsPowerFlex Dynamic Braking Resistor CalculatorPowerFlex AC Drives in Common Bus ConfigurationsRockwell Automation Publication 520-UM001I-EN-E - July 2016Publication520-TD001PFLEX-AT001DRIVES-AT0029
PrefaceOverviewThe following publications provide specific Network Communicationsinformation:TitlePowerFlex 525 Embedded EtherNet/IP AdapterPowerFlex 25-COMM-D DeviceNet AdapterPowerFlex 25-COMM-E2P Dual-Port EtherNet/IP AdapterPowerFlex 25-COMM-P PROFIBUS DPV1 AdapterManual OM-UM003520COM-UM004 In this manual we refer to PowerFlex 520-Series Adjustable Frequency ACDrive as; drive, PowerFlex 520-series, PowerFlex 520-series drive orPowerFlex 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:P 031 [Motor NP Volts]NameNumberGroupb Basic DisplayP Basic Programt Terminal BlocksC CommunicationsL Logicd Advanced DisplayA Advanced ProgramN NetworkM Modifiedf Fault and DiagnosticG AppView and CustomView The following words are used throughout the manual to describe anaction:WordsCanCannotMayMustShallShouldShould Not10MeaningPossible, able to do somethingNot possible, not able to do somethingPermitted, allowedUnavoidable, you must do thisRequired and necessaryRecommendedNot RecommendedRockwell Automation Publication 520-UM001I-EN-E - July 2016
OverviewPreface The Studio 5000 Engineering and Design Environment combinesengineering and design elements into a common environment. The firstelement in the Studio 5000 environment is the Logix Designerapplication. The Studio 5000 Logix Designer application is therebranding of RSLogix 5000 software and will continue to be the productto program Logix 5000 controllers for discrete, process, batch, motion,safety, and drive-based solutions. The Studio 5000 environment is thefoundation for the future of Rockwell Automation engineering designtools and capabilities. It is the one place for design engineers to develop allthe elements of their control system.Drive Frame SizesSimilar PowerFlex 520-series drive sizes are grouped into frame sizes to simplifyspare parts ordering, dimensioning, etc. A cross reference of drive catalognumbers and their respective frame sizes is provided in Appendix B.Rockwell Automation Publication 520-UM001I-EN-E - July 201611
PrefaceOverviewGeneral PrecautionsATTENTION: The drive contains high voltage capacitors which take time todischarge after removal of mains supply. After power has been removed fromthe 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 toGround) to ensure mains power has been disconnected. Measure DC voltageacross 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 toground and keep the meter on the terminals until the voltage discharges to zerovolts. The discharge process may take several minutes to reach zero volts.Darkened display LEDs is not an indication that capacitors have discharged tosafe voltage levels.ATTENTION: Only qualified personnel familiar with adjustable frequency ACdrives and associated machinery should plan or implement the installation,start-up and subsequent maintenance of the system. Failure to comply mayresult in personal injury and/or equipment damage.ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive partsand assemblies. Static control precautions are required when installing, testing,servicing or repairing this assembly. Component damage may result if ESDcontrol procedures are not followed. If you are not familiar with static controlprocedures, reference A-B publication 8000-4.5.2, “Guarding AgainstElectrostatic Damage” or any other applicable ESD protection handbook.ATTENTION: An incorrectly applied or installed drive can result in componentdamage or a reduction in product life. Wiring or application errors, such asundersizing the motor, incorrect or inadequate AC supply, or excessive ambienttemperatures may result in malfunction of the system.ATTENTION: The bus regulator function is extremely useful for preventingnuisance overvoltage faults resulting from aggressive decelerations,overhauling loads, and eccentric loads. However, it can also cause either of thefollowing two conditions to occur.1. Fast positive changes in input voltage or imbalanced input voltages can causeuncommanded positive speed changes;2. Actual deceleration times can be longer than commanded deceleration timesHowever, a “Stall Fault” is generated if the drive remains in this state for 1minute. If this condition is unacceptable, the bus regulator must be disabled(see parameter A550 [Bus Reg Enable]). In addition, installing a properly sizeddynamic brake resistor will provide proper stopping requirements based onbraking resistor sizing.ATTENTION: Risk of injury or equipment damage exists. Drive does not containuser-serviceable components. Do not disassemble drive chassis.12Rockwell Automation Publication 520-UM001I-EN-E - July 2016
OverviewPrefaceCatalog Number DriveDashVoltage RatingRatingEnclosureReservedEmission ClassReservedDashDashCode25A25BTypePowerFlex 523PowerFlex 525CodeVABDECode01Voltage120V AC240V AC240V AC480V AC600V ACPhase11333Code1CodeNEMC FilterNo FilterFilterCode4BrakingStandardInterface ModuleStandardEnclosureIP20 NEMA / OpenOutput Current @ 1 Phase, 100.120V InputCodeAmps Frame NDHDHP kW HP1P6(1) 1.6A0.25 0.2 0.252P52.5A0.5 0.4 0.54P84.8B1.0 0.75 1.06P06.0B1.5 1.1 1.5kW0.20.40.751.1Output Current @ 1 Phase, 200.240V InputCodeAmps Frame NDHDHP kW HPA0.25 0.2 0.251P6(1) 1.62P52.5A0.5 0.4 0.54P84.8A1.0 0.75 1.08P08.0B2.0 1.5 2.001111.0B3.0 2.2 3.0kW0.20.40.751.52.2Output Current @ 3Phase, 200.240V InputCodeAmps Frame NDHDHP kW HPA0.25 0.2 0.251P6(1) 1.62P52.5A0.5 0.4 0.55P05.0A1.0 0.75 1.08P08.0A2.0 1.5 2.001111.0A3.0 2.2 3.001717.5B5.0 4.0 5.002424.0C7.5 5.5 7.503232.2D10.0 7.5 10.0(2)04848.3E15.0 11.0 10.0062(2) 62.1E20.0 15.0 15.0kW0.20.40.751.52.24.05.57.57.511.0Output Current @ 3 Phase, 380.480V InputCodeAmps Frame NDHDHP kW HP1P41.4A0.5 0.4 0.52P32.3A1.0 0.75 1.04P04.0A2.0 1.5 2.06P06.0A3.0 2.2 3.001010.5B5.0 4.0 5.001313.0C7.5 5.5 7.501717.0C10.0 7.5 10.002424.0D15.0 11.0 15.0030(2) 30.0D20.0 15.0 15.0037(2) 37.0E25.0 18.5 20.0043(2) 43.0E30.0 22.0 25.0kW0.40.751.52.24.05.57.511.011.015.018.5Output Current @ 3 Phase, 525.600V InputCodeAmps Frame NDHDHP kW HP0P90.9A0.5 0.4 0.51P71.7A1.0 0.75 1.03P03.0A2.0 1.5 2.04P24.2A3.0 2.2 3.06P66.6B5.0 4.0 5.09P99.9C7.5 5.5 7.501212.0C10.0 7.5 10.001919.0D15.0 11.0 15.0022(2) 22.0D20.0 15.0 15.0027(2) 27.0E25.0 18.5 20.0032(2) 32.0E30.0 22.0 25.0kW0.40.751.52.24.05.57.511.011.015.018.5(1) This rating is only available for PowerFlex 523 drives.(2)Normal and Heavy Duty ratings are available for this drive.Rockwell Automation Publication 520-UM001I-EN-E - July 201613
PrefaceOverviewNotes:14Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Chapter1Installation/WiringThis chapter provides information on mounting and wiring the PowerFlex 520series drives.For information on.Mounting ConsiderationsAC Supply Source ConsiderationsGeneral Grounding RequirementsFuses and Circuit BreakersPower and Control ModuleControl Module CoverPower Module Terminal GuardPower WiringPower Terminal BlockCommon Bus/Precharge NotesI/O WiringControl I/O Terminal BlockStart and Speed Reference ControlCE ConformitySee page.1519202328313132353636374952Most start-up difficulties are the result of incorrect wiring. Every precaution mustbe taken to assure that the wiring is done as instructed. All items must be read andunderstood before the actual installation begins.ATTENTION: The following information is merely a guide for properinstallation. Rockwell Automation cannot assume responsibility for thecompliance or the noncompliance to any code, national, local or otherwise forthe proper installation of this drive or associated equipment. A hazard ofpersonal injury and/or equipment damage exists if codes are ignored duringinstallation.Mounting Considerations Mount the drive upright on a flat, vertical and level surface.FrameABCDEScrew SizeM5 (#10.24)M5 (#10.24)M5 (#10.24)M5 (#10.24)M8 (5/16 in.)Screw Torque1.56.1.96 Nm (14.17 lb-in.)1.56.1.96 Nm (14.17 lb-in.)1.56.1.96 Nm (14.17 lb-in.)2.45.2.94 Nm (22.26 lb-in.)6.0.7.4 Nm (53.65 lb-in.) Protect the cooling fan by avoiding dust or metallic particles.Rockwell Automation Publication 520-UM001I-EN-E - July 201615
Chapter 1Installation/Wiring Do not expose to a corrosive atmosphere. Protect from moisture and direct sunlight.Minimum Mounting ClearancesSee Appendix B for mounting dimensions.Vertical, Zero StackingNo clearance between drives.Vertical50 mm(2.0 in.)EscSel50 mm(2.0 in.)25 mm(1.0 in.)EscVertical with Control Module Fan KitEscSel50 mm(2.0 in.)50 mm(2.0 in.)(1)EscSelEscSelEsc25 mm(1.0 in.)50 mm(2.0 in.)(1)Sel(2)EscSelEscSel25 mm(1.0 in.)50 mm(2.0 in.)Horizontal with Control Module Fan Kit50 mm(2.0 in.)Horizontal, Zero Stacking withControl Module Fan KitNo clearance between drives.(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.16Rockwell Automation Publication 520-UM001I-EN-E - July 2016Sel50 mm(2.0 in.)EscSel50 mm(2.0 in.)50 mm(2.0 in.)(1)EscSel50 mm(2.0 in.)50 mm(2.0 in.)(1)Esc50 mm(2.0 in.)Sel50 mm(2.0 in.)50 mm(2.0 in.)50 mm(2.0 in.)Vertical, Zero Stacking withControl Module Fan KitNo clearance between drives.EscSel(2)
Installation/WiringChapter 1Ambient Operating TemperaturesSee Appendix B for option kits.MountingEnclosure Rating(1)VerticalIP 20/Open TypeIP 30/NEMA 1/UL Type 1IP 20/Open TypeIP 30/NEMA 1/UL Type 1IP 20/Open TypeVertical, Zero StackingHorizontal withControl Module Fan Kit(4)(5)Horizontal, Zero Stackingwith Control Module Fan Kit(4)(5)Ambient TemperatureMinimumMaximum (No Derate) Maximum (Derate)(2) Maximum withControl Module Fan Kit (Derate)(3)(5)50 C (122 F)60 C (140 F)70 C (158 F)45 C (113 F)55 C (131 F)–45 C (113 F)55 C (131 F)65 C (149 F)40 C(104 F)50 C(122 F)–-20 C (-4 F)50 C (122 F)–70 C (158 F)IP 20/Open Type45 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 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 zerostacking 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.Current Derating CurvesSingle DriveZero Stacking120with ControlIP 30/NEMA 1Module Fan Kit11010090IP 20/Open Type807060504030 35 40 45 50 55 60 65 70 75 80120with ControlIP 30/NEMA 1Module Fan Kit11010090IP 20/Open Type807060504030 35 40 45 50 55 60 65 70 75 80Percentage of Rated Current (%)Percentage of Rated Current (%)Vertical MountingAmbient Temperature ( C)Ambient Temperature ( C)Single DriveZero Stacking120with ControlModule Fan Kit11010090IP 20/Open Type807060504030 35 40 45 50 55 60 65 70 75 80120with ControlModule F
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
20D PowerFlex 700S 22A PowerFlex 4 22F PowerFlex 4M 22B PowerFlex 40 22D PowerFlex 40P 22C PowerFlex 400 25A PowerFlex 523 25B PowerFlex 525 25C PowerFlex 527 Reliance Electric A
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