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520-TD001E-EN-E PowerFlex 520-Series AC Drive Specifications Technical Data

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Technical DataPowerFlex 520-Series AC Drive SpecificationsOriginal InstructionsDrive Features: AppView™, CustomView™, QuickView™, and MainsFree™ configuration and programming tools.TopicPageProduct Overview2Catalog Number Explanation8Technical Specifications9Environmental Specifications12Certifications13Dimensions and Weights14Design Considerations16Fuses and Circuit Breaker Ratings27Accessories and Dimensions32Safe-Torque-Off Function42Additional Resources472Rockwell Automation Publication 520-TD001E-EN-E - July 2016PowerFlex 520-Series AC Drive SpecificationsProduct OverviewThe 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.PowerFlex 520-Series AC Drives FeatureModular 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, providing a 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, provides 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: 110% overload for 60 seconds or 150% for 3 seconds. Heavy duty: 150% overload for 60 seconds or 180% overload (200% programmable) for 3seconds provides robust overload protection.•Adjustable PWM frequency up to 16 kHz ensures quiet operation.Rockwell Automation Publication 520-TD001E-EN-E - July 20163PowerFlex 520-Series AC Drive SpecificationsPowerFlex 520-Series AC Drive Advanced FeaturesControl Performance•Variety of motor control options, including:•Volts per hertz (V/Hz)•Sensorless Vector Control (SVC)•Closed loop velocity vector control (PowerFlex 525 drives only)•Permanent Magnet motor control (PowerFlex 525 drives only)•Variety of Positioning Control, including:•PointStop™ stops motor load in a consistent position without encoder feedback•Closed loop feedback with an optional encoder card (PowerFlex 525 drives only)•Point-to-point positioning mode (PowerFlex 525 drives only)•Integral PID functionality enhances application flexibility(PowerFlex 523 drives have one PID loop, PowerFlex 525 drives have two PID loops)I/O WiringPowerFlex 523•One (1) Analog Input (unipolar voltage or current) independently isolated from the rest of the drive I/O.•Five (5) Digital Inputs (four programmable) provide application versatility.•One (1) Analog Output(1) which is jumper selectable between either 0-10V or 0-20 mA. This scalable, 10-bit output is suitable for metering or as a speed reference to another device.•One (1) Relay Output (form C) can be used to indicate various drive, motor or logic conditions.(1)Analog output (terminal 15) is only available on PowerFlex 523 series B drive and requires firmware 3.001 and later to configure the analog output parameters.PowerFlex 525•Two (2) Analog Inputs (one unipolar and one bipolar) are independently isolated from the rest of the driveI/O. These inputs can be toggled via a digital input.•Seven (7) Digital Inputs (six programmable) provide application versatility.•One (1) Analog Output which is jumper selectable between either 0-10V or 0-20 mA. This scalable, 10-bit output is suitable for metering or as a speed reference to another drive.•Two (2) Opto Outputs and two (2) Relay Outputs (one form A and one form B) can be used to indicate various drive, motor or logic conditions.0405060701020308111213141516171819Digital CommonDigIn TermBlk 05DigIn TermBlk 06DigIn TermBlk 07/PulseStop (1)DigIn TermBlk 02/Start/Run FWD (2)DigIn TermBlk 03/Direction/Run REVDigIn TermBlk 08R1R2S1S2S+Relay 1 N.O.Relay 1 Common+24V DC+10V DC0-10V (or ±10V) Input Analog Common4-20mA InputAnalog OutputOpto Output 1Opto Output 2RJ45 ShieldComm CommonOpto Common+24V+10VSafety 1Safety 2Safety +24VTypicalSNK wiringTypicalSRC wiringR1S1S2S+111213141516171819R2R5R60102030405060708C1C230V DC50 mANon-inductiveCommon24V(3)Pot must be1...10 k ohm2 W min.0-10V0/4-20 mASNKDigital InDigIn TermBlk 07 SelAnalog OutJ10J9J5Pulse InSRCDigitalInput0/4-20mA0-10VSRCSNKR5R6Relay 2 CommonRelay 2 N.C.C1C2Safe-Torque-OffPowerFlex 525 Control I/O Wiring Block Diagram0405060102031112131415C1C2Digital CommonDigIn TermBlk 05/PulseDigIn TermBlk 06Stop (1)DigIn TermBlk 02/Start/Run FWD (2)DigIn TermBlk 03/Direction/Run REVR1R2Relay N.O.Relay Common+24V DC+10V DCAnalog Input Analog CommonAnalog Output (3)RJ45 ShieldComm Common+24V+10VTypicalSNK wiringTypicalSRC wiringR11112131415C1C2R2R3010203040506Pot must be (4)1...10 k ohm2 W min. 4-20 mAsource1314SNKDigital InDigIn TermBlk 05 SelJ7J8Pulse InSRCDigitalInputSRCSNKR3Relay N.C.0/4-20 mAAnalog OutJ130-10V4-20 mAAnalog InJ40-10V81RS485(DSI)0-10V4-20 mA0-10V0/4-20 mAPowerFlex 523 Series B Control I/O Wiring Block Diagram4Rockwell Automation Publication 520-TD001E-EN-E - July 2016PowerFlex 520-Series AC Drive SpecificationsCommunications•Embedded EtherNet/IP™ port allows easy configuration, control, and collection of drive data over the network.(PowerFlex 525 drives only)•Dual port EtherNet/IP option card supports Device Level Ring (DLR) topologies, providing fault-tolerant connectivity for optimum drive availability.•Integral RS485/DSI communications enable the drives to be used in a multi-drop network configuration.•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 InstallationsEnhanced Control of Internal Pre-chargeCommon 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.•Configurable pre-charge control using digital inputs.•Direct DC Bus connection to power terminal blocks.Improved Ride ThroughOperation Down to 1/2 Line VoltageThe 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.•Selectable 1/2 line voltage operation.•Increased power loss ride through.Rockwell Automation Publication 520-TD001E-EN-E - July 20165PowerFlex 520-Series AC Drive SpecificationsAdditional Features of PowerFlex 525 DrivesClosed Loop FeedbackEncoder/Pulse Train InputThe 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.•Improved speed regulation•Basic position controlBasic Position ControlLocal Position Control•Position regulator with StepLogic™•8 positions (local logic)Outer Position Control Loop•Analog input bipolar mode offers improved zero-cross performance.•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 DetailsLine Driver Type Incremental Encoder Option Card•Quadrature (dual channel) or Single Channel•5V/12V DC supply, 10 mA min per channel•Single Ended or Differential (A, B Channel)•Duty Cycle of 50%, +10%•Input Frequency up to 250 kHzPulse Train Input•Configurable Input Voltage 5V/12V/24V DC autodetect•Input Frequency up to 100 kHzSafety Inside using Safe-Torque-Off FunctionSafe 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.•Safe Torque-Off functionality removes rotational power without powering down the drive.•Embedded safety reduces wiring and saves on installation space.•Meets ISO 13849-1 standards and provides safety ratings up to and including SIL 2/PLd.I/OConnection ExampleI/OConnection ExampleEncoderPower –Internal DrivePowerInternal (drive)12V DC, 250 mAEncoderPower –ExternalPowerSourceEncoderSignal – Single-Ended,Dual ChannelEncoderSignal –Differential,Dual ChannelCommon+12V DC(250 mA)AA-BB-Cm+Vto SHLD+CommonExternalPowerSupplytoSHLDA NOTABB NOTto SHLDto Power SupplyCommonAA-BB-Cm+Vto SHLDA NOTBAB NOTAA-BB-Cm+VEncoder Wiring Examples

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