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520-TD001 - Rockwell Automation

1. Frame A D Frame E A S C J A A F E a th T Lei i LN E ES N 047 ES i kees OX NO U Gi a eS B s l 2 LE T E II ol PasrarFex ee DL E B eem Cl Allen Bradley 4 Frame Size A B C D E F A 72 0 2 83 152 0 5 98 57 5 2 26 140 0 5 51 56 0 2 20 99 8 3 93 B 87 0 3 43 180 0 7 09 72 5 2 85 168 0 6 61 56 0 2 20 99 8 3 93 C 109 0 4 29 220 0 8 66 90 5 3 56 207 0 8 15 56 0 2 20 99 8 3 93 D 130 0 5 12 260 0 10 24 116 0 4 57 247 0 9 72 56 0 2 20 99 8 3 93 E 196 0 7 72 300 0 11 81 185 0 7 28 280 0 11 02 196 0 7 72 114 3 4 50 Specifications 25 FAN1 70C 25 FAN2 70C Rated Voltage 24V DC Operation Voltage 14 27 6V DC Input Current 0 1A 0 15A Speed Reference 7000 rpm 4500 1096 rpm Maximum Air Flow At zero static pressure 0 575 m3 min 1 574 m min Maximum Air Pressure At zero air flow 7 70 mmH 0 9 598 mmH 0 Acoustical Noise 40 5 dB A 46 0 dB A Insulation Type UL Class A Frame Size Frame A D Frame E Wire
2. 1 0 Wirin g PowerFlex 523 sg stings 0 Control 1 0 L ye m Ke E igin TermBik 03 PowerFlex 523 Wi ring Block 4 zy bien tn REV Wi H SNK SRC Digital Common E Diagram Digln TermBlk 05 Pulse ge e Two 2 Analog Inputs two unipolar are jen independently isolated from the rest of the drive I O T m Eum np w EE wes Five 5 Digital Inputs four programmable provide en EL lu Analog Common application versatility nang n o RJ45 Shield One 1 Relay Output form C can be used to canon indicate various drive motor or logic conditions PowerFlex 525 ae SNK 3 Pulse In et Vv Su Two 2 Analog Inputs one unipolar and one bipolar ad i are independently isolated from the rest of the drive Vv R m I O These inputs can be toggled via a digital input Si B 6 Seven 7 Digital Inputs six programmable provide B icati ili PowerFlex 525 A JS application versatility S NN d i 2 Control 1 0 um M se toque ot La v sump 3 One 1 Analog Output is jumper selectable between WiringBlock H mamas D D Digital Common either 0 10V or 0 20 mA This scalable 10 bit output Diagram pum M is suitable for metering or as a speed reference for 07 another drive vg DiiTembik os KA q taw e Two 2 Opto Outputs and tw
3. EMC Line Filters Drive Ratings Input Voltage HP kW Current A Frame Size Catalog No 100 120V 0 25 0 2 16 A 25 RFOTI AL 50 60 Hz 0 5 04 25 A 25 RFO11 AL Hie 10 075 48 B 25 RFO23 BL 15 11 6 0 B 25 RF023 BL 200 240V 025 02 16 A 25 RF011 AL 50 60 Hz 0 5 04 25 A 25 RF011 AL EES 10 075 48 A 25 RF011 AL 20 15 8 0 B 25 RFO23 BL 30 22 11 0 B 25 RFO23 BL 200 240V 0 25 0 2 16 A 25 RFO14 AL 50 60 Hz 0 5 04 25 A 25 RFO14 AL ES 10 075 5 0 A 25 RF014 AL 20 15 8 0 A 25 RFO14 AL 3 0 22 11 0 A 25 RFO14 AL 5 0 40 175 B 25 RF021 BL 75 55 24 0 C 25 RFO27 CL 10 0 75 32 2 D 25 RFO35 DL 15 0 11 0 483 B 25 RFO56 EL 20 0 15 0 62 1 B 25 RFO56 EL 380 480V 0 5 04 14 A 25 RF7P5 AL 50 60 Hz 10 075 23 A 25 RF7P5 AL SES 2 0 15 40 A 25 RF7P5 AL 3 0 22 6 0 A 25 RF7P5 AL 50 40 10 5 B 25 RFO14 BL 75 55 13 0 C 25 RFO18 CL 10 0 75 17 0 C 25 RFO18 CL 15 0 11 0 24 0 D 25 RFO33 DL 20 0 15 0 30 0 D 25 RF033 DL 25 0 185 37 0 B 25 RFO39 EL 30 0 220 43 0 E 25 RF039 EL 525 600V 0 5 04 0 9 A 25 RF8PO BL 50 60 Hz 1 0 0 75 17 A 25 RF8PO BL ou 20 15 30 A 25 RF8PO BLU 30 22 42 A 25 RF8P0 BLO 50 40 6 6 B 25 RF8PO BL 75 55 99 C 25 RFO14 CL 10 0 75 120 C 25 RFO14 CL 15 0 11 0 19 0 D 25 RFO27 DL 20 0 15 0 22 0 D 25 RF027 DL 25 0 185 27 0 B 25 RFO29 EL 30 0 220 320 E 25 RF029 EL 1 EMCLine Filter size is based on the input current ofthe drive See the tables on page 34 and page 35 for
4. Allen Bradley J Allen Bradley F Allen Br adley 4 Frame A Frame B Frame C Frame D Frame E PowerFlex 525 Drive Family _ PowerFlex III Powertiex 2 Quemdy QAllenBradey 7 Allen Bradley Allen Bradley Frame A Frame B Frame C Frame D Frame E Rockwell Automation Publication 520 TD001D EN E January 2014 7 PowerFlex 520 Series AC Drive Specifications Catalog Number Explanation 1 3 4 5 6 8 9 10 11 12 13 14 25B _ B 2P3 N 1 1 4 _ _ oe Dash ei 4 Standard 25A PowerFlex 523 0 No Filter 25B PowerFlex 525 1 Filter V 120VAC 1 1 Standard A 240VAC 1 B 240VAC 3 D AB0V AC 3 IP20 NEMA Open E 600VAC 3 1P6 16 A 0 25 02 025 02 1P4 14 JA 05 04 05 04 2P5 25 A 05 04 05 04 2P3 23 A 10 075 10 0 75 4P8 48 B 10 075 10 075 4P0 40 In 20 15 20 15 6P0 60 B 15 11 15 111 6P0 60 A 30 22 30 22 010 105 B 50 40 Ten 40 013 130 C 75 55 75 55 017 170 C 10 0 7 5 10 0 7 5 SE EE Seelen calm NL S MR 00 370 TE 25 0 18 5 20 0 15 0 wl EE KN 030 Ton TE 300 22 0 25 0 18 5 8P0 80 B 20 115 20 15 011 110 B 30 22 30 22 1P6 1 6 A 0 25 0 2 0 25 0 2 2P5 25 A 05 04 05 04 5P0 5 0 A 10 075 1 0 0 75 8P0 8 0 A 20 15 20 15 011 110 A 30 22 30 22
5. 240V AC 10 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications Specifications PowerFlex 523 PowerFlex 525 0pto Quantity _ 2 Programmable Specification 30V D 50 mA Non inductive Analog Quantity _ 1 Non Isolated 0 10V or 4 20 mA Specification Resolution 10 bit 0 10V DC Analog 1k ohm minimum 4 20 mA Analog 525 ohm maximum Encoder Specifications PowerFlex 523 PowerFlex 525 Type _ Incremental dual channel Supply 12V 250 mA Quadrature 90 27 25 C Duty Cycle 50 10 Requirements Encoders must be line driver type quadrature dual channel or pulse single channel 3 5 26V DC output single ended or differential and capable of supplying a minimum of 10 mA per channel Allowable input is DC up to a maximum frequency of 250 kHz The encoder I 0 automatically scales to allow 5V 12V and 24V DC nominal voltages Rockwell Automation Publication 520 TD001D EN E January 2014 11 PowerFlex 520 Series AC Drive Specifications Environmental Specifications Specifications PowerFlex 523 PowerFlex 525 Altitude See 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 Surrounding Air Temperature max See Current
6. Building structure steel 1 Some installations require a shielded enclosure Keep wire length as short as possible between the enclosure entry point and the EMI filter PowerFlex 520 Series RF Emission Compliance and Installation Requirements Standard Limits EN61800 3 Category C2 EN61800 3 Category C1 EN61000 6 4 EN61800 3 Category C3 I lt 100 A EN61000 6 3 CISPR11 Group 1 Class A CISPR11 Group 1 Class A Filter Type CISPR11 Group 1 Class B Input power lt 20 kVA Input power gt 20 kVA Internal _ 10 m 33 ft 20 m 66 ft External 30m 16 ft 100 m 328 ft 100 m 328 ft 1 See Accessory Dimensions on page 43 for more information on optional external filters 26 Rockwell Automation Publication 520 TD001D EN E January 2014 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 The tables on pages 32 35 provide drive ratings and recommended AC line input fuse and circuit breaker information Both types of short circuit protection are acceptable for UL and IEC requirements Sizes listed are the recommended sizes based on 40 C 104 F and the US N E C Other country state or lo
7. 01 32 n z gt PowerFlex S DM D 1 nnonnonannn Frame B 4 i 66 1 2 60 EI a 63 1 248 5 S 132 aS M U 23 9 0 94 en i Allen Bradley K N ao H z T Pas UU 921 5 00 85 Maz T ZN 927 5 01 08 i E El Z 1 aes 3 L ane 35 Frame E gun 127 5 5 02 emm EA li a8 82 5 3 25 62 5 2 46 0000 sta 2m 42 5 1 67 ke ON m amp 1 Ki E NOD al m GOU See u e i 7M 943 7 01 72 Frame C DE 80 5 3 17 e F gt F 6650 62 351136 q 3 SS gt oh 26 5 1 04 a N i Z E N 021 5 00 85 a 5 sony SS 027 5 91 08 Wee 2 p E e ml SS F EN L unc E 0 Ca 0 me I D z m SON m e xU i Lt S A ri Frame Size A B C D E F G H A 72 0 2 83 219 0 8 62 172 0 6 77 57 5 2 26 152 0 5 98 92 7 3 65 6 0 0 24 140 0 5 51 B 87 0 3 43 218 0 8 58 172 0 6 77 72 5 2 85 180 0 7 09 92 7 3 65 6 0 0 24 168 0 6 61 C 109 0 4 29 255 0 10 04 184 0 7 24 90 5 3 56 222 0 8 66 92 7 3 65 6 0 0 24 207 0 8 15 D 130 0 5 12 295 0 11 61 212 0 8 35 116 0 4 57 260 0 10 24 6 0 0 24 247 0 9 74 E 185 0 7 28 350 0 13 78 279 0 10 98 160 0 6 30 300 0 11 81 7 6 0 30 280 0 11 02 43 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications Control Module Fan Kit Dimensions are in mm and in
8. 017 17 5 B 5 0 40 50 4 0 024 24 0 C 75 55 75 55 032 32 2 D 10 0 7 5 100 7 5 082 483 TE 15 0 11 0 10 0 7 5 0627 621 E 20 0 15 0 15 0 11 0 1 This rating is only available for PowerFlex 523 drives 2 Rockwell Automation Publication 520 TD001D EN E January 2014 Normal and Heavy Duty ratings are available for this drive 0P9 0 9 A 05 104 05 04 1P7 17 A 10 0 75 1 0 0 75 3P0 3 0 A 20 15 20 15 4P2 4 2 A 3 0 22 30 22 6P6 6 6 B 5 0 40 50 40 9P9 9 9 C 75 55 75 55 012 12 0 C 10 0 7 5 10 0 7 5 019 19 0 D 15 0 11 0 15 0 11 0 ol mo D 20 0 15 0 15 0 11 0 0279 xo E 25 0 18 5 20 0 15 0 0327 320 E 30 0 220 25 0 18 5 PowerFlex 520 Series AC Drive Specifications Technical Specifications Protection Specifications Bus Overvoltage Trip 100 120V AC Input 200 240V AC Input 380 480V AC Input 525 600V AC Input PowerFlex 523 PowerFlex 525 405V DC bus equivalent to 150V AC incoming line 405V DC bus equivalent to 290V AC incoming line 810V DC bus equivalent to 575V AC incoming line 1005V DC bus equivalent to 711V AC incoming line Bus Undervoltage Trip 100 120V AC Input 200 240V AC Input 380 480V AC Input 525 600V AC Input P038 3 600V P038 2 480V 190V DC bus equivalent to 75V AC incoming line 190V DC bus equivalent to 150V AC incoming li
9. ATTENTION PowerFlex 520 Series drives contain protective MOVs that are referenced to ground These devices must be ATTENTION Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground 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 Rockwell Automation Publication 520 TD001D EN E January 2014 19 PowerFlex 520 Series AC Drive Specifications Jumper Location Typical Power Module IMPORTANT Tighten screw after jumper removal Phase to Ground MOV Removal Three Phase B o ACInput AU I TA3 T npe 1 2 3 4 H H H H Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive see Input Power Conditions on page 20 Listed in the Input Power Conditions table below are certain input power conditions which may cause component damage or reduction in product life If any of these condition
10. ZE 384 WOFL 0S 99H NObL 1 001 1 c j vee oce BL Osc Ovzc OOE vOLNCEOT VSC 0S 140 SSVD ZEI 384 WOPL SE I9H NOPL 0 001 3 Le T8 oLz gei ooz eg OST vOLN COT VSC E 09 140 SSVD 7ZE 384 WOPL SEI I9H NOPL 0 001 a Zjcie OZ Oll OSL Cell O07 vOLNCCOT VSC E 3 05 1100 SSVD S2O 394 WOPL 0 9H 00r1 0 001 dd mir 061 ul gei CU osL POLN6103 VSZ 91 380 WOrL O Y S10 140 17 SHY SSVD 912 320O WOPL 02 090 f0vl 001 SEL HSL OTL SZ O0l SZ OOL vOLNCLOF VSC 91D 380 WOrL SCW 10 1101 SHY SSVD 91 30 WorL SL 090 NobL 91 001 ul 66 ss CU ai CU steigt 01 380 W0rL OZ 8 S10 110 12 MW SSYTD 0 30 WorL 0L 090 NObL 60 001 8 og 16 99 mi el Ov Os POLN9493 VSZ 99 380 WorL sL S10 110020 SHY SSVT 99 30 WOrL 088 090 NObL 602 001 V es ro cv TZ Ot Cl O vOlNCdVi VsC 08 3 WOtL 0L3 510 110 SHY SSVDD 0 9 30 WovL OSd 09d NObL 602 001 V se ml Of SL Cl SL 7 vOlNOdET VSC SC O WOVL 93 510 110 W SSVDD SC8 30 WOv O 8 090 NObL 602 001 V ez 92 CU sco OL sco OL POLN dI3 VSZ 78 32 WOPL 93 510 110 1 Sw SSYTD Szg 32O WOPL 074 090 NOPL 602 001 V TL vi 60 vol soj voj Soj vOLN6dOT VSC Sy WO L UO ON Bojeye seet Nort Bupeg xew Buneu unw oN bopeye ezis sdwy vj sduv MA dH Wl dH ON Bojexe Si19yeo1g 31n241 Buey Xew Sosnj S19 eaJg JINDAL s snj 1019010 Wed xew Ayng Kaeay Ayng jeulon
11. suone iddy 10 suone3iiddy 10 uoN 331 sbuneu mdut sbuneu 1nding 3 V SaUDIj sana U01 22 01d Indu asbujd A009 676 panuiuo z xa 449MOd 10 S1oeaJg UD pue sasnj 31 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications swiayss punoa 3ue sis 1 uBiu 10 punosb 13u10 e1 q e1 q A009 10 A0gr uo asn 104 PAS IN JON Mdu JY p A009 pue Z A09r 10 POSI TIN l l01uo 1010W uolneulquuio 3 ad j papayoig Jjog jenuew y di JOU JIM 3IA p ay PY uru WNWIUIW au 0 385 du au aui aAeY pinous uea 3uaum qe snfpe yum WOPL ugang E c L SHUEY uonerddy stayeaig M WON IAI 1010W WOF L Ull l ng LE Aew Siayealg 11741 4019104 4030 WOY L Ufang au o sbunei y au Dune yuan mut aap 104 ayejdaweu IAP I4 0 1 J 1 sugea du samo YIM S10 OW Bul 011u02 SI AHp ay UaY C 381 WOvL SED 2 9H NOVL 05 110 SSVD S 384 WOPL S 9H 0vL 1 001 g SCT 09 OLL C 0t C OE vLINLLOV 8SC C 383 WOvL C 9H OvL 05 110 SSVD 2 384 WOPL SED Z99H NOFL 001 g SCC 09 OLL CC 0t C OE vVOLNLLOV dSC C 183 WOvL C ca9d novL 0v 110 SSVD O 383 WOPL 7 2090 NOrL O 001 8 08L 8t 08 SL 0c SL O Z vLINOd8V 8SC C 1831 WOvL C ca9d7novL Op 110 SSVD 383 WOPL Z7 7090 NOrL O 001 H O8L 8v 08 SL 07 SL
12. 41 for specific line reactor part numbers 2 See Accessories and Dimensions on page 36 for accessory ordering information 20 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications 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 e wu III x S L2 x Der CRUS TEE 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 G 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 te
13. 520COM UM003 PowerFlex 25 COMM P PROFIBUS DP Adapter User Manual 520COM UM004 Dynamic Braking Resistor Calculator PFLEX ATO01 Wiring and Grounding Guidelines for 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 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 TD001D EN E January 2014 51 Important 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
14. 88 0 A 25A D010N114 25B D010N114 5 0 4 0 5 0 4 0 10 5 323 528 133 0 B 25A D013N114 25B D013N114 7 5 5 5 7 5 5 5 13 0 323 528 175 0 C 25A D017N114 25B D017N114 10 0 75 10 0 75 17 0 323 528 230 0 C 25A D024N114 25B D024N114 15 0 11 0 15 0 110 24 0 323 528 313 0 D 25A D030N114 25B D030N114 20 0 15 0 15 0 110 300 323 528 402 0 D 25A D037N114 25B D037N114 25 0 18 5 20 0 15 0 37 0 323 528 602 0 E 25A D043N114 25B D043N114 30 0 22 0 25 0 18 5 43 0 323 528 697 0 E 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 25A E0P9N104 25B E0P9N104 0 5 0 4 0 5 0 4 0 9 446 660 22 0 A 25A E1P7N104 25B E1P7N104 1 0 0 75 1 0 0 75 1 7 446 660 32 0 A 25A E3P0N104 25B E3P0N104 2 0 15 2 0 15 3 0 446 660 50 0 A 25A F4P2N104 25B E4P2N104 3 0 2 2 3 0 2 2 4 2 446 660 65 0 A 25A E6P6N104 25B E6P6N104 5 0 4 0 5 0 4 0 6 6 446 660 95 0 B 25A E9P9N104 25B E9P9N104 7 5 5 5 7 5 5 5 9 9 446 660 138 0 C 25A E012N104 25B E012N104 10 0 7 5 10 0 7 5 12 0 446 660 164 0 C 25A E019N104 25B E019N104 15 0 11 0 15 0 11 0 19 0 446 660 290 0 D 25A E022N104 25B E022N104 20 0 15 0 15 0 11 0 220 446 660 336 0 D 25A E027N104 25B E027N104 25 0 18 5 20 0 15 0 270 446 660 466 0 E 25A E032N104 25B E032N104 30 0 22 0 25 0 18 5 32 0 446 660 562 0 E 1 Anon filtered drive is not available for 380 480V AC 25 HP 18 5 kW and 30 HP 22 0 kW ratings Filtered drives are available however you must verify that the application w
15. 9 F for all mounting methods For catalogs 25x D1P4N104 and 25x E0P9N104 the temperature listed under the Max with Control Module Fan Kit Derate column is reduced by 10 C 18 F for vertical and vertical with zero stacking Rockwell Automation Publication 520 TD001D EN E January 2014 17 PowerFlex 520 Series AC Drive Specifications Current Derating Curves Vertical Mounting Single Drive 120 IP 30 NEMA1 with Control 110 Module Fan Kit 100 90 IP 20 0pen Type 80 70 60 50 Percentage of Rated Current Percentage of Rated Current 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Horizontal Mounting Floor Single Drive 120 with Control 110 Module Fan Kit 100 90 80 70 60 50 40 Percentage of Rated Current Percentage of Rated Current 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Derating Guidelines for High Altitude Zero Stacking 120 IP30 NEMAT with Control 110 Module Fan Kit 100 30 IP 20 0pen Type 80 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Zero Stacking 120 With Control 110 Module Fan Kit 100 90 80 70 60 50 40 IP 20 0pen Type 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C 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 e Derate the maximum ambient
16. 90 C 194 F XHHW2 RHW 2 e Four tinned copper conductors with XLPE insulation Anixter B209500 B209507 Belden 29501 29507 or equivalent Copper braid aluminum foil combination shield and tinned copper drain wire PVC jacket Standard Option 2 Tray rated 600V 90 C 194 F Three tinned copper conductors with XLPE insulation RHH RHW 2 Anixter OLF 7xxxxx or equivalent 5mil single helical copper tape 25 overlap min with three bare copper grounds in contact with shield PVC jacket Class amp Il Tray rated 600V 90 C 194 F Three bare copper conductors with XLPE insulation and impervious corrugated Division amp II RHH RHW 2 Anixter 7V 7xxxx 3G or equivalent continuously welded aluminum armor Black sunlight resistant PVC jacket overall Three copper grounds on 10 AWG and smaller Reflected Wave Protection The drive should be installed as close to the motor as possible Installations with long motor cables may require the addition of external devices to limit voltage reflections at the motor reflected wave phenomena Refer to Reflected Wave in Wiring and Grounding Guide PWM AC Drives publication DRIVES IN001 The reflected wave data applies to all carrier frequencies 2 16 kHz For 240V ratings and lower reflected wave effects do not need to be considered Rockwell Automation Publication 520 TD001D EN E January 2014 23 PowerFlex 520 Series AC Drive Specifications Out
17. 9g 1O WOvL 093 090 00r 605 001 v9 HU 9 TO SCH vOLNOdLA VSC waor Nov ON Doje3e sse norL Buneg xew Pupen um on 5olele qduv WAN sduy Wl dH oNbojex siayeaig HN Dune xew sasny s1ayeaig UN soen 20 23U0 xew kyng een suoneddy 10 suone uddy 10 uoN 3I suey ynduy suey yndjng gY SOUDI s 2lA uorajod Indu asbud AOZ 17001 EZS X3 419MOg 10J S19Xe24g JINDAL pue seat Rockwell Automation Publication 520 TD001D EN E January 2014 28 PowerFlex 520 Series AC Drive Specifications din ou Wu 3IA p au Jey uea nu ay 0 Jas diy 1u 11n2 ay BALY Pinoys uea uaund qe1snfpe YUM wor UNIMA Sburey voned dy sr9yealg TT U01191014 1010W WOr L OST aas aas Aaea APU Slayeadg UNY 103223014 4010 WOy Una ng 24740 shunned Jy y Dune zuan 1mdu auup 10 ayejdaweu aAUp ay 0 19J91 sugea due Jamo YIM S10 0W Bul 01 u02 SI aAUp IY UY SCL 140 TJD SSVT 0 2 d8H WOFL 06 99H N0Y L CL 001 1 09s occ L79 OLL OSL OSL 0 02 pOLNZ908 SSZ 06 1J0 T SSV SpD 384 WOFL 0 3 629H 00rl 099 001 1 Otri LOZ 8v SZ OOL OU OSL PpOLN8PO9 VSZ Dall 04 8 510 L10 T e SSVID S J84 WOPL 099 99H NOrL v 001 q 8vt OSL cce SL OOL SZ ODL vOLNCEOR VSC C 383 WOvL SE E99H flOV 09 110 SSVD ZED J84 WOPL 9H f0vL 001 D 99c CC OZ SS SL SS SZ vOLNFCOS VS
18. AK R2 030P1K2 15 0 11 0 14 15 AK R2 030P 120 20 0 150 10 15 AK R2 030P1K2 380 480V 0 5 04 89 360 AK R2 360P500 50 60 Hz 10 0 75 89 360 AK R2 360P500 3 Phase 20 15 89 360 AK R2 360P500 3 0 22 89 120 AK R2 120P1K2 5 0 4 0 47 120 AK R2 120P1K2 75 55 47 120 AK R2 120P1K2 10 0 75 47 120 AK R2 120P1K2 15 0 11 0 43 60 AK R2 120P1K2 20 0 15 0 43 60 AK R2 120P 120 25 0 18 5 27 40 AK R2 120P1K2 30 0 220 27 40 AK R2 120P1K2 525 600V 0 5 04 112 360 AK R2 360P500 50 60 Hz 1 0 0 75 112 360 AK R2 360P500 3 Phase 20 15 112 360 AK R2 360P500 3 0 22 112 120 AK R2 120P1K2 5 0 4 0 86 120 AK R2 120P1K2 75 55 59 120 AK R2 120P1K2 10 0 75 59 120 AK R2 120P1K2 15 0 11 0 59 60 AK R2 120P 120 20 0 15 0 59 60 AK R2 120P 120 25 0 18 5 53 60 AK R2 120P1K2 30 0 220 34 40 AK R2 120P1K2 1 The resistors listed in this tables are rated for 5 duty cycle 2 Use of Rockwell Automation resistors is always recommended The resistors listed have been carefully selected for optimizing performance in a variety of applications Alternative resistors may be used however care must be taken when making a selection See the PowerFlex Dynamic Braking Resistor Calculator publication PFLEX AT001 Requires two resistors wired in parallel 4 Requires three resistors wired in parallel 36 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications
19. IP 11 NEMA UL Type 1 IP 00 Open Style IP 11 NEMA UL Type 1 HP kW HP kW Catalog No Catalog No Catalog No Catalog No 5 0 40 5 0 40 1321 3R18 A 1321 3RA18 A 1321 3R18 A 1321 3RA18 A 75 5 5 75 5 5 1321 3R25 A 1321 3RA25 A 1321 3R25 A 1321 3RA25 A 10 0 75 10 0 75 1321 3R35 A 1321 3RA35 A 1321 3R35 A 1321 3RA35 A 15 0 11 0 15 0 11 0 1321 3R45 A 1321 3RA45 A 1321 3R45 A 1321 3RA45 A 20 0 15 0 15 0 11 0 1321 3R55 A ND 1321 3RA55 A ND 1321 3R55 A ND 1321 3RA55 A ND 1321 3R45 A HD 1321 3RA45 A HD 1321 3R45 A HD 1321 3RA45 A HD 380 480V 50 60 Hz 3 Phase 0 5 0 4 0 5 0 4 1321 3R2 B 13213RA2 B 1321 3R2 B 1321 3RA2 B 1 0 0 75 1 0 0 75 1321 3R4 C 1321 3RA4 C 1321 3R4 C 13213RM C 2 0 15 20 15 1321 3R4 B 1321 3RA4 B 1321 3R4 B 13213RM B 3 0 22 3 0 2 2 1321 3R8 C 1321 3RA8 C 1321 3R8 C 1321 3RA8 C 5 0 4 0 5 0 4 0 1321 3R12 B 1321 3RA12 B 13213R12 B 1321 3RA12 B 75 5 5 75 5 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 10 0 15 10 0 75 1321 3R18 B 1321 3RA18 B 1321 3R18 B 1321 3RA18 B 15 0 11 0 15 0 11 0 1321 3R25 B 1321 3RA25 B 1321 3R25 B 1321 3RA25 B 20 0 15 0 15 0 11 0 1321 3R35 B ND 1321 3RA35 B ND 1321 3R35 B ND 1321 3RA35 B ND 1321 3R25 B HD 1321 3RA25 B HD 1321 3R25 B HD 1321 3RA25 B HD 25 0 18 5 20 0 15 0 1321 3R35 B 1321 3RA35 B 1321 3R35 B 1321 3RA35 B 30 0 22 0 25 0 18 5 1321 3R45 B ND 1321 3RA45 B ND 1321 3R45 B ND 1321 3RA45 B ND 1321 3R35 B HD 1321 3RA35 B HD 1321 3R35 B HD 1321
20. O Z vOLNOd8V 8SC 9L2 3O WOtL 12 7q90 n0vL sSZ g S1Q L10 eyd SSY 912 30 WOrL 12 7090 n0vL c12 001 V LOL SC sv SCH OL SCH OL vLINSdyV 8SC 9L2 3O WOtL SLI Z090 NOVL SZ Y S10 L10 SY SSvD 912 30 WOvL SL CO90 nOrL 12 001 V LOL SC sv SCH OL SCH 01 vOLN8dyV 8SC 012 3O WOtL OLD Z090 NOVL SL Y S1d L10 oy SSVD 012 3O WOvL 0L CQ90 nOrL 602 001 V G9 LL SC 0 0 v0 0 viLINSdCV 8SC 012 3O WOtL OLD ZA90 NOPL SGL 510 L10 f SY SSVD 012 3O WOtL 0L ZA9A N0Y L 602 001 V 9 LL SC vo o vo SD vOLNSdCV dSC Geo WOtL Nov ON boeze sser Worl NOrL Buey xew Guney um oN 6oleje ezis sduy yay sduy Wl dH Wi dH on bore siayearg PMI buey xey sasny saaye ag Wun sosnj 4032e3U0 auiery XEW kyng KAeag fang jeuuoN suoneriddy 10 suoneiddy 15 uoy 53I sbuney ynduy sbuney 1nding C 383 WOYL 0 2 Ca90 f0v L 05 48 8910 140 Syd SSY gy SOUDI s 2lA UONJ J04d 1nduj SDYd L AOFZ 007 C 383 WOt L 0 Cq90 n0vl C 001 VOLNOd9A dSC 0C0 380 WOT L SC CI90 f0vL 0 u S1d 140 5 Syd SSY 02 380 WOt L SC CQ90 0vL C 001 VOLN8drA dsc 012 3O WOvL ty eycoWOv t C O90700rL NOvL 0C 4 S10 140 T SAY SSY ON Bojeye ssen 015 3O WOtL WOtL CL ca9q nort Novi Buney xew puey UW 713 001 on 5o e3e saayeorg HINDI Gurney xew sas
21. SSV D Sv0 383 WOtL 099 99H NOvL v 001 q Sve OSL TTE GL OOL SZ OOL vOLNCEOG gSC Z 384 WOPL SED ED9H NOPL 09 110 TJ SSV D Z J84 WOrL SE 99H NOvL Z 001 997 CO Ovc GSS GL SS SL vOLNFCOB 8SC 7 384 WOvL S7 090 NOPL Sv 110 SSVD 0 383 WOvL Z 090 NOvL O 001 g VL 96 SLL Ov OS OF QS pOLN LOS 8SZ 91 32Z WOrL SLI 090 NOPL O Y STd 140 T SHY SSY 912 3O WOvL SLI 09d NOvL 7 00L V SEL 9 OLL cc EI CZ O POLNLLOG 8Sz 012 3O WOtL OLD EQ9G NOPL OZ 4 S10 110 T SHY SSY 012 30 WOtL OLI A9d NorL c12 001 V 96 Et 08 d 07 cl O Z vOLNOd88 8SC 9g 30 WOtL O8 E090 NOPL SL 8 910 110 T SAY SSY 98 30 WOvL 089 090 NOvL 602 001 V B S LU OS SLO OL SLO OL POLNOdSd 857 Ov8 JZ WOPL OPE EQ9G NOPL 9 4 S10 L10 T SAY SSY 058 32 WOvL 0Y9 EQ9A NOYL 105 001 V LC Cl Sd vo SO vo SO vOLNSdCa 8sc egy WO L nori ON Bojeye seg NOvL Buey xew Dune um oN Gojeyey ezis sdun vj sduy Wl dH MA dH y oN foree 19ye2Jg NDI Eupen xew sasny S19ye2Jg PNI sosnj 4032ejU0 aurery WEN Kang gan Aang jeuuov suonexiddy 10 suone iuddy 10 uoN 331 suey ndu suizey 1nding JY SOUDI S J G U01 3 01d ndu SDYd E NOHT 007 p nunuo 7S xo 449MOd 104 s1 V 14g UD pue sasnj 33 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications suajs
22. Sinusoidal PWM Volts Hertz Sensorless Vector Control Economizer SVC motor control and Closed Loop Velocity Vector Control Closed Loop Velocity Vector Control is not applicable to PowerFlex 523 drives Carrier Frequency 2 16 kHz Drive rating based on 4 kHz Frequency Accuracy Digital Input Within 0 05 of set output frequency Analog Input Within 0 5 of maximum output frequency 10 Bit resolution Analog Output _ 2 of full scale 10 Bit resolution Rockwell Automation Publication 520 TD001D EN E January 2014 9 PowerFlex 520 Series AC Drive Specifications Specifications Performance V Hz Volts per Hertz SVC Sensorless Vector SVC Economizer VVC Velocity Vector Control PowerFlex 523 1 of base speed across a 60 1 speed range 0 5 of base speed across a 100 1 speed range 0 5 of base speed across a 100 1 speed range PowerFlex 525 0 5 of base speed across a 60 1 speed range Not applicable to PowerFlex 523 drives Performance with Encoder SVC Sensorless Vector SVC Economizer VVC Velocity Vector Control 0 1 of base speed across a 100 1 speed range 0 1 of base speed across a 100 1 speed range 0 1 of base speed across a 1000 1 speed range Output Voltage Range OV to rated motor voltage Output Frequency Range 0 500 Hz programmable Efficiency 97 596 typical Stop Modes Multiple programmable stop modes including Ramp Coa
23. V4P8N104 1 0 0 75 1 0 075 48 85 132 53 0 B 25A V6PON104 25B V6PON104 15 1 1 15 1 1 6 0 85 132 67 0 B 200 240V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25A A1P6N104 0 25 0 2 025 0 2 1 6 85 132 20 0 A 25A A2P5N104 25B A2P5N104 0 5 0 4 0 5 0 4 2 5 170 264 29 0 A 25A A4P8N104 25B MP8N104 1 0 0 75 10 075 48 170 264 50 0 A 25A A8P0N104 25B A8P0N104 2 0 1 5 2 0 1 5 8 0 170 264 81 0 B 25A A011N104 25B A011N104 3 0 2 2 3 0 2 2 11 0 170 264 111 0 B 200 240V AC 15 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 25A A1P6N114 0 25 0 2 025 02 1 6 85 132 20 0 A 25A A2P5N114 25B A2P5N114 0 5 0 4 0 5 0 4 2 5 170 264 29 0 A 25A A4P8N114 25B A4P8N114 1 0 0 75 1 0 075 48 170 264 53 0 A 25A A8P0N114 25B A8P0N114 2 0 15 2 0 15 8 0 170 264 84 0 B 25A A011N114 25B A011N114 3 0 2 2 3 0 2 2 11 0 170 264 116 0 B 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 25A B1P6N104 0 25 02 025 02 1 6 85 132 20 0 A 25A B2P5N104 25B B2P5N104 0 5 0 4 0 5 0 4 2 5 170 264 29 0 A 25A B5PON104 25B B5PON104 1 0 0 75 10 075 50 170 264 50 0 A 25A B8P0N104 25B B8P0N104 2 0 1 5 2 0 1 5 8 0 170 264 79 0 A 25A B011N104 25B B011N104 3 0 2 2 3 0 2 2 11 0 170 264 107 0 A 25A B017N104 25B B017N104 5 0 4 0 5 0 4 0 17 5 170 264 148 0 B 25A B024N104 25B B024N104 7 5 5 5 7 5 5 5 24 0 170 264 259 0 C 25A B032N104 25B B032N104 10 0 75 10 0 7 5 32 2 170 264 323 0 D 25A B048N104 25B B048N104 1
24. WOY L UN JINg ayy Jo sBul1e1 IV L Bunea juauno 1ndiul eAup 104 ayejdaweu AUP ay 0 19421 Shue dwe Jamo UNA Sl010uu Bul 011u02 sr IAP ay Udy 1e1 ng Aa pue jeuuoN SAUP S144104 e qejIeAe aie sur 09 140 SSVD ZED 384 WOPL 05 9H NObL 001 3 TETI VEE OTE t OST Occ OE vOLNCEO3 8GC 0S 110 f DSSYTI C 383 WOvL SED 99H NOvL 0 5 001 3 Lyd C8c OLT OSL OOZ S8L OSC vOLNZCO3 8GC 09 140 SSV C 393 WOvL SED 99H NOvL 0 001 q ELT TLE OTZ OLL OSL OSL O0c vOLNCCOT GSC 05 1401 SSVD 7 J84 WOPL O 9 99H NOFL 0 5 001 d Ove v C 061 OLL OSL OLL OSL POLN6LOI 8S7 91L 380 WOrL O U S10 140 SU SSVD 912 3O WOrL 02 090 NOrL 7 001 SEL VSL OTL SZ 001 SZ O OL vOLNZLOI 857 9912 380 WOtl SCW S10 L10 SHY SSVI 91 30 WOvL 1 E090 f0rL 915 001 TLL SZL 66 SS SL S6 SU v0LN6d61 8SC 012 380 WOv L DEHATI L10 1 Syd SSVI 010 3O WOtL 01 EQ90 fOrL 602 001 g 08 L 6 99 OF OS OF 0S rO1N9494 8SZ 9g 380 WOvL SL U S10 L10 T SAY SSVI 98 30 WOvL 089 09d NovL 602 001 V es 9 cv Cl EI Cl EI vOLNCdr3 8SC 0v8g 3O WOtL OL W S10 L10 T yu SSV D 0rg 3 WOvL 0Sg d90 fOvL 605 001 V se Ev DEI GL OZ SL OCI vOLNOdC3 8GC 79 42 WovL 93 510 1409 yu SSVD SC8 30 WOvL 0 4 090 NOFL 605 001 V c 97 LL SLO OL SCH OL vOLN
25. liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this publication 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 Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Allen Bradley Rockwell Software Rockwell Automation PowerFlex Connected Components Workbench Studio 5000 DriveTools SP AppView CustomView MainsFree Programming and P ointStop are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382
26. 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 e Derate the output current by 10 for every additional 1000 m 3300 ft subject to limits listed in the Altitude Limit Based on Voltage table below Altitude Limit Based on Voltage Corner Ground Impedance Drive Rating Center Ground Wye Neutral 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 18 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications High Altitude _ 12 60 10 e z 10 g 5 2 9 E z 80 40 ap 60 g 30 S 5 4 20 0 1000 2000 3000 4000 0 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 e Store within an ambient temperature range of 40 85 c e Store within a relative humidity range of 0 95 noncondensing e Do not expose toa Corrosive atmosphere 1 The maximum ambient temperature for storing a Frame E drive is 70 C AC Supply Source Considerations Ungrounded Distribution Systems disconnected if the drive is installed on an ungrounded or resistive grounded distribution system
27. to the drive to start and stop the used the input device must not exceed one operation per minute or drive damage can occur ATTENTION The drive start stop control circuitry includes solid state components If hazards due to accidental contact with moving machinery or unintentional flow of liquid gas or solids exist an additional hardwired stop circuit may be required to remove the AC line to the drive When the AC line is removed there will be a loss of any inherent regenerative braking effect that might be present the motor will coast to a stop An auxiliary braking method may be required Alternatively use the drive s safety input function Important points to remember about I O wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control and signal wires should be separated from power wires by at least 0 3 m 1 ft IMPORTANT UO terminals labeled Common are not referenced to the safety ground PE terminal and are designed to greatly reduce common mode interference ATTENTION Driving the 4 20 mA analog input from a voltage source could cause component damage Verify proper configuration prior to applying input signals 24 Rockwell Automation Publication 520 TD001D EN E January 2014 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
28. wire must be used for 70 C ambient temperature Recommended Signal Wire Signal Type Where Used Belden Wire Type s or equivalent Description Min Insulation Rating Analog 1 0 amp PTC 8760 9460 0 750 mm 18 AWG twisted pair 10096 shield with drain 300V Remote Pot 8770 0 750 mm 18 AWG 3 conductor shielded 60 C 140 F Encoder Pulse 1 0 9728 9730 0 196 mm 24 AWG individually shielded pairs 1 Stranded or solid wire 2 Ifthe wires are short and contained within a cabinet which has no sensitive circuits the use of shielded wire may not be necessary but is always recommended Recommended Control Wire for Digital 1 0 Wire Type s Per US NEC or applicable national or local code Min Insulation Rating 300V 60 C 140 F Unshielded Shielded Multi conductor shielded cable such as 0 750 mm 18 AWG 3 conductor shielded Belden 8770 or equivalent Maximum Control Wire Recommendation Do not exceed control wiring length of 30 m 100 ft Control signal cable length is highly dependent on electrical environment and installation practices To improve noise immunity the I O terminal block Common may be connected to ground terminal protective earth If using the RS485 DSI port I O Terminal C1 should also be connected to ground terminal protective earth Additionally communication noise immunity can also be improved by connecting I O Terminal C2 to ground terminal protective e
29. 0 28 0 1 10 5 5 0 22 Rockwell Automation Publication 520 TD001D EN E January 2014 45 PowerFlex 520 Series AC Drive Specifications Safe Torque 0ff Function The PowerFlex 525 Safe Torque Off function when used with other safety components helps provide protection according to EN ISO 13849 and EN62061 for safe off and protection against restart The PowerFlex 525 Safe Torque Off function is just one component in a safety control system Components in the system must be chosen and applied appropriately to achieve the desired level of operator safeguarding PowerFlex 525 Safe Torque Off Overview The PowerFlex 525 Safe Torque Off function e Provides the Safe Torque Off STO function defined in EN IEC 61800 5 2 e Blocks gate firing signals from reaching the Insulated Gate Bipolar Transistor IGBT output devices of the drive This prevents the IGBTs from switching in the sequence necessary to generate torque in the motor e Can be used in combination with other safety devices to fulfill the requirements of a system safe torque off function which satisfies Category 3 PL d according to EN ISO 13849 1 and SIL CL2 according to EN IEC 62061 IEC 61508 and EN IEC 61800 5 2 EC Type Examination Certification TUV Rheinland has certified the PowerFlex 525 Safe Torque Off function compliant with the requirements for machines defined in Annex I of the EC Directive 2006 42 EC and that it complies with the r
30. 0 22 0 446 660 D 25 PM1 E022 25 0 18 5 20 0 15 0 27 0 446 660 E 25 PM1 E027 30 0 22 0 25 0 18 5 32 0 446 660 E 25 PM1 E032 PowerFlex 520 Series Control Module Replacement control module for use with PowerFlex 520 Series drives Includes PowerFlex 523 Control Module PowerFlex 525 Control Module Control Module Control Module Front Cover Catalog No 25A CTM1 25B CTM1 Other Parts Item Description FrameSize Catalog No PowerFlex 523 Control Module Front Replacement cover for the control module 1 0 terminals EtherNet IP and DSI ports AE 25A CTMFCT Cover PowerFlex 525 Control Module Front 25B CTMFC1 Cover PowerFlex 520 Series Power Module Replacement cover for the PowerFlex 520 Series power module B 25 PMFC FB Front Cover C 25 PMFC FC D 25 PMFC FD E 25 PMFC FE PowerFlex 520 Series Power Terminal Replacement finger guard for power terminals A 25 PTG1 FA Guard B 25 PTG1 FB C 25 PTG1 FC D 25 PTG1 FD 25 PTG1 FE 40 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications 0ther Parts Item Description Frame Size Catalog No PowerFlex 520 Series Heatsink Fan Kit Replacement fan for drive power module A 25 FAN1 FA B 25 FANT FB C 25 FANT FC D 25 FAN1 FD E 25 FAN1 FE Communication Option Kits and Accessories Item Description Catalog No Communication Adapter
31. 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 520 TD001D EN E January 2014 Supersedes Publication 520 TD001C EN E September 2013 Copyright 2014 Rockwell Automation Inc All rights reserved
32. 25 PM1 D017 15 0 11 0 15 0 11 0 24 0 323 528 D 25 PM1 D024 20 0 15 0 15 0 11 0 30 0 323 528 D 25 PM1 D030 Rockwell Automation Publication 520 TD001D EN E January 2014 39 PowerFlex 520 Series AC Drive Specifications Output Ratings Normal Duty Heavy Duty HP kW HP kW Output Current A Input Voltage Range Frame Size Catalog No 380 480V AC 15 10 3 Phase Input with EMC Filter 0 460V 3 Phase Output 0 5 0 4 0 5 0 4 14 323 528 A 25 PM2 D1P4 1 0 0 75 1 0 0 75 23 323 528 A 25 PM2 D2P3 2 0 1 5 2 0 1 5 4 0 323 528 A 25 PM2 D4P0 3 0 2 2 3 0 2 2 6 0 323 528 A 25 PM2 D6P0 5 0 40 5 0 40 10 5 323 528 B 25 PM2 D010 75 5 5 75 5 5 13 0 323 528 C 25 PM2 D013 10 0 7 5 10 0 7 5 17 0 323 528 C 25 PM2 D017 15 0 11 0 15 0 11 0 24 0 323 528 D 25 PM2 D024 20 0 15 0 15 0 11 0 30 0 323 528 D 25 PM2 D030 25 0 18 5 20 0 15 0 37 0 323 528 E 25 PM2 D037 30 0 22 0 25 0 18 5 43 0 323 528 E 25 PM2 D043 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 0 5 0 4 0 5 0 4 0 9 446 660 A 25 PM1 E0P9 1 0 0 75 1 0 0 75 1 7 446 660 A 25 PM1 E1P7 2 0 1 5 2 0 1 5 3 0 446 660 A 25 PM1 E3P0 3 0 2 2 3 0 2 2 42 446 660 A 25 PM1 E4P2 5 0 4 0 5 0 4 0 6 6 446 660 B 25 PM1 E6P6 7 5 5 5 7 5 5 5 9 9 446 660 C 25 PM1 E9P9 10 0 75 10 0 75 12 0 446 660 C 25 PM1 E012 15 0 11 0 15 0 11 0 19 0 446 660 D 25 PM1 E019 20 0 15 0 15 0 11
33. 3RA35 B HD 525 600V 50 60 Hz 3 Phase 0 5 0 4 0 5 0 4 1321 3R1 C 1321 3RA1 C 1321 3R1 C 1321 3RA1 C 1 0 0 75 1 0 0 75 1321 3R2 B 1321 3RA2 B 1321 3R2 B 1321 3RA2 B 2 0 15 2 0 15 1321 3R4 C 13213RM C 1321 3R4 C 13213RM C 3 0 22 3 0 2 2 1321 3R4 B 1321 3RA4 B 1321 3R4 B 13213RM B 5 0 4 0 5 0 40 1321 3R8 C 1321 3RA8 C 1321 3R8 C 1321 3RA8 C 75 5 5 75 5 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 10 0 15 10 0 75 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 15 0 11 0 15 0 11 0 1321 3R18 B 1321 3RA18 B 1321 3R18 B 1321 3RA18 B 20 0 15 0 15 0 11 0 1321 3R25 B ND 1321 3RA25 B ND 1321 3R25 B ND 1321 3RA25 B ND 1321 3R18 B HD 1321 3RA18 B HD 1321 3R18 B HD 1321 3RA18 B HD 25 0 18 5 20 0 15 0 1321 3R35 C ND 1321 3RA35 C ND 1321 3R35 C ND 1321 3RA35 C ND 1321 3R25 C HD 1321 3RA25 C HD 1321 3R25 C HD 1321 3RA25 C HD 30 0 22 0 25 0 18 5 1321 3R35 C ND 1321 3RA35 C ND 1321 3R35 C ND 1321 3RA35 C ND 1321 3R25 B HD 1321 3RA25 B HD 1321 3R25 B HD 1321 3RA25 B HD 1 Normal Duty and Heavy Duty ratings for 15 HP 11 kW and below are identical except for 200 240V 3 Phase 15 HP 11 kW drive 2 Catalog numbers listed are for 3 impedance 5 impedance reactor types are also available See 1321 Power Conditioning Products Technical Data publication 1321 TD001 3 Input line reactors were sized based on the NEC fundamental motor amps Output line reactors were sized based on the V
34. 5 0 11 0 10 0 75 48 3 170 264 584 0 E 25A B062N104 25B B062N104 20 0 15 0 15 0 110 62 1 170 264 708 0 E 380 480V AC 15 10 3 Phase Input 0 460V 3 Phase Output 25A D1P4N104 25B D1P4N104 0 5 0 4 0 5 0 4 14 323 528 27 0 A 25A D2P3N104 25B D2P3N104 1 0 0 75 1 0 075 23 323 528 37 0 A 25A D4P0N104 25B D4P0N104 2 0 15 2 0 15 4 0 323 528 80 0 A 25A D6P0N104 25B D6P0N104 3 0 2 2 3 0 2 2 6 0 323 528 86 0 A 25A D010N104 25B D010N104 5 0 40 5 0 40 10 5 323 528 129 0 B 25A D013N104 25B D013N104 75 55 75 55 13 0 323 528 170 0 C 25A D017N104 25B D017N104 10 0 75 10 0 7 5 17 0 323 528 221 0 C 25A D024N104 25B D024N104 15 0 11 0 15 0 110 24 0 323 528 303 0 D 25A D030N104 25B D030N104 20 0 15 0 15 0 110 300 323 528 387 0 D 14 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications Output Ratings PowerFlex 523 PowerFlex 525 Normal Duty Heavy Duty Output Input Catalog No Catalog No HP kw HP kw 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 25A D1P4N114 25B D1P4N114 0 5 0 4 0 5 0 4 14 323 528 27 0 A 25A D2P3N114 25B D2P3N114 1 0 0 75 1 0 0 75 23 323 528 37 0 A 25A D4P0N114 25B D4P0N114 2 0 1 5 2 0 1 5 4 0 323 528 81 0 A 25A D6P0N114 25B D6P0N114 3 0 2 2 3 0 22 6 0 323 528
35. 520 Series PowerFlex 520 Series PowerFlex 520 Series with Comms card with Comms card with Comms card DeviceNet to EtherNet IP KW RK ww RTU up to 4 PowerFlex 520 Series PowerFlex 4 or PowerFlex 40 drives SCM up to 31 PowerFlex 520 Series PowerFlex 4 or PowerFlex 40 drives Supports plug and play connectivity through a standard USB connection e AppView tool provides parameter groups for several of the most common applications e Create and save custom parameter groups using the CustomView tool e Supports PowerFlex drives Micro800 controllers and PanelView component graphic terminals Studio 5000 Logix Designer e Add on profiles AOPs for PowerFlex 520 seriers AC drives provide seamless integration into the Logix environment e Configuration files from Studio 5000 Logix Designer can be transferred directly to the PowerFlex 520 Series drive over EtherNet IP e Automatic Device Configuration ADC uploads configuration parameters to a replaced drive minimizing the need for a manual reconfiguration 1 The Logix Designer application is the rebranding of RSLogix 5000 software You can also use RSLogix 5000 version 17 or greater 6 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications PowerFlex 523 Drive Family _ NNI PowerFlex 523 Powertiex 523 Allen Bradley
36. B power supply 14 S34 42 14 24 34 1 Gate control circuit p d S1 Li b 2 1 lee ee ee ere deeg eu 24V DC GuardMaster Trojan Gate ACline input power LI PF 525 1 1 e i GuardMaster 24V DC SC Trojan E So L O Start h Start L l Gate control Ke power supply button A Gate control circuit 3 LEI 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 48 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications Stop Category 0 Coast with Two PowerFlex 525 Drives 24V DC Supply eS ps a oe ee SSeS Se SS eS eS Sees i L Reset Aline input power PF525 24V DC Stop Stop L zl Start Start Dig comm Gate control power supply Gate control 24V DC COM 1 Enclosure Recommended No
37. C 0 384 WOvL SO E090 N0 1 SY 110 SSVD SO 384 WOhL SZ 090 NOFL 7 00L g VIZ 96 S 0v os Dk O S vOLNZLOG VSC 9123O WOtL SLI EQ90 NOvL DE HeI0 LU0TTTD SHY SSY 912 30 WOtL S1D Q90 nObl 7 00L V SEL 9 OLL CC 0t C OE vOLNLLOG VSC 012 30 WOtL OL EG90 NOPL OZ 4 S10 110 T Oy SSY 012 30 WOtL OLI a9d NOvL 719 001 V 6 Chi 08 SL Oc SL O07 POLNOd8d Sz 99g 3O WOvL O89 090 NOPL SL 4 S10 L10 T SAY SSVT 99 3Z WOrL 084 09d NOrL 605 001 V BSS LZ OS SLO OL SCH OL voLNOdSg VSc 0v8 32 WOtL OvE E09G NOPL 9 Y S10 L10 0 Sa SSVD OP8 3Z WOrL 0v8 E190 n0rL 105 001 V LTU CV SG vo SO O SO vOLNSdCE VSC SC8 3 WOvL O 9 E09G NOVL SL Y S10 110 2 SY SSY SC8 30 WOvL O 9 090 NOrL 100 001 V 61 60 OL CO SCO TOJ SCH vOLNOdLG VSC Spe WOt L Nov ON Bojeyey sser nort Burey xew on Gojeyey zs G vi sduy MA dH MA dH i ON Dojeye S1oyeaJg UM Bugey xew sasny S1oyeaJg UNN 109e u0 wes xew Ayng Aaeay fang jewson suonexiddy 10 suonexiddy 10 uoN 91 sbuneu ynduy sbuney 3ndjng JY sau sarinag U01 23 01d 1ndu asbud NOPZ 007 panuiuo z xa 449MOgd 10J S1 j e 1g UD pue sasnj 29 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications suiaysAs punoif 3ue1sis 1 uBiu Jo punosb 1auJ02 2430 2420 A009 40 A09 Uo asn 104 P S 17 ION Mdu JY p A009 pu
38. COQ GSC 020 380 WOvL Ot L10 SSVD 022 380 WOvL Z 090 NOvL Ov SC 7 00L D v8 SOL OI GL OOL Si OOL vILNZLOQ 8SC 02 380 WOTL E Ov L10 SSYD 000 380 WOFL 7 090 NOFL Ov SC C 001 VBL 89L OZL SZ O0L SZ 0 0L vOLNZLOQ GGC 020 380 WOT 1 SE 110 SSVD 07 380 W0YL 7 090 NOFL St 0c 001 VSL UU OEL SS GL SS SZ vILNELOQ aSC 02 48d WO0rL S 140 T SSY1D 070 380 W0Y1 S73 090 N0YL SE 0c 001 VSL UU EL SS GL SS SZ vOLNELOQ gGC 91 3O WOvL DEHATI L10 T yu SSYD 912 30 WOtL L EQ90 f0vL 0 0c O 001 g SEL ITL SOL Ov O S Ov Os PLLNOLOG 8Sz 91 3O WOvL 0E4 S10 110 e SSVD 912 30 WOtL L2 E090 00vL oE 02 O 001 g SEL OL FOL 0v 0s DP Up vOLNOLOQ 8SC 015 3O WOvL SLAFS10 110 T ou SSVD 012 30 WOtL 012 E090 n0vL SL 0L 602 001 V GL 69 09 CC 0t C OE VLLNOd9d 8S2 015 3O WOvL SL 4 S10 L10 yu SSVD 012 30 WOtL 0L 09d NOFL SL OL 602 001 V Si 69 09 ctt O0t CZ EI POLNOd9d 852 9g 3O WOvL Sl 4 S10 L10 T SY SSVD 98 30 WOtL 099 E Q90 N0 L SL OL 60 001 V LS TS Ov SL OZ SL OZ PLLNOdpd 8sz 9g 3O WOvL Sl 4 S10 L10 T SHY SSVD 98 30 WOtL 099 EQ90 N0 L SL 0L 60 001 V LS TS Ov SL OZ SL OZ POLNOdpd 85z 0v8 42 WOrL 0L 4 910 L10 1 yu SSYD 0r8 320 WOPL 099 09d NOrL 0L 9 105 001 V C 67 CC SLO OU SLOJ OL vLINEdCO 86C 0t8 3O WOrL OL Y S10 110 SHY SSVD 0v8 30 WOvL 098 Q90 n0bl 0
39. Derating Curves on page 18 for derating guidelines Without derating 20 50 C 4 122 F With derating 20 60 C 4 140 F or 20 70 C 4 158 F with optional Control Module Fan kit Storage Temperature Frame A D 40 85 C 40 185 F Frame E 40 70 C 40 158 F Atmosphere IMPORTANT Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust If the drive is not going to be installed for a period of time it must be stored in an area where it will not be exposed to a corrosive atmosphere Relative Humidity 0 95 noncondensing Shock Complies with IEC 60068 2 27 Vibration Complies with IEC 60068 2 6 1995 Frame _ Operating and Nonoperating Nonoperating Transportation Size Force Shock Vibration Mounting Type Force Shock Vibration Mounting Type A 15g 2g DIN rail or screw 309 2 5g Screw only B 15g 2g DIN rail or screw 309 2 5g Screw only C 15g 2g DIN rail or screw 309 2 5g Screw only D 15g 2g Screw only 309 2 5g Screw only E 159 1 5g Screw only 309 2 5g Screw only Conformal Coating Complies with IEC 60721 3 3 to level 3C2 chemical and gases only Surrounding Environment Pollution Degree Pollution Degree 1 amp 2 All enclosures acceptable Sound Pressure Level A weighted Frame A amp B Frame C Frame D Frame E 12 Measurements are taken 1 m from the drive Maximum 53 dBA Maximum 57 dBA Maxim
40. FD rated output currents 42 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications Accessory Dimensions IP 30 NEMA 1 UL Type 1 Kit Dimensions are in mm and in s Frame A A 9S 51 1 2 01 D 21 0 0 82 921 5 00 85 UF ES Frame D W 96 0 3 78 B x 70 0 2 76 440 1 73 2 30 0 1 18 I i UYTN 021 5 00 85 aes i H 6542 N 933 5
41. L 9 102 001 V Ct 6t ET SCH OL SCH 01 vOLNEdC 8SC SC9 3O WOVL 93 910 L10 5 SY SSVD SC8 30 WOvL 0 g EQ90 f0vL 9 t 10 001 V 61 LL FU v0 SO vo SO vLLNFdLO 8GC 79 32 W0vL 93 510 1409 SAA SSY SCHMOL 0 g EQ90 f0vL 9 t 10 001 V 61 LL vi vo SO FPO 0 vOLNFdLO SSC eye Worl nori oN boje e sep Worl Nobl Buneu xew Buueg um oN Dateien oke sdwy vay sduy wl dH MA dH y ON foree siayearg On Gurney xey sasny S1 e 1g NDI sosnj 4032ejU0 aurery Xe Kyng Kaeag Aang jeuuov suonw ddy 10 suoneddy 10 uoN 331 sbuijyey ndu sburyey 1nding j y SOUDI sana U01 22 01d Indu 2sbuq N08 OBE panuiuo z xo 449MOd 10 S1oeaJg UD pue sasnj Rockwell Automation Publication 520 TD001D EN E January 2014 34 PowerFlex 520 Series AC Drive Specifications UL ZOOL SLX SL tutu g 692 X Sh X C Sh Jo as UNI au UIW aunsopua p lelnu A uou Jo paze NUAA e u p elsu aq INU p016463 8SZ Y Iayeaiq UNUD WOPL au YUM pasn au swuaysAs punos arueysisas Yb1y 10 punos6 ou 03 e1 q e1l q A009 40 A0gr UO asn 104 pisi IN JON Mdu JY p A009 pue Z A09F 10 Parsi IN ll0muo2 101oW uoneurquuo 3 ad papaioig Jjas jenuey diy ou IM adIAap ay ey aGued uinuirumu au 0 Jas dri uam ay aAeY pjnous abued Juan ajqeysn pe YM WOPL un ling r shuney uoneddy stayealg 324r U011291014 1010W WOPL UNaTINg aas eA Au Siayealg 11210 JOa O1g 1030W
42. Logic 8 positions local logic Outer Position Control Loop e Analog input bipolar mode offers improved zero cross performance e Simple motion control applications with more complex position profiles Speed reference supplied to drive via Analog Input or multiple field bus network options Speed ratio available for simple draw applications Feedback Details Line Driver Type Incremental Encoder Option Card Encoder Wiring Examples e Quadrature dual channel or Single Channel 1 0 Connection Example 1 0 Connection Example i Encoder BE Encoder e 5V 12V DC supply 10 mA min per channel Encoder wf a Encoder e Single Ended or Differential A B Channel Internal Drive 5 sm External Power B dS ssp Power e Duty Cycle of 50 10 Internal drive 4S Y Source 12V DC 250 mA e Input Frequency up to 250 kHz Encoder to Power Supply Encoder Signal Hep u C Signal Pulse Train Input Single Ended o Del Differential Dual Channel 17 Sie Dual Channel e Configurable Input Voltage 5V 12V 24V DC re jj autodetect sdu e Input Frequency up to 100 kHz Safety Inside using Safe Torque Off Function Safe Torque Off is a standard safety feature of the PowerFlex 525 drive to help protect personnel and equipment Safe Torque off allows you to restart your application faster after a safety related situation e Safe Torque Off fun
43. OL vOLNZLOC VSC 022 380 W0rL 110 0 SSVD 022 380 WOvL 7 090 NOFL 001 ra ttf fl SS SL SS CU PLEIN 02 380 WOrL E 110 1 SSVD 022 380 WOvL S2 q90 forl 001 ra evf fl Ss EI SS CU vOLNELOC VSC 91 32 WOrl O 3 510 120 Sa SSY 919 329 WObL S1 090 NorL 001 8 SEL ZL sof Ov os Ov O S PLLNOLOG vszZ 91 32 WOrl 0O 4 S10 140 Sa SSVT 919 329 WObL S1 090 NorL 001 8 SEL ZL sof Ov os Ov O S POLNOLOG vszZ 01230 WO0rl SI3 510 120 9 389 SSVD 012 3O WOVL 019 090 NorL 602 001 V SL 69 09 ZZ 0t ctc E PLLN0490 VSZ 013 32 Worl SI3 810 L0 9 389 SSVD 019 329 WObL 019 090 NorL 602 001 V CU 69 09 Cl mp ctt 0t OLNOd9Q VSC 99 32 WOrL Sl3k S10 14099 89 SSVT 98 329 WObL 098 090 NOrL 602 001 V LS TS ml SL Ov SL OT vLINOdvQ VSC 98 30 WOFL Sl3k S10 1409 SAY SSVT 98 32 WObL 098 090 NOrL 602 001 V LS Cs ml SL Ov SL OC vOLNOdvQ VSC 0v8 32 WOrL 0L3 S10 110 2 38 SSVD 058 30 WOPL 098 090 NOrL 109 001 V Te 67 Cl SLO OL sco OL vLINEdCI VGC 0v8 32 WOrL 0L3F S10 110 0 8 SSVD 058 3 WOPL 098 090 NOrL 109 001 V cel 67 Cl SLO OL SC OL vOLNEdC VGC S79 32 WOPL 9510 1101 SHY SSVD 79 3Z WObL O 8 090 NOrL 10 001 V el LL FEU vo eu vol SO vilNrdLO Vec SC3 30 WOVL 93F510 110 SHY SSVD SCg 30 WOvL 0 8 190 horl 109 001 V OL CU EU vo SO vol SO vOLNFdlO VSC ege Wort Novi ON D
44. Phase Input 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 170 264 A 25 PM1 A1P6 0 5 0 4 0 5 0 4 25 170 264 A 25 PM1 A2P5 1 0 0 75 1 0 0 75 48 170 264 A 25 PM1 A4P8 2 0 1 5 2 0 1 5 8 0 170 264 B 25 PM1 A8P0 3 0 2 2 3 0 2 2 11 0 170 264 B 25 PM1 A011 200 240V AC 15 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 170 264 A 25 PM2 A1P6 0 5 0 4 0 5 0 4 2 5 170 264 A 25 PM2 A2P5 1 0 0 75 1 0 0 75 4 8 170 264 A 25 PM2 A4P8 2 0 1 5 2 0 1 5 8 0 170 264 B 25 PM2 A8P0 3 0 2 2 3 0 2 2 11 0 170 264 B 25 PM2 A011 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 170 264 A 25 PM1 B1P6 0 5 0 4 0 5 0 4 2 5 170 264 A 25 PM1 B2P5 1 0 0 75 1 0 0 75 5 0 170 264 A 25 PM1 B5P0 2 0 1 5 2 0 1 5 8 0 170 264 A 25 PM1 B8P0 3 0 2 2 3 0 2 2 11 0 170 264 A 25 PM1 B011 5 0 4 0 5 0 4 0 17 5 170 264 B 25 PM1 B017 75 5 5 75 5 5 24 0 170 264 C 25 PM1 B024 10 0 7 5 10 0 7 5 322 170 264 D 25 PM1 B032 15 0 11 0 10 0 7 5 48 3 170 264 E 25 PM1 B048 20 0 15 0 15 0 11 0 62 1 170 264 E 25 PM1 B062 380 480V AC 15 10 3 Phase Input 0 460V 3 Phase Output 0 5 0 4 0 5 0 4 14 323 528 A 25 PM1 D1P4 1 0 0 75 1 0 0 75 23 323 528 A 25 PM1 D2P3 2 0 1 5 2 0 1 5 4 0 323 528 A 25 PM1 D4P0 3 0 2 2 3 0 2 2 6 0 323 528 A 25 PM1 D6P0 5 0 4 0 5 0 4 0 10 5 323 528 B 25 PM1 D010 7 5 5 5 7 5 5 5 13 0 323 528 C 25 PM1 D013 10 0 75 10 0 75 17 0 323 528 C
45. Size 0 32 mm 22 AWG Torque 0 29 0 39 Nm 2 6 3 47 Ib in 44 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications EMC Line Filter Dimensions are in mm and in Frame A D Frame E A B 95 5 A H B 95 5 D F 0 22 D F 0 22 ssssssO 2 lelelelelo 6 o E oO o E C E E C E k t fig G H o o Lt L2 L3 Pn es F Frame Size A B C D E F G H I A 55 0 2 17 72 0 2 83 234 0 9 21 30 0 1 18 223 0 8 78 54 0 2 13 20 0 0 79 23 0 0 91 5 5 0 22 B 70 0 2 76 87 0 3 43 270 0 10 63 35 0 1 38 258 0 10 16 58 0 2 28 25 0 0 98 24 0 0 94 5 5 0 22 C 70 0 2 76 109 0 4 29 275 0 10 83 37 0 1 46 263 0 10 35 76 0 2 99 25 0 0 98 28 0 1 10 5 5 0 22 D 80 0 3 15 130 0 5 12 310 0 12 20 33 0 1 30 298 0 11 73 90 0 3 54 33 0 1 30 28 0 1 10 5 5 0 22 E 80 0 3 15 155 0 6 10 390 0 15 35 33 0 1 30 375 0 14 76 110 0 4 33 33 0 1 3
46. Technical Data Allen Bradley PowerFlex 520 Series AC Drive Specifications Original Instructions I Power Topic Page Product Overview 2 Catalog Number Explanation 8 Technical Specifications 9 Environmental Specifications 12 Certifications 13 Dimensions and Weights 14 Design onsiderations 16 Fuses and Circuit Breaker Ratings 27 Accessories and Dimensions 36 Safe Torque Off Function 46 Additional Resources 51 Drive Features AppView CustomView QuickView and MainsFree configuration and programming tools LISTEN m Rockwell Allen Bradley Rockwell Software Automation PowerFlex 520 Series AC Drive Specifications Product Overview The PowerFlex 520 Series AC drive delivers an innovative design that is remarkably versatile and can accommodate systems ranging from standalone machines to simple system integration The PowerFlex 523 drive provides general purpose control for applications ranging up to 30 HP and 22 kW The PowerFlex 525 drive provides maximum flexibility and performance ranging up to 30 HP and 22 kW By combining a variety of motor control options communications energy savings and standard safety features in a cost effective drive the PowerFlex 520 Series drive is suitable for a wide array of applications Maximize your system performance and productivity by taking advantage of the following key features offered in a PowerFlex 520 Series drive PowerF
47. ZdL3 8SC 79 42 WOvL 93 510 L409 yu SSY SC8 30 WOvL 079 090 NOvL 60 001 V TL VL 60 vo SO 0 0 vOLN6dOJ 8SC eye Worl Nov ON Bojeye seg NOvL Guney ew Gurney um oN Gojeyey ezis sdun gu sdwy Wl dH MA dH N56ole e siayeasg NDI Buneu xey sasny siayeasg Vun sosnj 4032ejU0 aurery WEN Kyng Kaeag Aang jewon suoljerijddy 10 suone3iddv 10 uoN 331 suey ndu suizey 1nding j y SOUDI sana Uol a O4d ndu SDYd E A009 62 panuiuo z xo 449MOd 10 S1 j e 1g UD pue sasnj 35 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications Accessories and Dimensions Dynamic Brake Resistors Drive Ratings Minimum Resistance Resistance Input Voltage HP kW Q 10 Q 5 Catalog Nell 100 120V 0 25 0 2 56 91 AK R2 091P500 50 60 Hz 0 5 04 56 91 AK R2 091P500 1 Phase 10 0 75 56 91 AK R2 091P500 15 11 4 91 AK R2 091P500 200 240V 0 25 0 2 56 91 AK R2 091P500 50 60 Hz 0 5 04 56 91 AK R2 091P500 1 Phase 1 0 0 75 56 91 AK R2 091P500 2 0 15 4 91 AK R2 091P500 3 0 22 32 47 AK R2 047P500 200 240V 0 25 0 2 56 91 AK R2 091P500 50 60 Hz 0 5 04 56 91 AK R2 091P500 3 Phase 1 0 0 75 56 91 AK R2 091P500 2 0 15 4 91 AK R2 091P500 30 22 32 4 AK R2 047P500 50 40 18 47 AK R2 047P500 75 55 16 30 AK R2 030P1K2 10 0 75 14 30
48. afely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage ATTENTION To avoid a possible shock hazard caused by induced voltages unused wires in the conduit must be grounded at both ends For the same reason if a drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled This will help minimize the possible shock hazard from cross coupled power leads Motor Cable Types Acceptable for 100 600 Volt Installations A variety of cable types are acceptable for drive installations For many installations unshielded cable is adequate provided it can be separated from sensitive circuits As an approximate guide allow a spacing of 0 3 m 1 ft for every 10 m 32 8 ft of length In all cases long parallel runs must be avoided Do not use cable with an insulation thickness less than 15 mils 0 4 mm 0 015 in Do not route more than three sets of motor leads in a single conduit to minimize cross talk If more than three drive motor connections per conduit are required shielded cable must be used UL installations above 50 C ambient must use 600V 90 C wire UL installations in 50 C ambient must use 600V 75 C or 90 C wire UL installations in 40 C ambient should use 600V 75 C or 90 C wire Use c
49. arth Control 1 0 Terminal Block Wire Specifications Frame Maximum Wire Size Minimum Wire Size Torque A E 1 3 mm 16 AWG 0 13 mm 26 AWG 0 71 0 86 Nm 6 2 7 6 Ib in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Machinery Directive 2006 42 EC e ENISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design e EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems e EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements e EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirement Functional Rockwell Automation Publication 520 TD001D EN E January 2014 25 PowerFlex 520 Series AC Drive Specifications Connections and Grounding Shielded dead P 30 NEMA 1 UL Type 1 option kit or EMC kit EMI fittings and metal conduit ist rar l EMI filter Uu I um pod Vm B HI ER z SES Enclosure ground connection Shielded motor cable t
50. cal codes may require different ratings Fusing The recommended fuse types are listed in the tables found on pages 32 35 If available current ratings do not match those listed in the tables provided choose the next higher fuse rating e IEC BS88 British Standard Parts 1 amp 2 U EN60269 1 Parts 1 amp 2 type GG or equivalent should be used e UL UL Class CC T RKI or J should be used 1 Typical designations include but may not be limited to the following Parts 1 amp 2 AC AD BC BD CD DD ED EFS EF FF FG GF GG GH Circuit Breakers The non fuse listings in the tables found on pages 32 35 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 e IEC Both types of circuit breakers and 140M self protected combination motor controllers are acceptable for IEC installations e UL Only inverse time circuit breakers and the specified 140M selfprotected 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 e Bulletin 140M can be used in single motor app
51. ctionality removes rotational power without powering down the drive e Embedded safety reduces wiring and saves on installation space e Meets ISO 13849 1 standards and provides safety ratings up to and including SIL 2 PL d Rockwell Automation Publication 520 TD001D EN E January 2014 5 PowerFlex 520 Series AC Drive Specifications Communications and Software Versatile Programming and Network Solutions e PowerFlex 520 Series drives are compatible with any device that acts as a RTU Master and supports standard 03 and 06 RTU commands e A network can be configured using PowerFlex 520 Series drives for high performance and flexible configuration capabilities e Embedded port for EtherNet IP PowerFlex 525 drives only e EtherNet IP dual port option card e DeviceNet option card e PROFIBUS DP option card e A multi drive solution can be reached using a single PowerFlex 520 Series drive with the ability for up to five 5 drives to reside on one 1 node e Integral RS485 communications enable the drives to be used in a multi drop network configuration A serial converter module SCM provides connectivity to any controller with a DEI port The SCM can be eliminated if the controller acts as a RTU Master PC Programming Software Connected Components Workbench M M Wi RTU up to 31 PowerFlex 520 Series PowerFlex 4 or PowerFlex 40 drives Network Communication Node 1 Node 2 Node 3 Mi Ii TI PowerFlex
52. e 2 A09b 40 D 1SI IN l011uo2 10304 uolleuiquio2 D ad p p2 101d Jl S enuey du JOU Wun 3IA D ayy PY Bue1 uinuutu uu ay 0 Jas di JUALIN ay AU Pinoys abued WS Um qe sn pe YIM WOPL Ufang Sburey UONEN Ady s1942 105JD UOIaIOl 1010W WoL OST aas aas Aaea APU Slayeadg UNY 103223014 4010 Wr UNAIINg ay jo shunned Jy y Bunea 1u un3a 1ndiul Alp 104 ayejdaweu AUP ay 0 Jajad sbul e1 due Jamo UNA lou Bul 011u02 sI IAP ay usuM ALP SIU110J s qe IeAe aie surea Kyng AP H pue euo Sv 384 WOrL 08 110 2 SSVD Sp 384 WOFL 09 9H NOrL 09 001 3 OBE NSE OEP BL Osc Ovc OE vLINEPOC VSC S 384 WOrlL 04 110 SSVD Sv 383 WOvL 0S 9H NOrL Sekt 3 LEE SOE OLE OSL OZ SeL OST vLINZEOC VSC 04 110 SSVD Sv2 383 WOvL 0S 9H NOFL Sak a OEE TOE ooe ul el el O0C vLLNOEOC VSZ 0 110 SSVD Sp 384 WOFL 0S 29H 0Orl 5 001 q OEE TOE ooe ul OSL OSL OOZ vOLNOEOC VSC 09 1101 SSYD ZED I84 WOPL 0FI E9H NOvL 1 001 a roi Ovc ul OSL Uu OSL vLLNFCOQ VSC 09 1101 SSYD ZED I84 WOPL 0 9H NOvL 1 001 GQ vec Vlvc Ovc ul OSL OLL OSL vOLNPCOQ VSC 022 380 WOF Ov 110 SSVD 02 380 WOPL S73 090 NOYL gek vel SOL ul SZ CoL SZ 00L PLLNZLOQ VSZ 022 380 WOvL 0 1101 SSVD 022 390 WOPL S73 090 N0Y L 001 HBL SOL fi SZ OL SZ
53. ents are based on the standards current at the time of certification 46 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications The PowerFlex 525 STO function is intended for use in safety related applications where the de energized state is considered to be the safe state All of the examples shown here are based on achieving de energization as the safe state for typical Machine Safety and Emergency Shutdown ESD systems PFD and PFH Data PFD and PFH calculations are based on the equations from Part 6 of EN 61508 This table provides data for a 20 year proof test interval and demonstrates the worst case effect of various configuration changes on the data PFD and PFH for 20 year Proof Test Interval Attribute Value PFD 6 62E 05 MTTF 3593 years PFHp 8 13E 10 SFF 8396 DC 62 596 CAT 3 HFT 1 1002 PTI 20 YEARS Hardware Type TypeA Safety Reaction Time The safety reaction time from an input signal condition that triggers a safe stop to the initiation of the configured Stop Type is 100 ms maximum Rockwell Automation Publication 520 TD001D EN E January 2014 47 PowerFlex 520 Series AC Drive Specifications Connection Examples Example 1 Safe Torque Off Connection with Coast to Stop Action SIL 2 PL d Stop Category 0 Coast l AC line 1 input power PF 525 24V DC Stop Stop L O Start Start a E j Gate control bL
54. equirements of the relevant standards listed below e EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design PowerFlex 525 STO achieves Category 3 PL d e EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional PowerFlex 525 STO achieves SIL CL 2 e EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems e IEC 61508 Part 1 7 2010 Functional safety of electrical electronic programmable electronic safety related systems Parts 1 7 T V 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 The TUV Rheinland certificate may be found at http www rockwellautomation com products certification 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 In addition the PowerFlex 525 STO function may be used together with other components in a safety application to achieve an overall Category 3 PL e according to EN ISO 13849 1 and SIL 3 according to EN 62061 and IEC 61508 This is illustrated in Example 3 on page 50 Safety requirem
55. fe Torque Off Connection with Coast to Stop Action Using External 24V supply SIL 3 PL e Stop Category 0 Coast External 100 C contactor 100S C qu Acline i input power I i PF525 L External 24V DC 24V DC Stop Start i Li COM Open i SE Gate control power supply i y MA 8211822 Closed Gate contro i i dot 4 I i 1 i l i H i l i I i l i i 1 X1 AUX 3 vi 132333 A1 Coil 142434 i A2 i I i i t 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 50 Rockwell Automation Publication 520 TD001D EN E January 2014 Additional Resources PowerFlex 520 Series AC Drive Specifications These documents contain additional information concerning related products from Rockwell Automation Title PowerFlex 520 Series Adjustable Frequency AC Drive User Manual PowerFlex 4 Class Human Interface Module HIM DSI Quick Reference Publication 520 UM001 22HIM QR001 PowerFlex 525 Embedded EtherNet IP Adapter User Manual 520COM UM001 PowerFlex 25 COMM D DeviceNet Adapter User Manual 520COM UM002 PowerFlex 25 COMM E2P EtherNet IP Adapter User Manual
56. ill support a filtered drive Rockwell Automation Publication 520 TD001D EN E January 2014 15 PowerFlex 520 Series AC Drive Specifications Drive Dimensions and Weight Dimensions are in mm and in Weights are in kg and Ib Aa C D gt D Si Aind 4 kwa QA L0 n vo vs B S l EE SS a u Gs h Allen Bradley T ET D F i J Frame Size A B C D E Weight A 72 0 2 83 152 0 5 98 172 0 6 77 57 5 2 26 140 0 5 51 1 1 2 4 B 87 0 3 43 180 0 7 09 172 0 6 77 72 5 2 85 168 0 6 61 1 6 3 5 C 109 0 4 29 220 0 8 66 184 0 7 24 90 5 3 56 207 0 8 15 2 3 5 0 D 130 0 5 12 260 0 10 24 212 0 8 35 116 0 4 57 247 0 9 72 3 9 8 6 E 185 0 7 28 300 0 11 81 279 0 10 98 160 0 6 30 280 0 11 02 12 9 28 4 Design Considerations Mounting Considerations e Mount the drive upright on a flat vertical and level surface Frame Screw Size Screw Torque A M5 10 24 1 56 1 96 Nm 14 17 Ib in B M5 10 24 1 56 1 96 Nm 14 17 Ib in C M5 10 24 1 56 1 96 Nm 14 17 Ib in D M5 10 24 2 45 2 94 Nm 22 26 Ib in E M8 5 16 in 6 0 7 4 Nm 53 65 Ib in e Protect the cooling fan by a
57. lex 520 Series AC Drives Feature Modular Design Detachable control module and power module allow simultaneous configuration and installation Each drive has a standard control module used across the entire power range MainsFree configuration allows you to simply connect your control module to a PC with a standard USB cable and quickly upload download and flash the drive with new settings Support for accessory cards without affecting footprint PowerFlex 523 drives support one PowerFlex 525 drives support two Packaging and Mounting Installation can be quick and easy using the DIN rail mounting feature on A B and C frame drives Panel mounting is also available providing added flexibility Zero Stacking is allowed for ambient temperatures up to 45 C saving valuable panel space Integral filtering is available on all 200V and 400V ratings providinga cost effective means of meeting EN61800 3 Category C2 and C3 EMC requirements External filters provide compliance to EN61800 3 Category C1 C2 and C3 EMC requirements for all PowerFlex 520 Series ratings An optional IP 30 NEMA UL Type 1 conduit box is easily adapted to the standard IP 20 NEMA Type Open product providing increased environmental ratings Optimized Performance Removable MOV to ground provides trouble free operation when used on ungrounded distribution systems A relay pre charge limits inrush current Integral brake transistor available on all ratings pr
58. lications e Bulletin 140M can be used up stream from the drive without the need for fuses Rockwell Automation Publication 520 TD001D EN E January 2014 27 PowerFlex 520 Series AC Drive Specifications suiaysAs punolb axuejsisa1 UDIU 10 punosb 1auJ02 2430 2420 A009 10 A08r UO asn 104 P S 1n ION Indu JY v A009 pue Z A09b 40 D 1SI IN ll011uo2 10304 UOIJeUIGWO D ad payajolg jas jenueW rp du JOU Wu 3IA p ay eun Bug um au 0 Jas di 3uaum Y aney pjnous abues Wa um ajqeisn pe uir wor un ling 7 Supp uone jddy 5191819 314r U0191014 1010W WOr T UNa eas aas LE ewu sjaxeajg 117210 10322304d 1030W WOp u ling ayy Jo sbune1 v au bu eJ quain md 3AUp 10 ayejdaweu 3AUp Y 0119J91 su nel due Joo YLM 10 0UJ Bul 01 U0 SI 9AHp 94 ueuM L C 381 WOtL S D O9H nOrlL 05 140 5 SSY C 384 WOrL CO9H fOvL 1 001 8 6t 09 DU 44 Dr vILNLLOV VSC C 381 WOvL S CO9H OL 06 110 SSY C 384 WOrL CO9H flOvL 1 001 8 6t 09 OLL 44 OE vOLNLLOV VSC 0 383 WOvL S caeq nov Ot L10 SSVD 0 384 WOrL SO ca9q novL O 001 8 081 8v 09 d OT vLLNOd8V Vec 0 383 WOvL S caeq nov Ov L10 SSY C 384 WOrL SO ca9q novL O 001 8 081 8v 09 d OT vOLNOd8V VSC 91 JZ WOvL SL 2090 NOVL SZ Y S10 110 SAY SSD 91 30 WOv
59. more information 2 This 600V drive rating needs to be matched with a frame B EMC Line Filter Rockwell Automation Publication 520 TD001D EN E January 2014 37 PowerFlex 520 Series AC Drive Specifications EMC Plates Item Description Frame Size Catalog No EMC Plate Optional grounding plate for shielded cables A 25 EMCI FA B 25 EMCI FB C 25 EMCI FC D 25 EMCI FD E 25 EMCI FE Human Interface Modules HIM Option Kits and Accessories Item Description Catalog No LCD Display Remote Panel Mount Digital speed control 22 HIM C2S CopyCat capable IP 66 NEMA Type 4X 12 indoor use only Includes 2 9 meter cable LCD Display Remote Handheld Digital speed control 22 HIM A3 Full numeric keyboard CopyCat capable IP 30 NEMA Type 1 Includes 1 0 m cable Panel mount with optional Bezel Kit Bezel Kit Panel mount for LCD Display Remote Handheld unit IP 30 NEMA Type 1 22 HIM B1 Includes 2 0 m DSI cable DSI HIM Cable 1 0 m 3 3 ft 22 HIM H10 DSI HIM to RJ45 cable 29m 9 51 ft 22 HIM H30 IP 30 NEMA 1 UL Type 1 Kit Item Description Frame Size Catalog No IP 30 NEMA 1 UL Type 1 Kit Field installed kit Converts drive to IP 30 NEMA 1 UL Type 1 enclosure Includes conduit box A 25 JBAA with mounting screws and plastic top panel B 25 JBAB C 25 JBAC D 25 JBAD E 25 JBAE Control Module Fan Kit Item Description Frame Size Catalog No ontrol Module Fan Kit For use with drive in envir
60. ne 390V DC bus equivalent to 275V AC incoming line 487V DC bus equivalent to 344V AC incoming line 390V DC bus equivalent to 275V AC incoming line Power Ride Thru 100 ms Logic Control Ride Thru 0 5 s minimum 2 s typical Electronic Motor Overload Protection Provides class 10 motor overload protection according to NEC article 430 and motor over temperature protection according to NEC article 430 126 A 2 UL 508C File 29572 Overcurrent 20096 hardware limit 30096 instantaneous fault Ground Fault Trip Phase to ground on drive output Short Circuit Trip Phase to phase on drive output Electrical Specifications PowerFlex 523 PowerFlex 525 Voltage Tolerance 15 10 Frequency Tolerance 47 63 Hz Input Phases Three phase input provides full rating Single phase input provides 35 rating on three phase drives Displacement Power Factor 0 98 across entire speed range Maximum Short Circuit Rating 100 000 Amps Symmetrical Actual Short Circuit Rating Determined by AIC Rating of installed fuse circuit breaker Transistor Type Isolated Gate Bipolar Transistor IGBT Internal DC Bus Choke 200 240V AC Input 380 480V AC Input 525 600V AC Input Only for Frame E drive ratings 11 kW 15 HP 15 18 5 kW 20 25 HP Heavy Duty 15 18 5 kW 20 25 HP Heavy Duty Control Specifications PowerFlex 523 PowerFlex 525 Method
61. ntrol of Internal Pre charge Common DC Bus offers additional inherent breaking capabilities by utilizing all the drives loads on the bus for energy absorption offering higher efficiency and cost savings The PowerFlex 520 Series drive has been optimized for use in Common DC Bus or Shared DC Bus installations e Configurable pre charge control using digital inputs e Direct DC Bus connection to power terminal blocks Improved Ride Through Operation Down to 1 2 Line Voltage The PowerFlex 520 Series drive allows for the selection of 1 2 DC Bus operation for use in critical applications where continued drive output is desired even in the event of brown out or low voltage conditions The PowerFlex 520 Series drive also supports enhanced inertia ride through for additional low voltage mitigation e Selectable 1 2 line voltage operation Increased power loss ride through 4 Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications Additional Features of PowerFlex 525 Drives Closed Loop Feedback Encoder Pulse Train Input The PowerFlex 525 drive allows for configurable closed loop control with an optional encoder card for either speed or position feedback for improved speed regulation basic position control or other pulse inputs for motor control e Improved speed regulation e Basic position control Basic Position Control Local Position Control e Position regulator with Step
62. ny siayearg HINDI sasn4 40 9e U0 suone iddy 30 gY sauibi SIAI uonajoq Induj asbud AOZ 17001 suone iddy 10 uoN 331 SZS X9 J19M04d 10J SJOWLolg FINDA pue s snj EUR dH xew Ayng Aaeay fang jewson sbuney 1ndu sBuney 1nding VOLNSdCA 8SC ON 50jeje Rockwell Automation Publication 520 TD001D EN E January 2014 32 PowerFlex 520 Series AC Drive Specifications Sulejs s punoa xue1sis Dune quand mut aAup 104 ayejdaweu aAup ay 011 J 1 bung dwe Jamo YLM S10 Bul 011u02 si AHp ay VAY AAUP si 104 jqejreae aie sue Ang Area pue JeuuoN YBiy 10 punosb 1 u102 e1 q e1 q A009 10 Mit UO SN 104 paysi IN JON Mdu JY p A009 pue Z Z ADP 10 paist IN 49 04300 10704 uoneurqwo D d 1 pepejoig jjes jenuew di JOU JIM adIAap ay PY abueJ uinum au 0 385 diu Wa um au aAeY pinous abuei 3uaum qe snfpe yum WOPL ugang r Sbureg uoneddy stayeoarg 324r U0191014 1010W WOPL UNaling eas AeA Kew sj ea1g 17210 JOPa Olg JOJOW WOPL un ljing ayy 40 sbune1 y aU c L SCL 140 SSVT 0 2 d8H WOFL 069 9H NOrL CL 001 3 09 9sc L79 CU OSL OSL 0 07 vOLNCOOS dSC z 06 110 SSVD SF D 384 WOPL 029 9H NOvL 099 001 1 Ov DOC E8 SZ 001 OU OSL hOLN8r08 8sz S7 384 W0vL 0 29 510 140 T yu
63. o 2 Relay Outputs amam ES poca Eis S i p ENON npa X one form A and one form B can be used to indicate Ee 2 n w Relay2 N C i EA n Potmustbe various drive motor or logic conditions um o Ene ps eee o DEUS Po Tim ap Laien Opto Output 1 ca m IT sati om SS ue 2 o P45 Shield v v v a Comm Common m 8 0 4 20mA 3 Pulse in SNK sa Spil sm En z eu iH Ej OX S Digital SRC Y E Vv Ri R2 RS R n 02 03 04 05 06 07 08 a o S Sr H Q B M 46 48 9 Rockwell Automation Publication 520 TD001D EN E January 2014 3 PowerFlex 520 Series AC Drive Specifications Communications e Embedded EtherNet IP port allows easy configuration control and collection of drive data over the network PowerFlex 525 drives only e Dual port EtherNet IP option card supports Device Level Ring DLR topologies providing fault tolerant connectivity for optimum drive availability Integral RS485 DSI communications enable the drives to be used in a multi drop network configuration e Optional communication cards such as DeviceNet and PROFIBUS DP can improve machine performance Online EDS file creation with RSNetWorx providing ease of set up on a network Optimized for Common DC Bus Installations Enhanced Co
64. onments with ambient temperatures up to 70 or horizontal A 25 FAN1 70C mounting 25 FAN2 70C Incremental Encoder Input Option fen Catalog No Incremental Encoder Incremental encoder input option board 25 ENC 1 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 JA 25 MAP FA PowerFlex 520 Series drive Select the catalog number based on the frame size of your 25 MAP FB Bulletin 160 drive 38 Rockwell Automation Publication 520 TD001D EN E January 2014 Replacement Parts PowerFlex 520 Series Power Module Item PowerFlex 520 Series Power Module Description Power Module Power Module Front Cover Power Terminal Guard e Heatsink Fan Replacement power module for use with PowerFlex 520 Series drives Includes PowerFlex 520 Series AC Drive Specifications Output Ratings Normal Duty Heavy Duty HP kW HP kW Output Current A Input Voltage Range Frame Size Catalog No 100 120V AC 15 10 1 Phase Input 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 85 132 A 25 PM1 V1P6 0 5 0 4 0 5 0 4 25 85 132 A 25 PM1 V2P5 1 0 0 75 1 0 0 75 48 85 132 B 25 PM1 V4P8 1 5 1 1 1 5 1 1 6 0 85 132 B 25 PM1 V6P0 200 240V AC 15 10 1
65. opper wire only Wire gauge requirements and recommendations are based on 75 C Do not reduce wire gauge when using higher temperature wire Unshielded THHN THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and or conduit fill rates limits are provided Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity AN ATTENTION Do not use THHN or similarly coated wire in wet areas 22 Rockwell Automation Publication 520 TD001D EN E January 2014 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 Applications with large numbers of drives in a similar location imposed EMC regulations or a high degree of communications networking are also good candidates for shielded cable Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications In addition the increased impedance of shielded cable may help extend the distance that the m
66. ote sep DEL Buey xew Gurney um oN boeze ezis sdun gu sdwy Wl dH Wu dH N5ole e 19 e2Jg JINDAL Buney xeW s snj Jo e2Jg JINDAL s snj 1019681802 Wwe xew Kmq Kaeay Ayng euuoN suone iddy 10 suonexrddy 10 uoN 331 sbuneundul sburyey 3nding JY sauiDi sarinag U01 23 01d ndul asvyg AOS 08 panunuo e z xa 449MOd 10J S1 e 1g UD pue sasnj Rockwell Automation Publication 520 TD001D EN E January 2014 30 PowerFlex 520 Series AC Drive Specifications Tu ZOOL XBL X BL tutu 8 697 X C Sp X C L6t Jo azis uinum au um eunso pua pare HnuaA uou 10 D 19 IU A e U p lle sui aq ISN tQ 6d63 VS7 AY Iyeaiq UNUD WOL aui YM p sn au stuaysAs punoif xue sis 1 uBiu 10 punosb ag e q e1 q A009 10 M t uo asn 104 paysi IN JON 1ndu JY A009 pue Z A09b 10 PSI f ll01uo2 10304 uoreuiquio D d 1 p p l01d Jl s jenuew diy JOU IM 3IA9p y FLY abuel WINWIUIWW 3y 0 Jos din uun 3y ALY pjnous bue1 Juan q lsnfpe UMA Worl unejng r SHUEY uonerddy Stayearg qr U01D1014 1010W WOPL OST AURA Aew sjoyeaig 11741 40193044 1010W WOY L Ufang au Jo sbunei 219 au Dune quan mut AHp 104 ayejdaweu AHp ay 0 Jajau bung dwe Jamo YIM S10 Bul 011u02 si AHp ay VAY AAUP SIU 40 q IPAP are surea Kang KAeag pue euJoN 09 140 SSVD
67. otor can be located from the drive without the addition of motor protective devices such as terminator networks Refer to Reflected Wave in Wiring and Grounding Guide PWM AC Drives publication DRIVES INO01 Consideration should be given to all of the general specifications dictated by the environment of the installation including temperature flexibility moisture characteristics and chemical resistance In addition a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75 An additional foil shield can greatly improve noise containment A good example of recommended cable is Belden 295xx xx determines gauge This cable has four 4 XLPE insulated conductors with a 100 coverage foil and an 85 coverage copper braided shield with drain wire surrounded by a PVC jacket Other types of shielded cable are available but the selection of these types may limit the allowable cable length Particularly some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield This construction can greatly increase the cable charging current required and reduce the overall drive performance Unless specified in the individual distance tables as tested with the drive these cables are not recommended and their performance against the lead length limits supplied is not known Recommended Shielded Wire Location Rating Type Description Standard Option 1 600V
68. ovides dynamic braking capability with simple low cost brake resistors A jumper to switch between 24V DC sink or source control for control wiring flexibility Dual Overload Rating available for drives above 15 HP 11 kW Normal duty 11096 overload for 60 seconds or 15096 for 3 seconds Heavy duty 15096 overload for 60 seconds or 18096 overload 20096 programmable for 3 seconds provides robust overload protection Adjustable PWM frequency up to 16 kHz ensures quiet operation Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications PowerFlex 520 Series AC Drive Advanced Features Control Performance e Variety of motor control options including e Volts per hertz V Hz e Sensorless Vector Control SVC e Closed loop velocity vector control PowerFlex 525 drives only e Variety of Positioning Control including e PointStop stops motor load in a consistent position without encoder feedback e Closed loop feedback with an optional encoder card PowerFlex 525 drives only Point to point positioning mode PowerFlex 525 drives only e Integral PID functionality enhances application flexibility PowerFlex 523 drives have one PID loop PowerFlex 525 drives have two PID loops
69. ows 7 Bulletin 1321 3R Series Line Reactors http ab rockwellautomation com programmable controllers connected components workbench software Output Ratings Input Line Reactor2 3 Output Line Reactor 3 Normal Duty Heavy Duty IP 00 Open Style IP 11 NEMA UL Type 1 IP 00 Open Style IP 11 NEMA UL Type 1 HP kW HP kW Catalog No Catalog No Catalog No Catalog No 200 240V 50 60 Hz 1 Phase 0 25 02 0 25 0 2 1321 3R4 A 1321 3RA4 A 1321 3R2 D 1321 3RA2 D 0 5 0 4 0 5 0 4 1321 3R8 A 1321 3RA8 A 1321 3R2 D 1321 3RA2 D 1 0 0 75 1 0 0 75 1321 3R8 A 1321 3RA8 A 1321 3R4 A 1321 3RA4 A 2 0 15 2 0 15 1321 3R18 A 1321 3RA18 A 1321 3R8 A 1321 3RA8 A 3 0 2 2 3 0 2 2 1321 3R18 A 1321 3RA18 A 1321 3R12 A 1321 3RA12 A 200 240V 50 60 Hz 3 Phase 0 25 0 2 0 25 0 2 1321 3R2 D 1321 3RA2 D 1321 3R2 D 1321 3RA2 D 0 5 0 4 0 5 0 4 1321 3R2 D 1321 3RA2 D 1321 3R2 D 13213RA2 D 1 0 0 75 10 0 75 1321 3R4 A 1321 3RM A 1321 3R4 A 1321 3RA4 A 2 0 15 2 0 15 1321 3R8 A 1321 3RA8 A 1321 3R8 A 1321 3RA8 A 3 0 2 2 3 0 2 2 1321 3R12 A 1321 3RA12 A 1321 3R12 A 1321 3RA12 A Rockwell Automation Publication 520 TD001D EN E January 2014 41 PowerFlex 520 Series AC Drive Specifications Bulletin 1321 3R Series Line Reactors Output Ratings Input Line Reactor2 3 Output Line Reactor Normal Duty Heavy Duty IP 00 Open Style
70. put 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 If it is necessary to disconnect power to the motor with the drive outputting power an auxiliary contact should be used to simultaneously disable drive Aux Fault or Coast to Stop Power Terminal Block Wire Specifications Frame Maximum Wire Size Minimum Wire Size Torque A 5 3 mm 10 AWG 0 8 mm 18 AWG 1 76 2 16 Nm 15 6 19 1 Ib in B 8 4 mm 8 AWG 2 1mm 14 AWG 1 76 2 16 Nm 15 6 19 1 Ib in C 8 4 mm 8 AWG 2 1 mm 14 AWG 1 76 2 16 Nm 15 6 19 1 Ib in D 13 3 mm 6 AWG 5 3 mm 10 AWG 1 76 2 16 Nm 15 6 19 1 Ib in E 26 7 mm 3 AWG 8 4 mm 8 AWG 3 09 3 77 Nm 27 3 33 4 Ib in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Common Bus Precharge Notes If drives are used with a disconnect switch to the common DC bus then an auxiliary contact on the disconnect must be connected to a digital input of the drive I 0 Wiring Motor Start Stop Precautions motor can cause drive hardware damage The drive is designed to use control input signals that will start and stop the motor If A ATTENTION A contactor or other device that routinely disconnects and reapplies the AC line
71. r Frame E with Control Module Fan Kit only clearance of 12 mm 0 5 in is required Ambient Operating Temperatures Horizontal Zero Stacking with Control Module Fan Kit No clearance between drives See Accessories and Dimensions on page 36 for option kits Ambient Temperature Maximum with Control Module Mounting Endosure Rating Minimum Maximum No Derate Maximum Derate 2 Fan Kit Derate 2 65 Vertical IP 20 0pen Type 50 C 122 F 60 140 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 0pen Type 45 C 113 F 55 C 131 F 65 C 149 F IP 30 NEMA 1 UL Type1 20 C 4 F 40 C 104 F 50 C 122 F _ Horizontal IP 20 0pen Type 50 C 122 F _ 70 C 158 F with Control Module Fan Kit Horizontal Zero Stacking IP 20 0pen Type 45 C 113 F 65 C 149 F with Control Module Fan Kit 9 3 mounting methods only 4 Catalogs 25x D1P4N104 and 25x EOP9N104 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 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 EOP9N104 the temperature listed under the Max Derate column is reduced by 5 C
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73. rminals 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 Rockwell Automation Publication 520 TD001D EN E January 2014 21 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 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 Power Wiring ATTENTION National Codes and standards NEC VDE BSI etc and local codes outline provisions for s
74. s Embedded communication options for use with the PowerFlex 520 Series drives DeviceNet 25 COMM D Dual Port EtherNet IP 25 COMM E2P e PROFIBUS DP V1 25 COMM P Compact 1 0 Module Three channel 1769 SM2 Universal Serial Bus USB Provides serial communication via DF1 protocol for use with Connected Components 1203 USB Converter Module Workbench software Includes e 2m USB cable 1 e 20 HIM H10 cable 1 e 22 HIM H10 cable 1 Serial Converter Module Provides serial communication via DF1 protocol for use with Connected Components 22 SCM 232 RS485 to RS232 Workbench software Includes DSI to RS232 serial converter 1 e 1203 SFC serial cable 1 22 RJ45CBL C20 cable 1 DSI Cable 2 0 m RJ45 to RJ45 cable male to male connectors 22 RJ45CBL 20 Serial Cable 2 0 m serial cable with a locking low profile connector to connect to the serial converter anda 1203 SFC 9 pin sub miniature D female connector to connect to a computer Splitter Cable RJ45 one to two port splitter cable Modbus only AK U0 RJ45 SC1 Terminating Resistors 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 Software Download or DVD ROM Windows based software packages for programming and configuring Allen Bradley drives and other Rockwell Automation products Compatibility Windows XP Windows Vista and Wind
75. s exist install one of the devices listed under the heading Corrective Action on the line side of the drive 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 e Install Line Reactor Greater than 120 kVA supply transformer e or Isolation Transformer Line has power factor correction capacitors e Install Line Reactor or Isolation Transformer Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V lightning Phase to ground voltage exceeds 12596 of normal line to line voltage Remove MOV jumper to ground e or Install Isolation Transformer with grounded secondary if necessary Ungrounded distribution system 240V open delta configuration stinger leg Install Line Reactor 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
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77. st DC Brake and Ramp to Stop Accel Decel Four independently programmable accel and decel times Each time may be programmed from 0 600 s in 0 01 s increments Intermittent Overload Normal Duty _ 110 Overload capability for up to 60 s 150 for up to 3 s Applies for power rating above 15 kW 20 HP only Based on 480V drive rating Heavy Duty 150 Overload capability for up to 60 s 180 for up to 3 s 200 programmable Control Inputs Specifications PowerFlex 523 PowerFlex 525 Digital Bandwidth 10 Rad s for open and closed loop Quantity 1 Dedicated for stop 1 Dedicated for stop 4 Programmable 6 Programmable Current 6mA Type Source Mode SRC 18 24V ON 0 6V OFF Sink Mode SNK 0 6V ON 18 24V OFF Pulse Train Quantity 1 Shared with one of the programmable digital input terminals Input Signal Transistor contact open collector Input Frequency 0 100 kHz Current Consumption 7 mA 24V DC maximum Analog Quantity 2 Isolated 0 10V and 4 20 mA 2 Isolated 10 10V and 4 20 mA Specification Resolution 10 bit 0 10V DC Analog 100k ohm input impedance 4 20 mA Analog 250 ohm input impedance External Pot 1 10k ohm 2 W minimum Control Outputs Specifications 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
78. te 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 Each safety input draws 6 mA from the supply Example 2 Safe Torque 0ff Connection with Controlled Stop Action SIL 2 PL d Stop Category 1 Controlled e PPP ye Minotaur MSR138DP TENTE A2 pa po pa x4 V39 40 38148158 14 T CJ LT LI l l 1 I 1 1 l 24V DC 1 1 I l I l l l Common 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 druit 4 i Stop L ACline input power Gate control dot 4 51 i PF525 H 24V DC Fu O Start Dig comm Gate control power supply AC line i input power I I PF525 I H 24V DC I Stop Stop O Start i Start i I Gate control power supply I 1 i I I Gate control i circuit i I si I 82 I Rockwell Automation Publication 520 TD001D EN E January 2014 49 PowerFlex 520 Series AC Drive Specifications Example 3 Sa
79. ualification Testing of Nonstructural Components and 2003 International Building Code for worst case seismic level for USA excluding site class F EPRI Electric Power Research Institute Certified compliant with the following standards PQ SEMI F47 IEC 61000 4 34 Lloyds Register Not applicable Lloyd s Register Type Approval Certificate 12 10068 E1 RoHS Compliant with the European Restriction of Hazardous Substances Directive The drive is also designed to meet the appropriate portions of the following specifications NFPA 70 US National Electrical Code NEMA ICS 7 1 Safety standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems Rockwell Automation Publication 520 TD001D EN E January 2014 13 PowerFlex 520 Series AC Drive Specifications Dimensions and Weights Frame Rating Cross Reference Catalog Number Description EE E EE ME EE e Wwe Mee m ms WW Ens Veson PowerFlex 520 Series Drive Ratings Output Ratings PowerFlex 523 PowerFlex 525 Normal Duty Heavy Duty Output Input Catalog No Catalog No HP kw HP kW Current A Voltage Range Total Watts Loss Frame Size 100 120V AC 15 10 1 Phase Input 0 230V 3 Phase 0utput 25A V1P6N104 _ 0 25 0 2 025 02 1 6 85 132 20 0 A 25A V2P5N104 25B V2P5N104 0 5 0 4 0 5 0 4 2 5 85 132 27 0 A 25A V4P8N104 25B
80. um 64 dBA Maximum 68 dBA Rockwell Automation Publication 520 TD001D EN E January 2014 PowerFlex 520 Series AC Drive Specifications Certifications Certification PowerFlex 523 PowerFlex 525 c UL us Listed to UL508C and CAN CSA C22 2 No 14 05 ipu CTick Australian Communications and Media Authority In conformity with the following Radiocommunications Act 1992 N223 Radiocommunications Standard 2008 Radiocommunications Labelling Notice 2008 Standards applied EN 61800 3 2004 CE In conformity with the following European Directives C EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC Standards applied EN 61800 3 2004 EN 61800 5 1 2007 TUV Not applicable TUV Rheinland T V Rheinland Standards applied EN ISO 13849 1 2008 EN 61800 5 2 2007 EN 61508 PARTS 1 7 2010 EN 62061 2005 EN 60204 1 2009 Certified to ISO 13849 1 SIL2 PLd with embedded Safe Torque 0ff function Meets Functional Safety FS when used with embedded Safe Torque 0ff function ATEX Not applicable Certified to ATEX directive 94 0 EC es Group H Category 2 GD Applications with ATEX Approved Motors I1 2 D KCC Korean Registration of Broadcasting and Communications Equipment Compliant with the following standards Article 58 2 of Radio Waves Act Clause 3 GOST R Russian GOST R Certificate no POCC US ME92 H00040 AC156 Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Q
81. voiding dust or metallic particles e Do not expose to a corrosive atmosphere Protect from moisture and direct sunlight 16 Rockwell Automation Publication 520 TD001D EN E January 2014 Minimum Mounting Clearances See Dimensions and Weights on page 14 for mounting dimensions Vertical Vertical Zero Stacking No clearance between drives Vertical with Control Module Fan Kit PowerFlex 520 Series AC Drive Specifications Vertical Zero Stacking with Control Module Fan Kit No clearance between drives 25mm 4 1 0 in e 50mm oin eg i QU Un 4 Zut 50 em 4 Qin 4 QU L rrrrrrE 2 4 D g JU PUT UUUUUUUHUDU UE Horizontal with Control Module Fan Kit 1 For Frame E with Control Module Fan Kit only clearance of 95 mm 3 7 in is required 2 Fo

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