PowerFlex® 525 AC Drives

Overview

Component Drives Business

5 May, 2016

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PUBLIC - 5058-CO900H Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
 PowerFlex 520-Series AC Drives
 The next generation of Allen-Bradley PowerFlex compact drives
 Provides ultimate flexibility for stand alone to integrated applications
 Features are unmatched in the market place today with a wide range of motor control
and many standard features
 Installation flexibility and simplified configuration
 Designed to help customers
 save money
 maximize system performance
 reduce time to design
 deliver machines

 Power range: 0.4…22 kW / (0.5…30 HP)

 Voltage range from 100 to 600V
PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 2
 Compact Market Product Positioning
Three Product Lines
Connected Components Mid-Range Offering

PowerFlex 527
• Designed to be used with an Allen-Bradley Logix
Programmable Automation Controller (PAC).
• Ideal for machines that can benefit from the same drive
configuration experience for both servo and AC drives, the
PowerFlex 527 drive features a built-in dual port for
EtherNet/IP and safety over the network.
Value

PowerFlex 525
• Ideal for networked machines and simple system integration, offering
standard features including built-in EtherNet/IP™ and safety.
PowerFlex 523
• Ideal for standalone machines that require cost-effective
motor control.
• Ease of installation with HIM, Application programming groups
and Software Tools

Performance / Functionality
3

PowerFlex 520-Series
The Next Generation of Powerful Performance. Flexible Control.

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

 Compact Market Product Positioning
Three Product Lines
Connected Components Mid-Range Offering

PowerFlex 527
• Integrated Motion
• 30 Hp
• Communication: Embedded Dual Port EtherNet/IP
• Safety: Embedded Safe Torque Off SIL3/Ple for both hardwired and
Integrated Network Safety
• Motor control Option: V/Hz, SVC, Closed Loop Velocity Vector, PM*
• Incremental Encoder Option
• Removable terminal blocks
• Programmed via embedded motion instructions
PowerFlex 525
Value

• 30 Hp
• Standard USB connectivity
• Comms: Embedded DSI + Single port EtherNet/IP
• Comms Options: Dual port EtherNet/IP with DLR, DeviceNet, Profibus
• Safety: Embedded Safe Torque Off SIL2/PLd
• Motor Control options: V/Hz, SVC, Economizer SVC, Closed Loop Velocity Vector,
Permanent Magnet
• Incremental Encoder Option
PowerFlex 523 • AppView & CustomView Application Configuration
• 30 Hp • CCW Programming Software
• Standard USB connectivity
• Comms: Embedded DSI
• Comm Options: Dual port EtherNet/IP with DLR, DeviceNet, Profibus
• Motor Control options: V/Hz, SVC, Economizer SVC
• AppView & CustomView Application Configuration * Future Firmware Release
• CCW Programming Software

Performance / Functionality
4

PowerFlex 520-Series: Common Attributes

Innovative Design Simplified Configuration
• Modularity design • Smallest clearance requirement • Simplified programming • Seamless integration into Logix with
• Common Power Module • Zero-stack • QuickView HIM add-on profiles for Studio 5000
• Extreme ambient temperatures
PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
 PowerFlex 520-Series AC Drives
PowerFlex 525 Overview

 Power, control, flexibility and features for a

wide range of applications
 Ideal for standalone machines and simple
system integration
 Unique modular design
 Seamless integration into Logix control
architectures
 Built-in port for EtherNet/IP and Safe Torque-
off standard Power Ratings:
 Easy to use configuration tools • 100 - 120V: 0.4...1.1 kW / 0.5...1.5 Hp
• 200 - 240V: 0.4...15 kW / 0.5...20 Hp
 Flexible motor control and installation options • 380 - 480V: 0.4...22 kW / 0.5...30 Hp
• 525 - 600V: 0.4...22 kW / 0.5...30 Hp

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 5

 PowerFlex 520-Series AC Drives
PowerFlex 525 Summary
 Power Ratings
 0.4…22 kW (0.5…30 Hp) at 400-480V
 Motor Control Performance
 V/Hz, SVC, Economizer SVC, PM
 Closed loop velocity vector control
 Permanent magnet motor control
 Positioning
 Closed loop feedback allows positioning
capability
 Communications
 Embedded DSI and single port EtherNet/IP
 Optional dual port card for EtherNet/IP
supporting ring topology and DLR
functionality
 Optional cards for DeviceNet, Profibus
Ideal for machines needing more control options and system integration
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 Embedded Safety
 Safe Torque-Off SIL2/PLd
 Input / Output
 7DI (6 programmable), 2AI, 2DO, 1AO, 2RO
(1 Form A & 1 Form B)
 Other Features
 7th IGBT braking, 2PID, Common DC Bus, ½
Line Voltage operation
 Fiber features: Traverse and P-Jump,
PointStop™ position control
 Multi-drive connectivity
 Data links: 8 (4 in, 4 out)
 Global Standard
 UL, cUL. CE, C-Tick, RoHS, GOST-R, KCC,
REACH, Marine (Lloyds), ATEX, TUV,
Semi-F47, ACS 156
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 6
 PowerFlex 520-Series AC Drives
Common Attributes
 Modular Design  Energy Saving
 Removable control module helps speed  Reduce energy costs with Economizer control
installation mode
 One control module supports entire power  CIP Energy - Energy sensing capability
range (PowerFlex 527 only)
 No size penalty when adding option cards  Global Voltages
 Ease of Programming  100V, 200V, 400V, 600V
 Studio 5000™ Logix Designer: AOPs & ADC  Multiple EMC filtering options
 Connected Component Workbench software  Embedded EMC filtering at 1ph 200V & 3ph
(PowerFlex 523 and 525 only) 400V class
 Dedicated application parameter groups  Optional external EMC filtering for longer
(PowerFlex 523 and 525 only) cable length
 MainsFree™ programming  Robustness
 Flexible Installation  Allow -15% / +10% input voltage
 Requires only 50mm (1.96 in) space for top  Conformal Coating to 3C2 specification
and bottom (Chemical Gases only)
 Horizontal mounting
 Zero Stacking up to 45oC (113oF)
 Din rail mounting for frames A, B and C and
high ambient temperature up to 70oC (158oF)
Ideal for standalone and simple-to-standard machine builders and simple system integration
PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 7
 PowerFlex 520-Series AC Drives
PowerFlex 525

Volts per hertz, sensorless vector control, closed loop

velocity vector control sensorless vector control with
Economizer and permanent magnet motor control to meet
a wide range of applications.

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 8

 PowerFlex 525 AC Drive
Permanent Magnet Motor Control

 Permanent magnet motor control helps improve

energy efficiency and reduce related costs
 Higher power density provided by permanent magnet
motors often results in a motor size reduction while
maintaining the same output torque
 Support for both interior mount and surface mount
permanent magnet motors
 iPM supports both open and closed loop control
 sPM supports open loop control only
 Available with firmware version 5 or higher — no new hardware
will be required. Firmware can be downloaded from Product
Compatibility and Download Center

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 9

 PowerFlex 520-Series AC Drives
Innovative Design
 Modular design helps reduce installation and configuration time
 Compact footprint
 No penalty for adding option cards
 Small mounting clearances at the top and bottom of drive
 High ambient temperature operation up to 70°C (158°F)
 Flexible installation with both vertical and horizontal and side-
by-side installation
 PowerFlex 525 has built in: single port for EtherNet/IP
and Safe Torque-off
 PowerFlex 527 has built-in: dual port for EtherNet/IP, hardwired
Safe Torque-off and Network safety

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 10

 PowerFlex 520-Series AC Drives
Installation and Configuration
 Install the power module while you configure your drive in
parallel
 Same control module supports entire power range helping
reduce customer spare part inventory
 MainsFree™ configuration for PowerFlex 523 and 525
transfers files between the computer and control module
with onboard data transfer tool
 Uses standard USB connection for upload,
download & flash (PowerFlex 523 and 525 only)
 Configuration streamline and easy to use with multiple
ways to configure:
 HIM
 Connected Components Workbench software
(PowerFlex 523 and 525 only)
 Studio 5000 Logix Designer
PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 11
 PowerFlex 520-Series AC Drives
Installation and Configuration
 USB connection is for upload/download
of configuration file (PowerFlex 523 and 525 only)
 Functions as a data transfer port only:
 Upload
 Download
 Flash
 No online programming via USB

 Configuration file created in Connected

Components Workbench software
 Software does not need to reside on PC to
download a file

 The USB configuration is similar

to synchronizing a smart device with a computer

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 12

 PowerFlex 520-Series AC Drives
Simplified Programming
 Dynamic Human Interface Module (HIM)
PF523
 LCD
 QuickView™ Scrolling Text
 Multiple Languages
 Connected Components Workbench™ Software (PowerFlex
523 and 525 only)
 Free software
PF525
 Application Programming Groups: AppView™
& CustomView™ configuration
 Studio 5000 Logix Designer™ Application
 Premier Integration
 Automatic Device Configuration (ADC)
 Integrated motion instructions (PowerFlex 527only) PF527

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 13

 PowerFlex 523 & 525 AC Drives
Application Specific Parameter Groups
AppView™ Configuration
 Helps speed up drive configuration for
common applications
 Application parameters grouped together
provide faster visibility to drive settings
 AppView has a total of 8 groups (7 for PF523)
including: conveyors, fans, mixers and pumps
 Available using Connected Components
Workbench software or the human interface
module (HIM)
Customization options for OEMs & an enhanced programming experience
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CustomView™ Configuration
 Configuration tool allows you to create and
save custom parameter groups
 Add or remove parameters from an AppView
group or create your own
 Up to 100 parameters
 CustomView programming is available using
Connected Components Workbench or HIM
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 14
 PowerFlex 520-Series AC Drives
Communications Adding option cards to the
PowerFlex 520-Series does not
 PowerFlex 523 AC drives affect the foot print of the drive
 Standard Serial (DSI) port
 Optional dual port EtherNet/IP card
 Additional network options
Device Level Ring topology
helps increase system resiliency
 PowerFlex 525 AC drives in the case of the loss of one
 Standard Serial (DSI) port network connection.
 Built-in EtherNet/IP single port Communication is rerouted to
help continue operations
 Optional dual port EtherNet/IP card
 Additional network options

 PowerFlex 527 AC drives

 Built-in EtherNet/IP dual port

 Dual port EtherNet/IP supports DLR topology

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 PowerFlex 520-Series AC Drives
EtherNet/IP™ Topologies

Linear

Star

Rockwell Automation supports rings

at the device level (DLR)
Ring

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 PowerFlex 520-Series AC Drives
Automatic Device Configuration (ADC)

 ADC allows a user to configure their Logix

system to automatically download a drive’s
configuration
 Ideal for drive replacement
 ADC is a version 20 and above feature
Download
 Also complements: button

 Stratix 6000 & 8000 and 5700 switches

 Automatically assigns IP Address Add-On Profile (AOP)
of desired drive in
Studio 5000
 Firmware Supervisor
 Flashes the drive and peripherals

Attribute PF523 PF525 PF527

Automatic Device Optional with dual Embedded single port Embedded dual port
Configuration (ADC) port Ethernet/IP EtherNet/IP as part of EtherNet/IP as part
Card the architecture of the architecture

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

 PowerFlex 520-Series AC Drives
Automatic Device Configuration (ADC)

Example

2:00 AM

Stratix 6000 /
8000 / 5700
EtherNet/IP
Configuration
Flash
IP Address

* Dual port EtherNet/IP supports DLR topology

Helps save the user time and money by reducing downtime

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
 PowerFlex 520-Series AC Drives
Safety
 Safe Torque-off can help increase safety and machine
uptime
 PowerFlex 525 AC drives: Built-in hardwired safety
 Certified to SIL2 / PLd
 Requires the use of any external safety relay to meet ISO
13849-1
 PowerFlex 527 AC drives: Choice of safety options
 Built-in Hardwired Safe Torque-off SIL3/PLe, Cat 3
 Built-in Network Safe Torque-off SIL3/PLe, Cat 3

 Help protect your personnel and assets with standard built-in

Safe Torque-off
 Helps with faster start ups and reduces wear on motor assets
 Reduce wiring and installation space with built in safety or
integrated safety-- safety over the network

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 19

 PowerFlex® 525 AC Drives

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PUBLIC - 5058-CO900H Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.