Allen-Bradley PowerFlex 525 Original Instructions Manual
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Allen-Bradley PowerFlex 525 Original Instructions Manual

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Table of Contents

See also: User Manual , Original Instruction Manual
Technical Data
PowerFlex 525 AC Drive Specifications
Original Instructions
Topic
Product Overview
Catalog Number Explanation
Technical Specifications
Environmental Specifications
Certifications
Dimensions and Weights
Design Considerations
Fuses and Circuit Breaker Ratings
Accessories and Dimensions
Safe-Torque-Off Function
Additional Resources
Page
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8
9
11
12
13
15
25
30
39
43

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Summary of Contents for Allen-Bradley PowerFlex 525

  • Page 1 Technical Data PowerFlex 525 AC Drive Specifications Original Instructions Topic Page Product Overview Catalog Number Explanation Technical Specifications Environmental Specifications Certifications Dimensions and Weights Design Considerations Fuses and Circuit Breaker Ratings Accessories and Dimensions Safe-Torque-Off Function Additional Resources...

  • Page 2: Product Overview

    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 525 drive is suitable for a wide array of applications.
  • Page 3 PowerFlex 525 AC Drive Specifications PowerFlex 525 Advanced Features Control Performance • Variety of motor control options, including: • Volts per hertz • Sensorless Vector Control (SVC) • Closed loop velocity vector control • Variety of Positioning Control, including: • PointStop™ stops motor load in a consistent position without encoder feedback •...
  • Page 4 Closed Loop Encoder/Pulse Train Input Standard The PowerFlex 525 drive allows for configurable closed loop control with an optional encoder card for either speed or position feedback for improved speed regulation, basic position control, or other pulse inputs for motor control.
  • Page 5 The PowerFlex 525 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 525 drive also supports enhanced inertia ride through for additional low voltage mitigation.
  • Page 6 • Supports PowerFlex drives, Micro800™ controllers and PanelView™ component graphic terminals. Studio 5000™ Logix Designer • Add-on profiles (AOPs) for PowerFlex 525 AC drives provide seamless integration into the Logix environment. • Configuration files from Studio 5000 Logix Designer can be transferred directly to the PowerFlex 525 drive over EtherNet/IP.
  • Page 7 PowerFlex 525 AC Drive Specifications PowerFlex 525 Drive Family Frame A Frame B Frame C Frame D Frame E Rockwell Automation Publication 520-TD001B-EN-E - June 2013...

  • Page 8: Catalog Number Explanation

    PowerFlex 525 AC Drive Specifications Catalog Number Explanation – – Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash Code Braking Standard Code Type 25B PowerFlex 525 Code EMC Filter No Filter Filter Code Voltage Phase Code Interface Module...

  • Page 9: Technical Specifications

    PowerFlex 525 AC Drive Specifications Technical Specifications Category Specifications Protection Bus Overvoltage Trip 100...120V AC Input: 405V DC bus (equivalent to 150V AC incoming line) 200...240V AC Input: 405V DC bus (equivalent to 290V AC incoming line) 380...480V AC Input: 810V DC bus (equivalent to 575V AC incoming line) 525...600V AC Input:...
  • Page 10 PowerFlex 525 AC Drive Specifications Category Specifications Control Inputs Digital Bandwidth: 10 Rad/s for open and closed loop Quantity: (1) Dedicated for stop (6) Programmable Current: 6 mA Type Source Mode (SRC): 18...24V = ON, 0...6V = OFF Sink Mode (SNK): 0...6V = ON, 18...24V = OFF...

  • Page 11: Environmental Specifications

    PowerFlex 525 AC Drive Specifications Environmental Specifications Category Specifications Altitude 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. See Current Derating Curves on page 16 derating guidelines.

  • Page 12: Certifications

    PowerFlex 525 AC Drive Specifications Certifications Certification PowerFlex 525 c-UL-us Listed to UL508C and CAN/CSA-C22.2 No. 14-05. C-Tick Australian Communications and Media Authority In conformity with the following: Radiocommunications Act: 1992 Radiocommunications Standard: 2008 N223 Radiocommunications Labelling Notice: 2008 Standards applied:...

  • Page 13: Dimensions And Weights

    PowerFlex 525 AC Drive Specifications Dimensions and Weights Frame/Rating Cross-Reference Catalog Number Description Drive Voltage Rating Rating Enclosure Emission Class Version PowerFlex 525 Drive Ratings Output Ratings Normal Duty Heavy Duty Catalog No. Output Current (A) Input Voltage Range Total Watts Loss Frame Size 100...120V AC (-15%, +10%) –...
  • Page 14 PowerFlex 525 AC Drive Specifications Output Ratings Normal Duty Heavy Duty Catalog No. Output Current (A) Input Voltage Range Total Watts Loss Frame Size 380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output 25B-D1P4N114 323...528 27.0 25B-D2P3N114 0.75...

  • Page 15: Design Considerations

    PowerFlex 525 AC Drive Specifications Design Considerations 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.)
  • Page 16 PowerFlex 525 AC Drive Specifications Ambient Operating Temperatures Accessories and Dimensions on page 30 for option kits. Ambient Temperature Maximum with Control Module (3)(5) Mounting Enclosure Rating Minimum Maximum (No Derate) Maximum (Derate) Fan Kit (Derate) 50 °C (122 °F) 60 °C (140 °F)
  • Page 17 AC Supply Source Considerations Ungrounded Distribution Systems ATTENTION: PowerFlex 525 contains 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 18 PowerFlex 525 AC Drive Specifications 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.
  • Page 19 PowerFlex 525 AC Drive Specifications Input Power Conditions Input Power Condition Corrective Action Low Line Impedance (less than 1% line reactance) • Install Line Reactor • or Isolation Transformer Greater than 120 kVA supply transformer Line has power factor correction capacitors •...
  • Page 20 PowerFlex 525 AC Drive Specifications Shield Termination - SHLD Either of the safety ground terminals 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).
  • Page 21 PowerFlex 525 AC Drive Specifications 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.
  • Page 22 PowerFlex 525 AC Drive Specifications 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, ”...
  • Page 23 PowerFlex 525 AC Drive Specifications I/O Wiring Motor Start/Stop Precautions ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If used, the input device must not exceed one operation per minute or drive damage can occur.
  • Page 24 Shielded motor cable 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 525 RF Emission Compliance and Installation Requirements Standard/Limits EN61800-3 Category C2...

  • Page 25: Fuses And Circuit Breaker Ratings

    Fuses and Circuit Breaker Ratings The PowerFlex 525 drive does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations.
  • Page 26 PowerFlex 525 AC Drive Specifications Rockwell Automation Publication 520-TD001B-EN-E - June 2013...
  • Page 27 PowerFlex 525 AC Drive Specifications Rockwell Automation Publication 520-TD001B-EN-E - June 2013...
  • Page 28 PowerFlex 525 AC Drive Specifications Rockwell Automation Publication 520-TD001B-EN-E - June 2013...
  • Page 29 PowerFlex 525 AC Drive Specifications Rockwell Automation Publication 520-TD001B-EN-E - June 2013...

  • Page 30: Accessories And Dimensions

    PowerFlex 525 AC Drive Specifications Accessories and Dimensions Dynamic Brake Resistors Drive Ratings Minimum Resistance Resistance Ω ± 10% Ω ± 5% (1)(2) Input Voltage Catalog No. 100...120V AK-R2-091P500 50/60 Hz 0.75 AK-R2-091P500 1-Phase AK-R2-091P500 200...240V AK-R2-091P500 50/60 Hz 0.75...
  • Page 31 PowerFlex 525 AC Drive Specifications EMC Line Filters Drive Ratings Input Voltage Current (A) Frame Size Catalog No. 100...120V 25-RF011-AL 50/60 Hz 0.75 25-RF023-BL 1-Phase 25-RF023-BL 200...240V 25-RF011-AL 50/60 Hz 0.75 25-RF011-AL 1-Phase 25-RF023-BL 11.0 25-RF023-BL 200...240V 25-RF014-AL 50/60 Hz 0.75...
  • Page 32 PowerFlex 525 AC Drive Specifications Human Interface Modules 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...
  • Page 33 PowerFlex 525 AC Drive Specifications Replacement Parts PowerFlex 520-Series Power Module Item Description PowerFlex 525 Power Module Replacement power module for use with PowerFlex 520-Series drives. Includes: • Power Module • Power Module Front Cover • Power Terminal Guard • Heatsink Fan...
  • Page 34 PowerFlex 525 AC Drive Specifications Output Ratings Normal Duty Heavy Duty Output Current (A) Input Voltage Range Frame Size Catalog No. 10.5 323...528 25-PM2-D010 13.0 323...528 25-PM2-D013 10.0 10.0 17.0 323...528 25-PM2-D017 15.0 11.0 15.0 11.0 24.0 323...528 25-PM2-D024 20.0 15.0...
  • Page 35 RJ45 120 Ohm resistors (2 pieces) AK-U0-RJ45-TR1 Terminal Block RJ45 Two position terminal block (5 pieces) AK-U0-RJ45-TB2P Connected Components Workbench Windows-based software packages for programming and configuring Allen-Bradley drives http://ab.rockwellautomation.com/ Software and other Rockwell Automation products. programmable-controllers/connected- (Download or DVD-ROM)
  • Page 36 PowerFlex 525 AC Drive Specifications Bulletin 1321-3R Series Line Reactors (2)(3) (2)(3) Output Ratings Input Line Reactor Output Line Reactor Normal Duty Heavy Duty IP 00 (Open Style) IP 11 (NEMA/UL Type 1) IP 00 (Open Style) IP 11 (NEMA/UL Type 1) Catalog No.
  • Page 37 PowerFlex 525 AC Drive Specifications Accessory Dimensions IP 30/NEMA 1/UL Type 1 Kit – Dimensions are in mm and (in.). Frame A 51.1 (2.01) 21.0 (0.82) ø21.5 (ø0.85) Frame D 96.0 (3.78) 70.0 (2.76) 44.0 (1.73) 30.0 (1.18) ø21.5 (ø0.85) ø33.5 (ø1.32)
  • Page 38 PowerFlex 525 AC Drive Specifications Control Module Fan Kit – Dimensions are in mm and (in.). Frame A...D Frame E Frame Size A...D 56.0 (2.20) 32.0 (1.26) 99.8 (3.93) 196.0 (7.72) 52.0 (2.05) 114.3 (4.50) EMC Line Filter – Dimensions are in mm and (in.).

  • Page 39: Safe-Torque-Off Function

    • IEC 61508 Part 1-7:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems – Parts 1-7. TÜV also certifies that the PowerFlex 525 STO may be used in applications up to Category 3/ PL(d) according to EN ISO 13849-1 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508.
  • Page 40 PowerFlex 525 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.
  • Page 41 (1) Safety relay and PowerFlex 525 must be installed in the same enclosure. (2) In some situations, a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure. Rockwell Automation Publication 520-TD001B-EN-E - June 2013...
  • Page 42 24V DC Common Gate control circuit (1) Safety relay and PowerFlex 525 must be installed in the same enclosure. Example 3 – Safe-Torque-Off Connection with Coast-to-Stop Action Using External +24V supply, SIL 3/PL e Stop Category 0 – Coast AC line...

  • Page 43: Additional Resources

    PowerFlex 525 Adjustable Frequency AC Drive User Manual 520-UM001 PowerFlex 4-Class Human Interface Module (HIM) DSI Quick Reference 22HIM-QR001 PowerFlex 525 Embedded EtherNet/IP Adapter User Manuals (Including dual port Ethernet) 520COM-UM001 PowerFlex 525 DeviceNet Adapter User Manual 520COM-UM002 PowerFlex 525 PROFIBUS DP Adapter User Manual...
  • Page 44 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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