PowerFlex 525 Selection Guide
The PowerFlex family of AC and DC drives provides benefits that matter the most. These carefully planned pieces are designed to be as flexible as possible, helping to improve productivity while providing a means for doing what they do best. They are giving industry standard motor control, but also with additions from specialized power systems such as open loop speed regulation and precise torque and speed controls.
FORCE Technology, which was patented by Allen-Bradley, offers excellent low-speed/zero-speed performance while delivering accurate torque and speed regulation. PowerFlex drives help streamline configuration and programming with easy-to-use software packages and tools that come alongside an intuitive user experience to make design faster, reducing design time while speeding up the delivery process for machines of all sorts.
PowerFlex Compact-Class AC drives provide a simple and cost-effective solution for standalone machine-level control applications or Simple System Integration. Easily accessible, these general-purpose class machines allow optimization of panel space while giving you the versatility needed in specific applications. Small enough to fit anywhere, PowerFlex 525 AC drives offer standard features like Hardwired Safe Torque-off and built-in ports for EtherNet/IP communication. This guide will explore each option so one can get familiar with the selection of the PowerFlex 525 series.
Features
PowerFlex 525 variable frequency drives have become famous for their high versatility and efficiency among Automation Professionals. These products are easy to install and configure due to their innovative modular design. The PowerFlex 525 series features embedded EtherNet/IP communication systems, safety protocols, and an integrated USB interface, making them cost-effective while meeting all needs one may want in a drive.
Depending on the application, Allen Bradley's PowerFlex 525 AC series of drives provide various motor control and flexible mounting choices with a power rating of 0.4-22kW (0.5-30HP) and several worldwide voltage classes ranging from 100-600V. These drives are ideal for powering motors such as conveyors, fans, pumps, and mixers since they can operate at temperatures as high as 158°F.
Motor Control Algorithms
PowerFlex 525 AC drives also provide an assortment of different motor control algorithms - such as Volts Per Hertz, Sensorless Vector Control, Closed Loop Velocity Vector Control, and Permanent Magnet Motor Control. It does this to accommodate many applications, some needing power efficiency, and safe torque-off. Safe Torque-Off is certified at PLd/SIL2 Cat 3 (for Power Equipment) under IEC 61508 - it removes rotational power from the motor without removing power from the drive for faster start-ups after a demand on the safety system has been activated.
Adapter Cards
Communication with the PowerFlex 525 drives is made possible by the PowerFlex 520 Series Communication Adaptor Cards through Integral RS485 with Modbus RTU/DSI, Embedded Ethernet/IP port, Dual-port Ethernet/IP option card, DeviceNet option card, and PROFIBUS DP option card. These cards can be deployed in the field without removing the complete drive if they are mounted in a modular chassis for each purpose and communicated through DSI (Device Serial Interface). When configured from a local or distant location, this could provide you access to some of the capabilities of these adaptors.
Packaging and Mounting
- The A, B, and C frame drives' DIN rail mounting feature make installation quick and straightforward. Additionally available is panel mounting, which offers more versatility.
- With Zero Stacking, power wires may be installed in any direction at temperatures up to 45 degrees Celsius. One will thereby free up priceless panel space.
- There are several solutions to satisfy EN 61800-3 Category C2 and 3 EMC standards without an external filter, thanks to the availability of integral filtering on all 200 V (230 VAC) or 400 V (415 VAC) ratings. This will save one's money.
- If one desires external filters, they are available in continuous ratings going up to 300 kW, each of which complies with EN 61800-3 Categories: C1 through 3 EM&Cs standards.
Optimized Performance
- When utilized on ungrounded distribution systems, a removable MOV to the ground and a relay pre-charge ensure trouble-free operation.
- Dynamic braking is made possible by an integral brake transistor, which is available in all grades and uses straightforward, inexpensive brake resistors.
- A jumper that allows 24V DC sink or source control for flexible control wiring.
- Drives with more than 15 HP/11 kW can have dual overload ratings. Standard duty: 150% for 3 seconds or 110% for 60 seconds of overload. Strong overload protection is provided by heavy duty: 150% overload for 60 seconds or 180% overload (200% programmable) for 3 seconds.
- Quiet operation is guaranteed with adjustable PWM frequency up to 16 kHz.
Available Inputs and Outputs
Depending on the version, a PowerFlex 525-series variable frequency drive may offer a variety of I/O ports, although all versions have 7 digital and 2 analog inputs. The outputs are restricted to 1 analog output, 2 optoisolated outputs, and 2 relay outputs for each type, albeit they may differ depending on the style selected. It is simple to make mistakes while configuring input points for the first time since they are all tied to a specific function by default.
This guide examines the procedure for setting up one's systems. The parameters one is dealing with are explained, and a step-by-step approach from start to finish is provided. One will utilize a single digital input, for example.
Hardware Wiring
The output of the relay must first be wired. These restrictions must be considered:
- The drive must provide 24V+ and -24V signals.
- The LED has polarization. Accepting the 24V+ signal directly or switching it through the relay will work.
Wiring for an output relay in a PowerFlex 525 Diagram demonstrates that the drive terminal 11 may draw a +24VDC signal directly. This terminal will always deliver this signal. The internal connection between this terminal and the S+ terminal, which is utilized for safety circuits, should be noted.
The "Digital Common" terminal 04 can connect to the -24VDC signal. However, the PCB jumper J5 will determine the polarity of this connection. The jumper's default value is "SRC," which causes the signal to be grounded. If J5 were set to SNK, the connector would be connected to +24VDC. This value must be carefully considered since without -24VDC. The output switching won't function.
The input signal will be shown using a normally open (NO) switch. These are limited by the following: - The controller has to toggle a digital input.
Digital Input Terminal 5 Wiring for the PowerFlex 525 shows that the push-button circuit is simple. On drive pin 11, a 24VDC contact may be utilized to transmit the signal while tying one side to DigIn TermBlk 05 when it is open. This terminal would display HIGH if it were closed.
Setting Parameters
One needs to identify the appropriate settings and set them up according to one's preferences now that the circuitry has been installed. For instance, check the datasheet if one is looking for a relay or digital input.
1. Relay Output Settings
The table that offers a starting place to customize the relay output may be found using the relay search and scrolling through the results. Output Relay 2 Settings in PowerFlex 525 identify the following crucial components:
- R5 and R6 are the Relay 2 terminals (as identified during the wiring step).
- The default setting for Relay 2 is Motor Running. One needs to adjust it.
- The reference for the Relay 2 Parameter is t081.
One needs to particularly value the parameter reference since one must modify the signal the relay reacts to.
PowerFlex 525 - T076 and T081 Parameter: All options for t076 and t081 parameters are available in Relay Out Settings.
Note: There are table settings and more options. This table also displays the parameters for both Relay 1 and Relay 2. Please be mindful of the parameter one would require based on whether one is using it as an input (for example, "HMI Control") or an output (for example, Voltage). Additionally, "ParamControl" or 13 from the list is specified since, in our scenario, one needs to look at managing the relay using the software. Furthermore, when a function has many ways to be controlled, it is referred to as an "output mode."
2. Digital Input Settings
Similarly, to a relay, one can search for digital inputs.
- PowerFlex 525 - Digital Terminal Settings provides an example of how the default setting is a Preset Frequency. One can use t065 to change which function the information has.
- PowerFlex 525 - Parameter t062- t068 Digital Input Settings shows how these settings work on all digital terminals.
It is important to note that the drive must be stopped before changing this parameter. Additionally, to set this parameter to Not Used or 0, one must do so inside the b013 and b014 registers.
Inclusion of On-board I/O
The PowerFlex 525 Variable Frequency Drive is used in many different fields. It has many Input and Output ports which can be configured for specific purposes by a PLC programmer to reduce the number of wires needed outside the machinery.
Certifications
The PowerFlex 525 series of drives have several certifications, including ACS 156, CE, Lloyd's Register, C-Tick, cUL, TUV, UL, ATEX, GOST-R, KCC, RoHS, and SEMI F47.