Allen-Bradley PowerFlex 525 Original Instructions Manual

Powerflex 520-series ac drive

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Original instructions manual (44 pages)

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Page 1: Table Of Contents
Aotewell Ltd www.aotewell.com Industry Automation Technical Data PowerFlex 520-Series AC Drive Specifications Original Instructions Topic Page Product Overview Catalog Number Explanation Technical Specifications Environmental Specifications Certifications Dimensions and Weights Design Considerations Fuses and Circuit Breaker Ratings Accessories and Dimensions Safe-Torque-Off Function Additional Resources Drive Features: AppView™, CustomView™, QuickView™, and MainsFree™...
Page 2: Product Overview
The PowerFlex 523 drive provides general purpose control for applications ranging up to 30 HP and 22 kW. The PowerFlex 525 drive provides maximum flexibility and performance ranging up to 30 HP and 22 kW.
Page 3 • Closed loop feedback with an optional encoder card (PowerFlex 525 drives only) • Point-to-point positioning mode (PowerFlex 525 drives only) • Integral PID functionality enhances application flexibility (PowerFlex 523 drives have one PID loop, PowerFlex 525 drives have two PID loops) I/O Wiring PowerFlex 523...
Page 4 Communications • Embedded EtherNet/IP™ port allows easy configuration, control, and collection of drive data over the network. (PowerFlex 525 drives only) • Dual port EtherNet/IP option card supports Device Level Ring (DLR) topologies, providing fault-tolerant connectivity for optimum drive availability.
Page 5 Closed Loop Feedback Encoder/Pulse Train Input The PowerFlex 525 drive allows for configurable closed loop control with an optional encoder card for either speed or position feedback for improved speed regulation, basic position control, or other pulse inputs for motor control.
Page 6 Network Communication performance and flexible configuration Node 1 Node 2 Node 3 capabilities. • Embedded port for EtherNet/IP (PowerFlex 525 drives only) PowerFlex 520-Series PowerFlex 520-Series PowerFlex 520-Series with Comms card with Comms card with Comms card • EtherNet/IP dual-port option card DeviceNet to EtherNet/IP •...
Page 7 PowerFlex 520-Series AC Drive Specifications PowerFlex 523 Drive Family Frame A Frame B Frame C Frame D Frame E PowerFlex 525 Drive Family Frame A Frame B Frame C Frame D Frame E Rockwell Automation Publication 520-TD001E-EN-E - July 2016 HongKong|UK|China sales@aotewell.com...
Page 8: Catalog Number Explanation
Reserved Emission Class Reserved Dash Dash Code Braking Standard Code Type Code EMC Filter PowerFlex 523 No Filter PowerFlex 525 Filter Code Voltage Phase Code Interface Module 120V AC Standard 240V AC Code Enclosure 240V AC IP20 NEMA / Open...
Page 9: Technical Specifications
PowerFlex 520-Series AC Drive Specifications Technical Specifications Protection Specifications PowerFlex 523 PowerFlex 525 Bus Overvoltage Trip 100...120V AC Input: 405V DC bus (equivalent to 150V AC incoming line) 200...240V AC Input: 405V DC bus (equivalent to 290V AC incoming line) 380...480V AC Input:...
Page 10 150% Overload capability for up to 60 s, 180% for up to 3 s (200% programmable) (1) For details on specific motor performance, see Knowledge Base article “PowerFlex 525 PM Motor Performance Testing Summary”. (2) For more information, see the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001.
Page 11 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Control Outputs Specifications PowerFlex 523 PowerFlex 525 Relay Quantity: (1) Programmable Form C (2) 1 Programmable Form A and 1 Programmable Form B Specification Resistive Rating: 3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC Inductive Rating: 0.5 A @ 30V DC, 0.5 A @ 125V, 0.5 A @ 240V AC...
Page 12: Environmental Specifications
Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Environmental Specifications Specifications PowerFlex 523 PowerFlex 525 Altitude Current Derating Curves on page 18 for derating guidelines. Without derating: 1000 m (3300 ft) max. With derating: Up to 4000 m (13,200 ft) max., with the exception of 600V drives at 2000 m (6600 ft) max.
Page 13: Certifications
2014/35/EU Low Voltage Directive (LVD) 2014/30/EU EMC Directive (EMC) 2014/34/EU ATEX Directive (ATEX) 2006/42/EC Machinery Directive (MD) Standards applied: EN 61800-3 EN 61800-5-1 (Applicable to PowerFlex 525 drives only) TÜV Rheinland Functional Safety Type Standards applied: Approved EN ISO 13849-1 www.tuv.com...
Page 14: Dimensions And Weights
Catalog Number Description Drive Voltage Rating Rating Enclosure Emission Class Version PowerFlex 520-Series Drive Ratings Output Ratings PowerFlex 523 PowerFlex 525 Normal Duty Heavy Duty Output Input Catalog No. Catalog No. Current (A) Voltage Range Total Watts Loss Frame Size 100...120V AC (-15%, +10%) –...
Page 15 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Output Ratings PowerFlex 523 PowerFlex 525 Normal Duty Heavy Duty Output Input Catalog No. Catalog No. Current (A) Voltage Range Total Watts Loss Frame Size 380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output...
Page 16: Design Considerations
Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Drive Dimensions and Weight Dimensions are in mm and (in.). Weights are in kg and (lb). Frame Size Weight 72.0 (2.83) 152.0 (5.98) 172.0 (6.77) 57.5 (2.26) 140.0 (5.51) 1.1 (2.4) 87.0 (3.43) 180.0 (7.09) 172.0 (6.77)
Page 17 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Minimum Mounting Clearances Dimensions and Weights on page 14 for mounting dimensions. Vertical Vertical, Zero Stacking Vertical with Control Module Fan Kit Vertical, Zero Stacking with No clearance between drives. Control Module Fan Kit No clearance between drives.
Page 18 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Current Derating Curves Vertical Mounting Single Drive Zero Stacking IP 30/NEMA 1 with Control IP 30/NEMA 1 with Control Module Fan Kit Module Fan Kit IP 20/Open Type IP 20/Open Type 60 65 70 75 80 60 65 70 75 80 Ambient Temperature (°C)
Page 19 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications High Altitude 1000 2000 3000 4000 1000 2000 3000 4000 Altitude (m) Altitude (m) Debris Protection Take precautions to prevent debris from falling through the vents of the drive housing during installation. Storage •...
Page 20 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Jumper Location (Typical) Power Module IMPORTANT Tighten screw after jumper removal. Phase to Ground MOV Removal R/L1 Three-Phase S/L2 AC Input T/L3 Jumper Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive (see Input Power Conditions on page 20).
Page 21 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications (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,”...
Page 22 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications 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.
Page 23 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Shielded/Armored Cable Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system.
Page 24 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Output Disconnect The drive is intended to be commanded by control input signals that will start and stop the motor. A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not be used.
Page 25 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Signal and Control Wire Types Recommendations are for 50 °C ambient temperature. 75 °C wire must be used for 60 °C ambient temperature. 90 °C wire must be used for 70 °C ambient temperature. Recommended Signal Wire Belden Wire Type(s)(or equivalent) Signal Type/Where Used...
Page 26 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Connections and Grounding Shielded enclosure (1) IP 30/NEMA 1/UL Type 1 option kit or EMC kit EMI fittings and metal conduit EMI filter R/L1 U/T1 S/L2 V/T2 T/L3 W/T3 Enclosure ground connection Shielded motor cable Building structure steel (1) Some installations require a shielded enclosure.
Page 27 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Fuses and Circuit Breaker Ratings The PowerFlex 520-Series 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.
Page 28 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Rockwell Automation Publication 520-TD001E-EN-E - July 2016 HongKong|UK|China sales@aotewell.com +86-755-8660-6182...
Page 29 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Rockwell Automation Publication 520-TD001E-EN-E - July 2016 HongKong|UK|China sales@aotewell.com +86-755-8660-6182...
Page 30 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Rockwell Automation Publication 520-TD001E-EN-E - July 2016 HongKong|UK|China sales@aotewell.com +86-755-8660-6182...
Page 31 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Rockwell Automation Publication 520-TD001E-EN-E - July 2016 HongKong|UK|China sales@aotewell.com +86-755-8660-6182...
Page 32 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Accessories and Dimensions Dynamic Brake Resistors Drive Ratings Minimum Resistance Resistance Ω ± 10% Ω ± 5% (1)(2) Input Voltage Catalog No. 100...120V 0.25 AK-R2-091P500 50/60 Hz AK-R2-091P500 1-Phase 0.75 AK-R2-091P500 AK-R2-091P500 200...240V...
Page 33 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications EMC Line Filters Short Circuit Current Rating = 100 kA Drive Ratings Input Voltage Current (A) Frame Size Catalog No. 100...120V 0.25 25-RF011-AL 50/60 Hz 25-RF011-AL 1-Phase 0.75 25-RF023-BL 25-RF023-BL 200...240V 0.25 25-RF011-AL...
Page 34 Incremental encoder input option board. 25-ENC-1 WARNING: Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525 drive. Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2 will cause damage to the PowerFlex 525 drive. Rockwell Automation Publication 520-TD001E-EN-E - July 2016 HongKong|UK|China sales@aotewell.com...
Page 35 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate B160 Item Description Frame Size Catalog No. Mounting Adapter Plate For use with drive when replacing Bulletin 160 drives in existing installations to a 25-MAP-FA PowerFlex 520-Series drive.
Page 36 PowerFlex 523 Control Module Front Replacement cover for the control module I/O terminals, EtherNet/IP and DSI ports. A...E 25A-CTMFC1 Cover PowerFlex 525 Control Module Front 25B-CTMFC1 Cover PowerFlex 520-Series Power Module Replacement cover for the PowerFlex 520-Series power module. 25-PMFC-FB...
Page 37 RJ45 120 Ohm resistors (2 pieces) AK-U0-RJ45-TR1 Terminal Block RJ45 Two position terminal block (5 pieces) AK-U0-RJ45-TB2P Connected Components Workbench Windows-based software packages for programming and configuring Allen-Bradley drives http://ab.rockwellautomation.com/ Software and other Rockwell Automation products. programmable-controllers/connected- (Download or DVD-ROM)
Page 38 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Bulletin 1321-3R Series Line Reactors (3)(4) (3)(4) Output Ratings Input Line Reactor Output Line Reactor Normal Duty Heavy Duty IP 00 (Open Style) IP 11 (NEMA/UL Type 1) IP 00 (Open Style) IP 11 (NEMA/UL Type 1) Catalog No.
Page 39 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Accessory Dimensions IP 30/NEMA 1/UL Type 1 Kit – Dimensions are in mm and (in.). Frame A 51.1 (2.01) 21.0 (0.82) ø21.5 (ø0.85) Frame D 96.0 (3.78) 70.0 (2.76) 44.0 (1.73) 30.0 (1.18) ø21.5 (ø0.85) ø33.5 (ø1.32)
Page 40 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Control Module Fan Kit – Dimensions are in mm and (in.). Frame A...D Frame E Frame Size 72.0 (2.83) 152.0 (5.98) 57.5 (2.26) 140.0 (5.51) 56.0 (2.20) 99.8 (3.93) 87.0 (3.43) 180.0 (7.09) 72.5 (2.85) 168.0 (6.61)
Page 41 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications EMC Line Filter – Dimensions are in mm and (in.). Frame A...D Frame E ø5.5 ø5.5 (ø0.22) (ø0.22) L1 L2 L3 YELLOW BLACK BLACK BLACK & GREEN Frame Size 55.0 (2.17) 72.0 (2.83) 234.0 (9.21) 30.0 (1.18)
Page 42 • IEC 61508 Part 1-7 Functional safety of electrical/electronic/programmable electronic safety-related systems – Parts 1-7. TÜV also certifies that the PowerFlex 525 STO may be used in applications up to Category 3/ PL(d) according to EN ISO 13849-1 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508.
Page 43 Safety Concept The PowerFlex 525 Safe-Torque-Off function is suitable for use in safety applications up to and including Category 3 / PL(d) according to EN ISO 13849-1 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508.
Page 44 (1) Enclosure Recommended. Note: External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other measure to exclude these failure modes should be used. (2) In some situations, a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure.
Page 45 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Stop Category 0 – Coast with Two PowerFlex 525 Drives 24V DC Supply AC line Reset input power PF 525 AC line input power E-Stop +24V DC Stop PF 525...
Page 46 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series AC Drive Specifications Example 3 – Safe-Torque-Off Connection with Coast-to-Stop Action Using External +24V supply, SIL 3/PL e Stop Category 0 – Coast AC line input power PF 525 External +24V DC +24V DC Stop Reset Start...
Page 47 Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1 You can view or download publications at http://www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Rockwell Automation Publication 520-TD001E-EN-E - July 2016 HongKong|UK|China sales@aotewell.com...
Page 48 RA-DU002 http://www.rockwellautomation.com/literature/ Allen-Bradley, Rockwell Software, Rockwell Automation, PowerFlex, Connected Components Workbench, Studio 5000, DriveTools SP, AppView, CustomView, QuickView, MainsFree Programming, and PointStop are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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Allen-Bradley PowerFlex 525 Original Instructions Manual

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