Allen-Bradley PowerFlex 523 Quick Start Manual
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Allen-Bradley PowerFlex 523 Quick Start Manual

Powerflex 520-series adjustable frequency ac drive
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Quick Start
PowerFlex 520-Series Adjustable Frequency AC Drive Quick Start
Quick Start Guide for PowerFlex 523 and PowerFlex 525 AC Drives
PowerFlex 523 Catalog Number 25A
PowerFlex 525 Catalog Number 25B
This Quick Start guide summarizes the basic steps needed to install, start-up and program the PowerFlex 520-Series
Adjustable Frequency AC Drive. The information provided DOES NOT replace the User Manual and is intended for
qualified drive service personnel only. For detailed PowerFlex 520-Series information including EMC instructions,
application considerations and related precautions, see the PowerFlex 520-Series User Manual, publication 520-UM001.

Additional Resources

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
PowerFlex 25-COMM-D DeviceNet Adapter User Manual
PowerFlex 25-COMM-E2P EtherNet/IP Adapter User Manual
PowerFlex 25-COMM-P PROFIBUS DP Adapter User Manual
Dynamic Braking Resistor Calculator
Wiring and Grounding Guidelines for PWM AC Drives
Preventive Maintenance of Industrial Control and Drive System Equipment
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control
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.
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Publication
520-UM001
22HIM-QR001
520COM-UM001
520COM-UM002
520COM-UM003
520COM-UM004
PFLEX-AT001
DRIVES-IN001
DRIVES-TD001
SGI-1.1
+86-755-8660-6182

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  • Page 1 Industry Automation Quick Start PowerFlex 520-Series Adjustable Frequency AC Drive Quick Start Quick Start Guide for PowerFlex 523 and PowerFlex 525 AC Drives PowerFlex 523 Catalog Number 25A PowerFlex 525 Catalog Number 25B This Quick Start guide summarizes the basic steps needed to install, start-up and program the PowerFlex 520-Series Adjustable Frequency AC Drive.
  • Page 2 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive ATTENTION: • Before installing, configuring, operating or maintaining this product, read this document and the documents listed in the Additional Resources section for installing, configuring, or operating equipment. Users should familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
  • Page 3 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Mounting Considerations • Mount the drive upright on a flat, vertical and level surface. Frame Screw Size Screw Torque M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.) M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.) M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.) M5 (#10...24)
  • Page 4 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Ambient Operating Temperatures See Appendix B of the PowerFlex 520-Series User Manual, publication 520-UM001 for option kits. Ambient Temperature Maximum with Control Module (2) (5) Mounting Enclosure Rating Minimum Maximum (No Derate) Maximum (Derate) Fan Kit (Derate)
  • Page 5 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Ungrounded Distribution Systems ATTENTION: PowerFlex 520-Series drives contain protective MOVs that are referenced to ground. These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system. ATTENTION: Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground.
  • Page 6 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Fuses and Circuit Breakers Catalog No. Output Ratings Input Ratings Branch Circuit Protection Normal Duty Heavy Duty 140M Motor Fuse Protectors PowerFlex PowerFlex Voltage Ratings (3) (4) (5) Range Amps Min/Max Contactors 100...120V AC (-15%, +10%) –...
  • Page 7 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Catalog No. Output Ratings Input Ratings Branch Circuit Protection Normal Duty Heavy Duty 140M Motor Fuse Protectors PowerFlex PowerFlex Voltage Ratings (3) (4) (5) Range Amps Min/Max Contactors 25A-D013N114 25B-D013N114 13.0 323...528 14.1 15.4 20/35...
  • Page 8 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Technical Specifications PowerFlex 523 Specifications Input/Output Ratings Digital Control Inputs (Input Current = 6 mA) Approvals UL508C CSA 22.2 N223 ® ® Output Frequency: 0...500 Hz (Programmable) SRC (Source) Mode:...
  • Page 9 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Power Wiring Recommended Shielded Wire Location Rating/Type Description Standard (Option 1) 600V, 90 °C (194 °F) XHHW2/RHW-2 • Four tinned copper conductors with XLPE insulation. • Copper braid/aluminum foil combination shield and tinned copper drain wire. Anixter B209500-B209507, Belden 29501-29507, or equivalent •...
  • Page 10 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive I/O Wiring Recommended Signal Wire Signal Type/ Where Used Belden Wire Type (or equivalent) Description Minimum Insulation Rating Analog I/O & PTC 8760/9460 0.750 mm (18 AWG), twisted pair, 100% shield with drain 300V, 60 °C (140 °F) Remote Pot...
  • Page 11 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Control Terminal Block PowerFlex 523 Control I/O Wiring Block Diagram Typical Typical SRC wiring SNK wiring Stop DigIn TermBlk 02/ Start/Run FWD DigIn TermBlk 03/ Direction/Run REV Digital Common...
  • Page 12 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive PowerFlex 523 Control I/O Terminal Designations No. Signal Default Description Parameter Relay N.O. Fault Normally open contact for output relay. t076 Relay Common Fault Common for output relay. t081 Relay N.C.
  • Page 13 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive PowerFlex 525 Control I/O Wiring Block Diagram Typical Typical SRC wiring SNK wiring Stop Safety 1 DigIn TermBlk 02/ Start/Run FWD Safe-Torque-Off Safety 2 DigIn TermBlk 03/ Direction/Run REV Safety +24V Digital Common DigIn TermBlk 05...
  • Page 14 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive PowerFlex 525 Control I/O Terminal Designations No. Signal Default Description Parameter Relay 1 N.O. Fault Normally open contact for output relay. t076 Relay 1 Common Fault Common for output relay. Relay 2 Common Motor Running Common for output relay.
  • Page 15 5. Inspect grounding, wiring, connections, and environmental compatibility. 6. Verify that the Sink (SNK)/Source (SRC) jumper is set to match your control wiring scheme. See the PowerFlex 523 Control I/O Wiring Block Diagram on page 11 PowerFlex 525 Control I/O Wiring Block Diagram on page 13 for location.
  • Page 16 To disable reverse operation, see A544 [Reverse Disable]. Fault Codes on page 29 for an explanation of the fault codes. Display, Control, and Navigation Keys PowerFlex 523 Menu Parameter Group and Description PowerFlex 525 Embedded EtherNet/IP Indicators Basic Display Display Commonly viewed drive operating conditions.
  • Page 17 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Viewing and Editing Parameters The following is an example of basic integral keypad and display functions. This example provides basic navigation instructions and illustrates how to program a parameter. Step Example Display When power is applied, the last user-selected Basic Display Group parameter number is briefly displayed...
  • Page 18 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Basic Display Group Parameters See the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001 for detailed descriptions of the parameters listed here, as well as the full list of available parameters. Parameter Min/Max Display/Options...
  • Page 19 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Parameter Min/Max Display/Options b022 [Elapsed MWh] 0.0/6553.5 MWh 0.1 MWh Accumulated output energy of the drive. b023 [Energy Saved] 0.0/6553.5 kWh 0.1 kWh Total energy savings of using this drive compared to an across the line starter since the last reset of the meters.
  • Page 20 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Smart Start-Up with Basic Program Group Parameters The PowerFlex 520-series drive is designed so that start-up is simple and efficient. The Basic Program group contains the most commonly used parameters. See the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001 for detailed descriptions of the parameters listed here, as well as the full list of available parameters.
  • Page 21 P048 = 2 Sets the default control scheme used to start the drive unless overriden by P048 [Start Source 2] or P050 P050 3 = “Serial/DSI” P050 = 3 (PowerFlex 523) [Start Source 3]. 4 = “Network Opt” 5 (PowerFlex 525) (1) When active, the Reverse key is also active unless disabled by A544 [Reverse Disable].
  • Page 22 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Advanced Program Group Parameters See the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001 for detailed descriptions of the parameters listed here, as well as the full list of available parameters. = Stop drive before changing this parameter.
  • Page 23 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive = Stop drive before changing this parameter. = Parameter is specific to PowerFlex 525 drives only. PF 525 Parameter Min/Max Display/Options Default A438 [DB Threshold] 10.0/110.0% 0.1% 100.0% Sets the DC bus voltage threshold for Dynamic Brake operation. If DC bus voltage rises above this level, Dynamic Brake turns on.
  • Page 24 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive = Stop drive before changing this parameter. = Parameter is specific to PowerFlex 525 drives only. PF 525 Parameter Min/Max Display/Options Default A458 [PID x Trim Sel] 0/13 0 = “Disabled” 0 = “Disabled”...
  • Page 25 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive = Stop drive before changing this parameter. = Parameter is specific to PowerFlex 525 drives only. PF 525 Parameter Min/Max Display/Options Default A466 [PID x Preload] 0.0/500.0 Hz 0.1 Hz 0.0 Hz Sets the value used to preload the integral component on start or enable.
  • Page 26 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive = Stop drive before changing this parameter. = Parameter is specific to PowerFlex 525 drives only. PF 525 Parameter Min/Max Display/Options Default A498 [Motor Rr] 0.00/655.35 ohm 0.01 ohm Based on Drive Rating PF 525 Rotor resistance of induction motor.
  • Page 27 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive = Stop drive before changing this parameter. = Parameter is specific to PowerFlex 525 drives only. PF 525 Parameter Min/Max Display/Options Default A535 [Motor Fdbk Type] 0 = “None” 0 = “None”...
  • Page 28 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive = Stop drive before changing this parameter. = Parameter is specific to PowerFlex 525 drives only. PF 525 Parameter Min/Max Display/Options Default A551 [Fault Clear] 0 = “Ready/Idle” 0 = “Ready/Idle” 1 = “Reset Fault”...
  • Page 29 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive = Stop drive before changing this parameter. = Parameter is specific to PowerFlex 525 drives only. PF 525 Parameter Min/Max Display/Options Default A566 [Pos Reg Gain] 0.0/200.0 PF 525 Sets the gain adjustment for the position regulator.
  • Page 30 Clear fault and verify all parameter settings. Do not remove or install the control module while power is applied. F106 Incompat C-P • Change to a different power module. • Change to a PowerFlex 523 control module. F107 Replaced C-P • Change to a different power module.
  • Page 31 DSIFlashUpdatReq Perform a firmware flash update operation using DSI communications to attempt to load a valid set of firmware. (1) This fault is not applicable to PowerFlex 523 drives. Drive Ratings PowerFlex 523 Frames – Ratings are in kW and (HP).
  • Page 32 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Dimensions and Weight IP 20/Open Type – Dimensions are in mm and (in.). Weights are in kg and (lb). Frame Size Weight 72.0 (2.83) 152.0 (5.98) 172.0 (6.77) 57.5 (2.26) 140.0 (5.51) 1.1 (2.4) 87.0 (3.43)
  • Page 33 Network wiring consists of a shielded 2-conductor cable that is daisy-chained from node to node. ATTENTION: Never attempt to connect a Power over Ethernet (PoE) cable to the RS485 port. Doing so may damage the circuitry. Network Wiring Diagram Example PowerFlex 525 PowerFlex 523 PowerFlex 525 Master Node 1 Node 2 Node “n”...
  • Page 34 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive The following PowerFlex 520-series drive parameters are used to configure the drive to operate on a DSI network. Configuring Parameters for DSI Network Parameter Description P046 [Start Source 1] Set to 3 “Serial/DSI”...
  • Page 35 Aotewell Ltd www.aotewell.com Industry Automation PowerFlex 520-Series Adjustable Frequency AC Drive Drive and Adapter Status Indicators Item Name State Description ENET Adapter is not connected to the network ENET LINK Steady Adapter is connected to the network and drive is controlled through Ethernet. EtherNet/IP Flashing Adapter is connected to the network but drive is not controlled through Ethernet.
  • Page 36 RA-DU002 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.

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