PowerFlex 520-Series Adjustable Guide Part 1

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. Topic Page General Precautions 2 Mounting Considerations 3 Fuses and Circuit Breakers 6 Technical Specifications 8 Power Wiring 9 I/O Wiring 10 Control Terminal Block 11 Prepare For Drive Start-Up 15 Network Communication 33 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 525 Embedded EtherNet/IP Adapter User Manual 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 Publication 520-UM001 22HIM-QR001 520COM-UM001 520COM-UM002 520COM-UM003 520COM-UM004 PFLEX-AT001 DRIVES-IN001 DRIVES-TD001 SGI-1.1 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. • Installation, adjustments, putting into service, use, assembly, disassembly, and maintenance shall be carried out by suitably trained personnel in accordance with applicable code of practice. • If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. • Solid state equipment has operational characteristics differing from those of electromechanical equipment. General Precautions ATTENTION: The drive contains high voltage capacitors which take time to discharge after removal of mains supply. Before working on drive, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook. ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system. ATTENTION: The bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations, overhauling loads, and eccentric loads. However, it can also cause either of the following two conditions to occur. 1. Fast positive changes in input voltage or imbalanced input voltages can cause uncommanded positive speed changes; 2. Actual deceleration times can be longer than commanded deceleration times However, a “Stall Fault” is generated if the drive remains in this state for 1 minute. If this condition is unacceptable, the bus regulator must be disabled (see parameter A550 [Bus Reg Enable]). In addition, installing a properly sized dynamic brake resistor will provide equal or better performance in most cases. ATTENTION: Risk of injury or equipment damage exists. Drive does not contain user-serviceable components. Do not disassemble drive chassis. Mounting Considerations • Mount the drive upright on a flat, vertical and level surface. Frame Screw Size Screw Torque A M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.) B M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.) C M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.) D M5 (#10...24) 2.45...2.94 Nm (22...26 lb-in.) E M8 (5/16 in.) 6.0...7.4 Nm (53...65 lb-in.) • Protect the cooling fan by avoiding dust or metallic particles. • Do not expose to a corrosive atmosphere. • Protect from moisture and direct sunlight. Minimum Mounting Clearances See Dimensions and Weight on page 32 for mounting dimensions. Vertical Vertical, Zero Stacking No clearance between drives. 50 mm (2.0 in.) Esc Sel Esc Sel Esc Sel Esc Sel 50 mm (2.0 in.) Esc Sel 50 mm (2.0 in.)(1) Esc 25 mm (1.0 in.) 50 mm (2.0 in.) 50 mm (2.0 in.)(1) 50 mm (2.0 in.) 50 mm (2.0 in.)(1) Se l 50 mm (2.0 in.) Sel Es c Esc Sel Sel 50 mm (2.0 in.) Sel 50 mm (2.0 in.) 50 mm (2.0 in.) 50 mm (2.0 in.) Vertical, Zero Stacking with Control Module Fan Kit No clearance between drives. 50 mm (1) (2.0 in.) 50 mm (2.0 in.) 25 mm (1.0 in.) Esc Vertical with Control Module Fan Kit (2) Es c 50 mm (2.0 in.) Horizontal with Control Module Fan Kit (1) For Frame E with Control Module Fan Kit only, clearance of 95 mm (3.7 in.) is required. (2) For Frame E with Control Module Fan Kit only, clearance of 12 mm (0.5 in.) is required. Se l Esc Sel 25 mm (1.0 in.) 50 mm (2.0 in.) Horizontal, Zero Stacking with Control Module Fan Kit No clearance between drives. Esc Sel (2) 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 (No Derate) Maximum (Derate)(4) Maximum with Control Module Fan Kit (Derate)(2) (5) IP 20/Open Type 50 °C (122 °F) 60 °C (140 °F) 70 °C (158 °F) IP 30/NEMA 1/UL Type 1 45 °C (113 °F) 55 °C (131 °F) – IP 20/Open Type 45 °C (113 °F) 55 °C (131 °F) 65 °C (149 °F) Mounting Enclosure Rating(3) Vertical Vertical, Zero Stacking IP 30/NEMA 1/UL Type 1 Minimum -20 °C (-4 °F) 40 °C (104 °F) 50 °C (122 °F) – Horizontal with Control Module Fan Kit(1) (2) IP 20/Open Type 50 °C (122 °F) – 70 °C (158 °F) Horizontal, Zero Stacking with Control Module Fan Kit(1)(2) IP 20/Open Type 45 °C (113 °F) – 65 °C (149 °F) (1) (2) (3) (4) (5) Catalogs 25x-D1P4N104 and 25x-E0P9N104 cannot be mounted using either of the horizontal mounting methods. Requires installation of the PowerFlex 520-Series Control Module Fan Kit, catalog number 25-FANx-70C. IP 30/NEMA 1/UL Type 1 rating requires installation of the PowerFlex 520-Series IP 30/NEMA 1/UL Type 1 option kit, catalog number 25-JBAx. For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature listed under the Max. (Derate) column is reduced by 5 °C (9 °F) for all mounting methods. For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature listed under the Max. with Control Module Fan Kit (Derate) column is reduced by 10 °C (18 °F) for vertical and vertical with zero stacking mounting methods only. General Grounding Requirements The drive Safety Ground – (PE) must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked. Typical Grounding Esc Esc Sel R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 SHLD 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. 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-toline voltage. To disconnect these devices, remove the jumper shown in the diagrams below. 1. Turn the screw counterclockwise to loosen. 2. Pull the jumper completely out of the drive chassis. 3. Tighten the screw to keep it in place. Jumper Location (Typical) Power Module IMPORTANT Tighten screw after jumper removal. Phase to Ground MOV Removal R/L1 Three-Phase AC Input S/L2 T/L3 Jumper 1 2 3 4 CE Conformity See the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001 for details on how to comply with the Low Voltage (LV) and Electromagnetic Compatibility (EMC) Directives. PowerFlex 520-Series Adjustable Frequency AC Drive Input Ratings Branch Circuit Protection 140M Motor Protectors Fuse Ratings Min/Max Contactors (3) (4) (5) 10/16 16/20 25/40 32/50 100-C09 100-C12 100-C23 100-C23 140M-C2E-B63 140M-C2E-C10 140M-D8E-C20 140M-F8E-C25 – – – – 20.0 27.0 53.0 67.0 6/10 10/16 16/25 25/40 32/50 100-C09 100-C09 100-C12 100-C23 100-C37 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 140M-F8E-C25 140M-F8E-C25 – – – – – 20.0 29.0 50.0 81.0 111.0 6/10 10/16 16/25 25/40 32/50 100-C09 100-C09 100-C12 100-C23 100-C37 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 140M-F8E-C25 140M-F8E-C25 – – – – – 20.0 29.0 53.0 84.0 116.0 3/6 6/6 10/16 16/20 20/32 32/45 35/63 45/70 63/90 70/125 100-C09 100-C09 100-C09 100-C12 100-C23 100-C23 100-C37 100-C43 100-C60 100-C72 140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 140M-F8E-C25 140M-F8E-C32 140M-F8E-C45 140M-F8E-C45 – – 20.0 – 29.0 – 50.0 – 79.0 – 107.0 – 148.0 – 259.0 – 323.0 1416.0(7) 584.0 – 708.0 3/6 6/10 10/16 10/16 20/32 20/35 25/40 35/63 100-C09 100-C09 100-C09 100-C09 100-C23 100-C23 100-C23 100-C37 140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 140M-D8E-C20 140M-D8E-C20 140M-F8E-C32 – – – – – – – 656.7(7) 27.0 37.0 80.0 86.0 129.0 170.0 221.0 221.0 33.0 45/70 100-C43 140M-F8E-C45 656.7(7) 387.0 1.9 3.2 5.7 7.5 13.8 3/6 6/10 10/16 10/16 20/32 100-C09 100-C09 100-C09 100-C09 100-C23 140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 – – – – – 27.0 37.0 81.0 88.0 133.0 PowerFlex PowerFlex Voltage Max HP kW HP kW 523 525 Range kVA Amps(2) 100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 25A-V1P6N104 – 0.25 0.2 0.25 0.2 1.6 85...132 0.8 6.4 25A-V2P5N104 25B-V2P5N104 0.5 0.4 0.5 0.4 2.5 85...132 1.3 9.6 25A-V4P8N104 25B-V4P8N104 1.0 0.75 1.0 0.75 4.8 85...132 2.5 19.2 25A-V6P0N104 25B-V6P0N104 1.5 1.1 1.5 1.1 6.0 85...132 3.2 24.0 200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 25A-A1P6N104 – 0.25 0.2 0.25 0.2 1.6 170...264 1.4 5.3 25A-A2P5N104 25B-A2P5N104 0.5 0.4 0.5 0.4 2.5 170...264 1.7 6.5 25A-A4P8N104 25B-A4P8N104 1.0 0.75 1.0 0.75 4.8 170...264 2.8 10.7 25A-A8P0N104 25B-A8P0N104 2.0 1.5 2.0 1.5 8.0 170...264 4.8 18.0 25A-A011N104 25B-A011N104 3.0 2.2 3.0 2.2 11.0 170...264 6.0 22.9 200...240V AC (-15%, +10%) – 1-Phase Input with EMC Filter, 0...230V 3-Phase Output 25A-A1P6N114 – 0.25 0.2 0.25 0.2 1.6 170...264 1.4 5.3 25A-A2P5N114 25B-A2P5N114 0.5 0.4 0.5 0.4 2.5 170...264 1.7 6.5 25A-A4P8N114 25B-A4P8N114 1.0 0.75 1.0 0.75 4.8 170...264 2.8 10.7 25A-A8P0N114 25B-A8P0N114 2.0 1.5 2.0 1.5 8.0 170...264 4.8 18.0 25A-A011N114 25B-A011N114 3.0 2.2 3.0 2.2 11.0 170...264 6.0 22.9 200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output 25A-B1P6N104 – 0.25 0.2 0.25 0.2 1.6 170...264 0.9 1.9 0.4 2.5 170...264 1.2 2.7 25A-B2P5N104 25B-B2P5N104 0.5 0.4 0.5 25A-B5P0N104 25B-B5P0N104 1.0 0.75 1.0 0.75 5.0 170...264 2.7 5.8 25A-B8P0N104 25B-B8P0N104 2.0 1.5 2.0 1.5 8.0 170...264 4.3 9.5 25A-B011N104 25B-B011N104 3.0 2.2 3.0 2.2 11.0 170...264 6.3 13.8 25A-B017N104 25B-B017N104 5.0 4.0 5.0 4.0 17.5 170...264 9.6 21.1 25A-B024N104 25B-B024N104 7.5 5.5 7.5 5.5 24.0 170...264 12.2 26.6 25A-B032N104 25B-B032N104 10.0 7.5 10.0 7.5 32.2 170...264 15.9 34.8 48.3 170...264 20.1 44.0 25A-B048N104 25B-B048N104 15.0 11.0 10.0 7.5 25A-B062N104 25B-B062N104 20.0 15.0 15.0 11.0 62.1 170...264 25.6 56.0 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output 25A-D1P4N104 25B-D1P4N104 0.5 0.4 0.5 0.4 1.4 323...528 1.7 1.9 25A-D2P3N104 25B-D2P3N104 1.0 0.75 1.0 0.75 2.3 323...528 2.9 3.2 25A-D4P0N104 25B-D4P0N104 2.0 1.5 2.0 1.5 4.0 323...528 5.2 5.7 25A-D6P0N104 25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 323...528 6.9 7.5 25A-D010N104 25B-D010N104 5.0 4.0 5.0 4.0 10.5 323...528 12.6 13.8 25A-D013N104 25B-D010N104 7.5 5.5 7.5 5.5 13.0 323...528 14.1 15.4 25A-D017N104 25B-D017N104 10.0 7.5 10.0 7.5 17.0 323...528 16.8 18.4 25A-D024N104 25B-D024N104 10.0 7.5 10.0 7.5 17.0 323...528 24.1 26.4 25A-D030N104 25B-D030N104 20.0 15.0 15.0 11.0 30.0 323...528 30.2 380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output 25A-D1P4N114 25B-D1P4N114 0.5 0.4 0.5 0.4 1.4 323...528 1.7 25A-D2P3N114 25B-D2P3N114 1.0 0.75 1.0 0.75 2.3 323...528 2.9 25A-D4P0N114 25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 323...528 5.2 25A-D6P0N114 25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 323...528 6.9 25A-D010N114 25B-D010N114 5.0 4.0 5.0 4.0 10.5 323...528 12.6 Min. Enclosure Volume (in.3) Output Ratings Normal Duty Heavy Duty Amps Catalog No.(1) IP 20 Open Type Watts Loss Fuses and Circuit Breakers Input Ratings PowerFlex PowerFlex Voltage HP kW HP kW 523 525 Range 25A-D013N114 25B-D013N114 7.5 5.5 7.5 5.5 13.0 323...528 25A-D017N114 25B-D017N114 10.0 7.5 10.0 7.5 17.0 323...528 25A-D024N114 25B-D024N114 15.0 11.0 15.0 11.0 24.0 323...528 25A-D030N114 25B-D030N114 20.0 15.0 15.0 11.0 30.0 323...528 25A-D037N114 25B-D037N114 25.0 18.5 20.0 15.0 37.0 323...528 25A-D043N114 25B-D043N114 30.0 22.0 25.0 18.5 43.0 323...528 525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output 25A-E0P9N104 25B-E0P9N104 0.5 0.4 0.5 0.4 0.9 446...660 25A-E1P7N104 25B-E1P7N104 1.0 0.75 1.0 0.75 1.7 446...660 1.5 2.0 1.5 3.0 446...660 25A-E3P0N104 25B-E3P0N104 2.0 25A-E4P2N104 25B-E4P2N104 3.0 2.2 3.0 2.2 4.2 446...660 25A-E6P6N104 25B-E6P6N104 5.0 4.0 5.0 4.0 6.6 446...660 25A-E9P9N104 25B-E9P9N104 7.5 5.5 7.5 5.5 9.9 446...660 25A-E012N104 25B-E012N104 10.0 7.5 10.0 7.5 12.0 446...660 25A-E019N104 25B-E019N104 15.0 11.0 15.0 11.0 19.0 446...660 25A-E022N104 25B-E022N104 20.0 15.0 15.0 11.0 22.0 446...660 25A-E027N104 25B-E027N104 25.0 18.5 20.0 15.0 27.0 446...660 25A-E032N104 25B-E032N104 30.0 22.0 25.0 18.5 32.0 446...660 (1) (2) (3) (4) (5) Branch Circuit Protection Heavy Duty Amps Normal Duty IP 20 Open Type Watts Loss Output Ratings Min. Enclosure Volume (in.3) Catalog No.(1) Max kVA Amps(2) 14.1 15.4 16.8 18.4 24.1 26.4 30.2 33.0 30.8 33.7 35.6 38.9 140M Motor Fuse Protectors Ratings Min/Max Contactors (3) (4) (5) 20/35 100-C23 140M-D8E-C20 25/40 100-C23 140M-D8E-C20 35/63 100-C37 140M-F8E-C32 45/70 100-C43 140M-F8E-C45 45/70 100-C43 140M-F8E-C45 50/80 100-C60 140M-F8E-C45 – – 656.7(7) 656.7(7) – – 1.4 2.6 4.3 6.1 9.1 12.8 15.4 27.4 31.2 28.2 33.4 3/6 3/6 6/10 10/16 10/20 16/25 20/32 32/50 35/63 35/50 40/63 – 22.0 – 32.0 – 50.0 – 65.0 – 95.0 – 138.0 – 164.0 656.7(7) 290.0 656.7(7) 336.0 1416.0(7) 466.0 1416.0(7) 562.0 1.2 2.3 3.8 5.3 8.0 11.2 13.5 24.0 27.3 24.7 29.2 100-C09 100-C09 100-C09 100-C09 100-C09 100-C16 100-C23 100-C30 100-C30 100-C30 100-C37 140M-C2E-B25 140M-C2E-B25 140M-C2E-B40 140M-D8E-B63 140M-D8E-C10 140M-D8E-C16(6) 140M-D8E-C16 140M-F8E-C25 140M-F8E-C32 140M-F8E-C32 140M-F8E-C32 175.0 230.0 313.0 402.0 602.0 697.0 Normal Duty (ND) and Heavy Duty (HD) ratings are available for this drive. When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating. The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection Circuit Breakers Application Ratings. Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip. Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems. (6) When used with the 140M circuit breaker, the 25A-E9P9104 must be installed in a ventilated or non-ventilated enclosure with the minimum size of 457.2 x 457.2 x 269.8 mm (18 x 18 x 10.62 in.). (7) When using a Manual Self-Protected (Type E) Combination Motor Controller with this drive power rating, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations may require a larger enclosure. PowerFlex 520-Series Adjustable Frequency AC Drive Technical Specifications PowerFlex 523 Specifications Input/Output Ratings Output Frequency: 0...500 Hz (Programmable) Efficiency: 97.5% (Typical) Digital Control Inputs (Input Current = 6 mA) SRC (Source) Mode: SNK (Sink) Mode: 18...24V = ON 0...6V = ON 0...6V = OFF 18...24V = OFF Approvals S TE D 96 6X LI S TE D 96 6X LI UL UL508C ® I ND OT E CN C UL ® I D N Q OT E CN CSA 22.2 N223 Q LV Directive 2006/95/EC: EN 61800-5-1 EMC Directive 2004/108/EC: EN 61800-3:2004 AC156 KCC: Article 58-2 of Radio Waves Act, Clause 3 GOST-R: POCC US.ME92.H00040 Control Output Analog Control Inputs Fuses and Circuit Breakers Programmable Output, Form C 4-20 mA Analog: 250 Ω input impedance Recommended Fuse Type: Resistive Rating: 3.0 A @ 30V DC, 125V AC and 240V AC 0-10V DC Analog: 100 kΩ input impedance UL Class CC, J, T or Type BS88; 600V (550V) or equivalent. Inductive Rating: 0.5 A @ 30V DC, 125V AC and 240V AC External Pot: 1...10 kΩ, 2 W min. Recommended Circuit Breakers: HMCP or equivalent. Protective Features Motor Protection: I2t overload protection – 150% for 60 s, 200% for 3 s (Provides Class 10 protection) Overcurrent: 200% hardware limit, 300% instantaneous fault Over Voltage: 100...120V AC Input – Trip occurs @ 405V DC bus voltage (equivalent to 150V AC incoming line) 200...240V AC Input – Trip occurs @ 405V DC bus voltage (equivalent to 290V AC incoming line) 380...480V AC Input – Trip occurs @ 810V DC bus voltage (equivalent to 575V AC incoming line) 525...600V AC Input – Trip occurs @ 1005V DC bus voltage (equivalent to 711V AC incoming line) Under Voltage: 100...120V AC Input – Trip occurs @ 190V DC bus voltage (equivalent to 75V AC incoming line) 200...240V AC Input – Trip occurs @ 190V DC bus voltage (equivalent to 150V AC incoming line) 380...480V AC Input – Trip occurs @ 390V DC bus voltage (equivalent to 275V AC incoming line) 525...600V AC Input – If P038 = 3 “600V” trip occurs @ 487V DC bus voltage (344V AC incoming line); – If P038 = 2 “480V” trip occurs @ 390V DC bus voltage (275V AC incoming line) Control Ride Through: Minimum ride through is 0.5 s - typical value 2 s Faultless Power Ride Through: 100 ms PowerFlex 525 Specifications Input/Output Ratings Output Frequency: 0...500 Hz (Programmable) Efficiency: 97.5% (Typical) Approvals E D 96 6 X L IS T UL ® N I D O C T Q E N E D 96 6X LIS T UL508C C UL CSA 22.2 ® N I DC O N Bauart geprüft Functional N223 TE Q Safety Type approved LV Directive 2006/95/EC: EN 61800-5-1 EMC Directive 2004/108/EC: EN 61800-3:2004 AC156 KCC: Article 58-2 of Radio Waves Act, Clause 3 GOST-R: POCC US.ME92.H00040 Digital Control Inputs (Input Current = 6 mA) SRC (Source) Mode: SNK (Sink) Mode: 18...24V = ON 0...6V = ON 0...6V = OFF 18...24V = OFF Control Output Programmable Output, Form A and Form B Resistive Rating: 3.0 A @ 30V DC, 125V AC and 240V AC Inductive Rating: 0.5 A @ 30V DC, 125V AC and 240V AC Protective Features .. TUV Rheinland II (2) G D Analog Control Inputs 4-20 mA Analog: 250 Ω input impedance 0-10V DC Analog: 100 kΩ input impedance External Pot: 1...10 kΩ, 2 W min. Fuses and Circuit Breakers Recommended Fuse Type: UL Class J, T or Type BS88; 600V (550V) or equivalent. Recommended Circuit Breakers: HMCP or equivalent. Opto Outputs 30V DC, 50 mA Non-inductive Analog Outputs (10-bit) 0-10V: 1 kΩ min. 4-20 mA: 525 Ω max. Motor Protection: I2t overload protection – 150% for 60 s, 200% for 3 s (Provides Class 10 protection) Overcurrent: 200% hardware limit, 300% instantaneous fault Over Voltage: 100...120V AC Input – Trip occurs @ 405V DC bus voltage (equivalent to 150V AC incoming line) 200...240V AC Input – Trip occurs @ 405V DC bus voltage (equivalent to 290V AC incoming line) 380...480V AC Input – Trip occurs @ 810V DC bus voltage (equivalent to 575V AC incoming line) 525...600V AC Input – Trip occurs @ 1005V DC bus voltage (equivalent to 711V AC incoming line) Under Voltage: 100...120V AC Input – Trip occurs @ 190V DC bus voltage (equivalent to 75V AC incoming line) 200...240V AC Input – Trip occurs @ 190V DC bus voltage (equivalent to 150V AC incoming line) 380...480V AC Input – Trip occurs @ 390V DC bus voltage (equivalent to 275V AC incoming line) 525...600V AC Input – If P038 = 3 “600V” trip occurs @ 487V DC bus voltage (344V AC incoming line); – If P038 = 2 “480V” trip occurs @ 390V DC bus voltage (275V AC incoming line) Control Ride Through: Minimum ride through is 0.5 s – typical value 2 s Faultless Power Ride Through: 100 ms PowerFlex 520-Series Adjustable Frequency AC Drive Power Wiring Recommended Shielded Wire Location Standard (Option 1) Rating/Type Description 600V, 90 °C (194 °F) XHHW2/RHW-2 • Four tinned copper conductors with XLPE insulation. Anixter B209500-B209507, Belden 29501-29507, or equivalent • Copper braid/aluminum foil combination shield and tinned copper drain wire. • PVC jacket. Standard (Option 2) Tray rated 600V, 90 °C (194 °F) • Three tinned copper conductors with XLPE insulation. • 5 mil single helical copper tape (25% overlap min.) with three bare copper grounds RHH/RHW-2 Anixter OLF-7xxxxx or equivalent in contact with shield. • PVC jacket. Class I & II; Division I & II Tray rated 600V, 90 °C (194 °F) • Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor. RHH/RHW-2 Anixter 7V-7xxxx-3G or equivalent • Black sunlight resistant PVC jacket overall. • Three copper grounds on #10 AWG and smaller. Power Terminal Block Diagrams and Wiring Specifications Terminal Description Frame A...D R/L1, S/L2 1-Phase Input Line Voltage Connection R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 R/L1, S/L2, T/L3 3-Phase Input Line Voltage Connection U/T1, V/T2, W/T3 Motor Phase Connection = DC- DC+ BRBR+ DC+, DC- DC Bus Connection (except for 110V 1-Phase) BR+, BR- Dynamic Brake Resistor Connection Safety Ground – PE Frame E R/L1 Switch any two motor leads to change forward direction. S/L2 T/L3 U/T1 V/T2 W/T3 Frame DC- DC+ BR+ BR- Maximum Wire Size(1) 2 (10 AWG) Minimum Wire Size(1) Torque 0.8 mm2 (18 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.) A 5.3 mm B 8.4 mm 2 (8 AWG) 2.1 mm2 (14 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.) C 8.4 mm 2 (8 AWG) 2.1 mm2 (14 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.) D 13.3 mm2 (6 AWG) 5.3 mm2 (10 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.) E 26.7 mm2 (3 AWG) 8.4 mm2 (8 AWG) 3.09...3.77 Nm (27.3...33.4 lb-in.) (1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations. Input Power Conditions Input Power Condition Corrective Action Low Line Impedance (less than 1% line reactance) Greater than 120 kVA supply transformer • Install Line Reactor(2) • or Isolation Transformer Line has power factor correction capacitors Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V (lightning) Phase to ground voltage exceeds 125% of normal line to line voltage Ungrounded distribution system • Install Line Reactor(2) • or Isolation Transformer 240V open delta configuration (stinger leg)(1) Install Line Reactor(2) • Remove MOV jumper to ground. • or Install Isolation Transformer with grounded secondary if necessary. (1) For drives applied on an open delta with a middle phase grounded neutral system, the phase opposite the phase that is tapped in the middle to the neutral or earth is referred to as the “stinger leg,” “high leg,” “red leg,” etc. This leg should be identified throughout the system with red or orange tape on the wire at each connection point. The stinger leg should be connected to the center Phase B on the reactor. See Appendix B of the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001 for specific line reactor part numbers. (2) See Appendix B of the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001 for accessory ordering information. PowerFlex 520-Series Adjustable Frequency AC Drive I/O Wiring Recommended Signal Wire Signal Type/ Where Used Belden Wire Type (or equivalent)(1) Description Minimum Insulation Rating Analog I/O & PTC 8760/9460 0.750 mm2 (18 AWG), twisted pair, 100% shield with drain(2) Remote Pot 8770 0.750 mm2 (18 AWG), 3 conductor, shielded 300V, 60 °C (140 °F) Encoder/Pulse I/O 9728/9730 0.196 mm2 (24 AWG), individually shielded pairs (1) Stranded or solid wire. (2) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended. Recommended Control Wire for Digital I/O Type Wire Type(s) Description Minimum Insulation Rating Unshielded Per US NEC or applicable national or local code – Unshielded Multi-conductor shielded cable such as Belden 8770 (or equivalent) 0.750 mm2 (18 AWG), 3 conductor, shielded. 300V, 60 °C (140 °F) Control I/O Terminal Block Wire Specifications Frame Maximum Wire Size(1) Minimum Wire Size(1) Torque A...E 1.3 mm2 (16 AWG) 1.3 mm2 (16 AWG) 0.71...0.86 Nm (6.2...7.6 lb-in.) (1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations. See the PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001 for recommendations on maximum power and control cable length.