Allen-Bradley PowerFlex 525 Bedienungsanleitung

Technical Data

PowerFlex 525 AC Drive Specifications

Original Instructions

Topic Page

Product Overview 2

Catalog Number Explanation 8

Technical Specifications 9

Environmental Specifications 11

Certifications 12

Dimensions and Weights 13

Design Considerations 15

Fuses and Circuit Breaker Ratings 25

Accessories and Dimensions 30

Safe-Torque-Off Function 39

Additional Resources 43

2Rockwell Automation Publication 520-TD001B-EN-E - June 2013

PowerFlex 525 AC Drive Specifications

Product Overview

The PowerFlex® 525 AC drive delivers an innovative design that is remarkably

versatile and can accommodate systems ranging from standalone machines to

simple system integration. The PowerFlex 525 provides general purpose control

for applications 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 525

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 525 drive.

PowerFlex 525 Drive Features

Modular Design

• Standard control module used across the entire power range.

•Detachable control module and power module allow simultaneous configuration and installation.

• 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.

•Simultaneous support for two accessory cards without affecting footprint.

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.

•ZeroStacking™ 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 525 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

•RemovableMOVto 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

3 seconds provides robust overload protection.

• Adjustable PWM frequency up to 16 kHz ensures quiet operation.

Rockwell Automation Publication 520-TD001B-EN-E - June 2013 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

•Closed loop feedback with an optional encoder card

•Point-to-point positioning mode

•2 Integral PID functionality enhance application flexibility.

I/O Wiring

• Two (2) Analog Inputs (one unipolar and one bipolar)

are independently isolated from the rest of the drive I/O.

These inputs can be toggled via a digital input.

•Seven(7)DigitalInputs(6 programmable)provide

application versatility.

• One (1) Analog Output is jumper selectable between

for either 0-10V or 0-20 mA. This scalable, 10-bit

output is suitable for metering or as a speed reference for

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.

Digital Common

DigIn TermBlk 05

DigIn TermBlk 06

DigIn TermBlk 07/Pulse

Stop (1)

DigIn TermBlk 02/

Start/Run FWD (2)

DigIn TermBlk 03/

Direction/Run REV

DigIn TermBlk 08

S+

Relay 1 N.O.

Relay 1 Common

+24V DC

+10V DC

0-10V (or ±10V) Input

Analog Common

4-20mA Input

Analog Output

Opto Output 1

Opto Output 2

RJ45 Shield

Comm Common

Opto Common

+24V

+10V

Safety 1

Safety 2

Safety +24V

Typical

SNK wiring

Typical

SRC wiring

S1 S2 S+ 11 12 13 14 15 16 17 1819

R2 R5 R6 01 02 03 04 05 06 07 08C1 C2

30V DC

50 mA

Non-inductive

Common

24V (3)

Pot must be

1...10 k ohm

2 W min.

0-10V

0/4-20 mA

SNK

Digital In

DigIn TermBlk 07 Sel

Analog Out

Pulse In

SRCDigital

Input

0/4-20mA

0-10V

SRCSNK

Relay 2 Common

Relay 2 N.C.

Safe-Torque-O

4Rockwell Automation Publication 520-TD001B-EN-E - June 2013

PowerFlex 525 AC Drive Specifications

Communications

•EmbeddedEtherNet/IP™portallows easy configuration, control, and collection of drive data over the network.

•DualportEtherNet/IPoptioncardsupports 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.

• Field installed option allows for future addition of stand-alone drives to a network.

• Online EDS file creation with RSNetWorx™ providing ease of set-up on a network.

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.

•Improved speed regulation

•Basic position control

Basic Position Control

Local 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.

•Speedratioavailable for simple draw applications.

Feedback Details

•Line Driver Type Incremental Encoder

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%

•Pulse Train Input

•Configurable Input Voltage 5V/12V/24V

DC autodetect

•Frequency controlled PWM

•Allowable Pulse Frequency DC to 250 kHz.

I/O Connection Example I/O Connection Example

Encoder

Power –

Internal Drive

Power

Internal (drive)

12V DC, 250 mA

Encoder

Power –

External

Power

Source

Encoder

Signal –

Single-Ended,

Dual Channel

Encoder

Signal –

Differential,

Dual Channel

Common

+12V DC

(250 mA)

A-

B-

to SHLD

Common

External

Power

Supply

SHLD

A NOT

B NOT

to SHLD

to Power Supply

Common

A-

B-

to SHLD

A NOT

B NOT

A-

B-

Rockwell Automation Publication 520-TD001B-EN-E - June 2013 5

PowerFlex 525 AC Drive Specifications

Improved Ride Through

Operation Down to 1/2 Line Voltage

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.

•Selectable 1/2 line voltage operation.

•Increased power loss ride through.

Optimized for Common DC Bus Installations

Enhanced Control 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 525 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.

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.

•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.

6Rockwell Automation Publication 520-TD001B-EN-E - June 2013

PowerFlex 525 AC Drive Specifications

Communications and Software

Versatile Programming and Network Solutions

•PowerFlex 525 is compatible with any device that

acts as a RTU Master and supports standard 03

and 06 RTU commands.

•A network can be configured using

PowerFlex 525 drives for high performance and

flexible configuration capabilities.

•EtherNet/IP standard

(Dual port option available)

•DeviceNet

•PROFIBUS DP

•PowerFlex 525 is compatible with any device that

acts as a RTU Master and supports standard 03

and 06 RTU commands.

•A multi-drive solution can be reached using a

single PowerFlex 525 drive, with the ability for

up to five (5) drives to reside on one (1) node.

• 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

DF1 port. The SCM can be eliminated if the controller acts as a RTU Master.

PC Programming Software

Connected Components Workbench™

•Supports plug-and-play connectivity through a standard USB connection.

•AppView™ tool provides parameter groups for several of the most common applications.

•Create and save custom parameter groups using the CustomView™ tool.

•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(1) can be transferred directly to the PowerFlex 525 drive over

EtherNet/IP.

•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.

up to 4 PowerFlex 525, PowerFlex 4, or PowerFlex 40 drives

DeviceNet to EtherNet/IP

RTU

up to 31 PowerFlex 525, PowerFlex 4, or PowerFlex 40 drives

Network Communication

Node 1 Node 2 Node 3

up to 31 PowerFlex 525, PowerFlex 4, or PowerFlex 40 drives

RTU

SCM

DF1

PowerFlex 40

with Comms card

PowerFlex 40

with Comms card

PowerFlex 40

with Comms card

Rockwell Automation Publication 520-TD001B-EN-E - June 2013 7

PowerFlex 525 AC Drive Specifications

PowerFlex 525 Drive Family

Frame A Frame B Frame C Frame D Frame E

8Rockwell Automation Publication 520-TD001B-EN-E - June 2013

PowerFlex 525 AC Drive Specifications

Catalog Number Explanation

Code Braking

4Standard

Code EMC Filter

0NoFilter

1Filter

Code Interface Module

1Standard

Code Enclosure

N IP20 NEMA/Open

Code Voltage Phase

V120VAC1

A240VAC1

B240VAC3

D480VAC3

E600VAC3

Code Type

25B PowerFlex 525

* Normal and Heavy duty ratings are

available for drives above 15 HP / 11 kW.

1-3 4 5 6-8 9 10 11 12 13 14

25B - B 2P3 N 1 1 4 – –

Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash

Output Current @ 1 Phase, 100...120V Input

Code Amps Frame ND HD

HP kW HP kW

2P5 2.5 A 0.5 0.4 0.5 0.4

4P8 4.8 B 1.0 0.75 1.0 0.75

6P0 6.0 B 1.5 1.1 1.5 1.1

Output Current @ 1 Phase, 200...240V Input

Code Amps Frame ND HD

HP kW HP kW

2P5 2.5 A 0.5 0.4 0.5 0.4

4P8 4.8 A 1.0 0.75 1.0 0.75

8P0 8.0 B 2.0 1.5 2.0 1.5

011 11.0 B 3.0 2.2 3.0 2.2

Output Current @ 3Phase, 200...240V Input

Code Amps Frame ND HD

HP kW HP kW

2P5 2.5 A 0.5 0.4 0.5 0.4

5P0 5.0 A 1.0 0.75 1.0 0.75

8P0 8.0 A 2.0 1.5 2.0 1.5

011 11.0 A 3.0 2.2 3.0 2.2

017 17.5 B 5.0 3.7 5.0 3.7

024 24.0 C 7.5 5.5 7.5 5.5

032 32.2 D 10.0 7.5 10.0 7.5

048 48.3 E 15.0 11.0 15.0 11.0

062 62.1 E20.0 15.0 15.0 11.0

Output Current @ 3 Phase, 380...480V Input

Code Amps Frame ND HD

HP kW HP kW

1P4 1.4 A 0.5 0.4 0.5 0.4

2P3 2.3 A 1.0 0.75 1.0 0.75

4P0 4.0 A 2.0 1.5 2.0 1.5

6P0 6.0 A 3.0 2.2 3.0 2.2

010 10.5 B 5.0 4.0 5.0 4.0

013 13.0 C 7.5 5.5 7.5 5.5

017 17.0 C 10.0 7.5 10.0 7.5

024 24.0 D 15.0 11.0 15.0 11.0

030 30.0 D20.0 15.0 15.0 11.0

037 37.0 E25.0 18.5 20.0 15.0

043 43.0 E30.0 22.0 25.0 18.5

Output Current @ 3 Phase, 525...600V Input

Code Amps Frame ND HD

HP kW HP kW

0P9 0.9 A 0.5 0.4 0.5 0.4

1P7 1.7 A 1.0 0.75 1.0 0.75

3P0 3.0 A 2.0 1.5 2.0 1.5

4P2 4.2 A 3.0 2.2 3.0 2.2

6P6 6.6 B 5.0 3.7 5.0 3.7

9P9 9.9 C 7.5 5.5 7.5 5.5

012 12.0 C 10.0 7.5 10.0 7.5

019 19.0 D 15.0 11.0 15.0 11.0

022 22.0 D20.0 15.0 15.0 11.0

027 27.0 E25.0 18.5 20.0 15.0

032 32.0 E30.0 22.0 25.0 18.5

Rockwell Automation Publication 520-TD001B-EN-E - June 2013 9

PowerFlex 525 AC Drive Specifications

Technical Specifications

Category Specifications

Protection Bus Overvoltage Trip

100...120V AC Input:

200...240V AC Input:

380...480V AC Input:

525...600V AC Input:

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 line)

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 NECarticle 430 and motor over-temperature protection

according to NEC article 430.126 (A) (2). UL 508C File 29572.

Overcurrent: 200% hardware limit, 300% instantaneous fault

Ground Fault Trip: Phase-to-ground on drive output

Short Circuit Trip: Phase-to-phase on drive output

Electrical 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)

Control Method Sinusoidal PWM, Volts/Hertz, Sensorless Vector Control, Economizer SVC motor control, and Closed Loop Velocity

Vector Control

Carrier Frequency 2...16 kHz, Drive rating based on 4 kHz

Frequency Accuracy

Digital Input:

Analog Input:

Analog Output:

Within ±0.05% of set output frequency

Within 0.5% of maximum output frequency, 10-Bit resolution

±2% of full scale, 10-Bit resolution

Speed Regulation

Open Loop with Slip Compensation:

With Encoder:

±1% of base speed across a 80:1 speed range

±0.3% of base speed across a 80:1 speed range

±0.05% of base speed across a 20:1 speed range

Output Voltage Range: 0V to rated motor voltage

Output Frequency Range: 0...500 Hz (programmable)

Efficiency: 97.5% (typical)

Stop Modes: Multiple programmable stop modes including – Ramp, Coast, 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:

Heavy Duty:

Normal and Heavy Duty ratings are available for drives above 15 HP/ 11 kW

110% Overload capability for up to 60 s, 150% for up to 3 s

150% Overload capability for up to 60 s, 180% for up to 3 s (200% programmable)

10 Rockwell Automation Publication 520-TD001B-EN-E - June 2013

PowerFlex 525 AC Drive 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):

Sink Mode (SNK):

18...24V = ON, 0...6V = OFF

0...6V = ON, 18...24V = OFF

Analog Quantity: (2) Isolated, -10-10V and 4-20mA

Specification

Resolution:

0-10V DC Analog:

4-20 mA Analog:

External Pot:

10-bit

100k ohm input impedance

250 ohm input impedance

1...10k ohm, 2 W minimum

Encoder 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/O automatically scales to allow 5V, 12V and 24V DC nominal

voltages.

Control

Outputs

Relay Quantity: (2)1 Programmable Form A and 1 Programmable Form B

Specification

Resistive Rating:

Inductive Rating:

3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC

0.5 A @ 30V DC, 0.5 A @ 125V, 0.5 A @ 240V AC

Opto Quantity: (2) Programmable

Specification: 30V DC, 50 mA Non-inductive

Analog Quantity: (1) Non-Isolated 0-10V or 4-20 mA

Specification

Resolution:

0-10V DC Analog:

4-20 mA Analog:

10-bit

1 k ohm minimum

525 ohm maximum

Category Specifications

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