Summary of Changes2
Product Overview3
PowerFlex 527 AC Drives Feature3
PowerFlex 527 AC Drive Advanced Features4
Communications and Software6
Catalog Number Explanation7
Technical Specifications8
Environmental Specifications11
Certifications12
Product Selection13
Drive Dimensions and Weights14
Design Considerations15
Fuses and Circuit Breaker Ratings25
Accessories30
Safe Torque Off Function39
Additional Resources41
Summary of Changes
This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect
all changes.
Top icPa ge
Updated certification table12
Changed Circuit Breakers Bulletin 140M-C2E-C16 to 140M-D8E-C16 for 380...480V 3-
Phase Input Protection Devices
Added EMC Ferrite Cores and Terminators to Accessories32
28
2Rockwell Automation Publication 520-TD002D-EN-E - October 2020
PowerFlex 527 AC Drive Specifications
Product Overview
PowerFlex® 527 AC drives are 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. The PowerFlex 527 drive provides maximum flexibility and performance
ranging up to 30 HP and 22 kW.
Designed to connect and operate only with the ControlLogix® 1756-L7x, GuardLogix® 1756-L7xS, and CompactLogix™ 5370 controllers and
Studio 5000 Logix Designer® application. The PowerFlex 527 is programmed with the embedded motion instructions within Studio 5000®,
these are the same instructions that are used for Allen-Bradley Kinetix® servo drives. This streamlined approach provides a common user
experience and just one software package to learn and use. The commonality and use of consolidated integration tools helps save valuable
engineering time.
Maximize your system performance and productivity by taking advantage of the following key features that are offered in a PowerFlex 527
drive.
PowerFlex 527 AC Drives Feature
Design
•Designed to be used exclusively with Allen-Bradley Logix controllers.
•Designed for machine applications – such as pumps, fans, and in-feed and out-feed conveyors – that need speed control for induction
motors.
•Logix integration helps deliver a high level of motor coordination.
•Built-in dual-port EtherNet/IP supports multiple network topologies and Device Level Ring functionality.
•Integrated Safety – controller-based safety delivered via EtherNet/IP. SIL 3 / PLe Cat 3.
•Reduce your spare parts with a standard control module that can be used across the entire power range.
•Support for an incremental encoder accessory card 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.
•Zero Stacking 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 520Series 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
•Removable MOV to ground provides trouble-free operation when used on ungrounded distribution systems.
•A relay precharge 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.
Rockwell Automation Publication 520-TD002D-EN-E - October 20203
PowerFlex 527 AC Drive Specifications
PowerFlex 527 Control I/O Wiring Block Diagram
(1) When using an opto output with an inductive load such as a relay, install a
recovery diode parallel to the relay as shown, to prevent damage to the output.
(2) Do not short across Terminals 01 and 011.
•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 8 kHz delivers quiet operation.
PowerFlex 527 AC Drive Advanced Features
Control Performance
•Frequency Control with the following options:
• Volts per Hertz (V/Hz)
• Sensorless Vector Control (SVC)
• Sensorless Vector Control (SVC) Economizer
•Position Loop, including:
- Closed Loop Position Vector Control (with optional encoder card)
•Velocity Loop, including:
• Closed Loop Velocity Vector Control (with optional encoder card)
I/O Wiring
•Two Analog Inputs (one current and one voltage) are independently
isolated from the rest of the drive I/O.
•Four Digital Inputs provide application versatility.
•One Analog Output is jumper selectable between 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 Opto Outputs and two Relay Outputs (one form A and one form
B) can be used to indicate various drive, motor or logic conditions.
Communications
•Built-in dual-port for EtherNet/IP allows easy configuration,
control, and collection of drive data over the network. It also
supports Device Level Ring (DLR) topologies, providing faulttolerant connectivity for optimum drive availability.
•Online EDS file creation with RSNetWorx™ providing ease of set-up
on a network.
Common DC Bus Installations
Safety 1
Safety 2
Safety +24V
Relay 1 N.O.
Relay 1 Common
Relay 2 Common
Relay 2 N.C.
S1
S2
S+
R1
R2
R5
R6
R1
R2 R5 R601
J1
SNK
Digital In
Analog Out
SRC
(2)
02 03 04 05 06 07
Typical
Typical
SNK wiring
C1 C2
C1
C2
SRC wiring
(1)
(1)
Ethernet
Comm Common
Pot must be
1...10 k ohm
2 W min.
24V
Common
(1)
SNK
+24V
+10V
0-10V
0/4-20 mA
J2
ACO
AVO
02
03
04
05
06
07
11
12
13
14
15
16
17
Digital In 1
Digital In 2
Digital In 3
Digital In 4
Opto Output 1
Opto Output 2
+24V DC
+10V DC
±10V Input
Analog Common
4-20mA Input
Analog Output
Opto Common
Digital Common
01
SRC
Common DC Bus offers additional inherent breaking capabilities by
utilizing the drives/loads on the bus for energy absorption offering
higher efficiency and cost savings. The PowerFlex 527 drive has been
optimized for use in Common DC Bus or Shared DC Bus installations.
•Direct DC Bus connection to power terminal blocks.
4Rockwell Automation Publication 520-TD002D-EN-E - October 2020
(2)
11
12 13 14 15 16 17
PowerFlex 527 AC Drive Specifications
I/OConnection ExampleI/OConnection 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
External
Power
Supply
to
SHLD
Encoder Wiring Examples
Improved Ride-through
Operation Down to 1/2 Line Voltage
The PowerFlex 527 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 527 drive also supports enhanced inertia ride-through for
additional low voltage mitigation.
•Selectable 1/2 line voltage operation.
•Increased power loss ride-through.
Basic Position Control
Closed loop position control using Logix motion instructions such as MAM (Motion Axis Move). For more information on Logix motion
instructions, see the Logix 5000™ Controllers Motion Instructions Reference Manual, publication MOTION-RM002
.
Closed Loop Feedback
Encoder Option Card
The PowerFlex 527 drive allows for configurable closed loop control with an optional encoder card for either speed or position feedback for
improved speed regulation or basic position control.
•Improved speed regulation
•Basic position control
Feedback Details
Line Driver Type Incremental Encoder Option Card
•Quadrature (dual channel)
•5V/12V DC supply, 10 mA min per channel
•Single Ended or Differential (A, B, and Z Channel)
•Duty Cycle of 50%, +10%
•Input Frequency up to 250 kHz
•DIP switches to select between HTL or TTL encoder signals
– for 25-ENC-2/B only
+12V DC
(250 mA)
+V
Cm
Common
ZZ
to SHLD
BB
AA
to Power Supply
Common
+V
Marker
Cm
Z NOT
Z-
Marker Z
Z
B-
B
B
A-
A
A
to SHLD
to SHLD
+V
Marker
Cm
Z NOT
Z-
Marker Z
Z
B NOT
B-
B
B
A NOT
A-
A
A
Safety Inside using Safe Torque Off Function
Safe Torque Off is a standard feature that can be applied through either hardwired safety or Integrated Safety via an EtherNet/IP network.
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.
•Built-in safety reduces wiring and saves on installation space.
•Meets ISO 13849-1 standards and provides safety ratings up to and including SIL 3/PLe.
Rockwell Automation Publication 520-TD002D-EN-E - October 20205
PowerFlex 527 AC Drive Specifications
Linear Topology
Star Topology
Ring Topology
Only Rockwell Automation supports
rings at the device level (DLR)
Frame AFrame BFrame CFrame DFrame E
Communications and Software
Versatile Programming and Network Solutions
•A network can be configured using PowerFlex 527 drives
for flexible configuration capabilities.
•Built-in dual-port for EtherNet/IP
EtherNet/IP is an established, broadly adopted network that helps
simplify and enhance machine design and operation. Dual-port
EtherNet/IP connectivity supports linear and ring topologies, and
Device Level Ring (DLR) functionality.
The application of the CIP Safety™ protocol enables the
simultaneous transmission of safety and standard control data
and diagnostics information through EtherNet/IP.
PC Programming Software
Studio 5000 Logix Designer application
•PowerFlex 527 drives are used exclusively with
Allen-Bradley Logix controllers.
•Drives are programmed using the motion instructions in Studio 5000 Logix Designer application.
(a)
•PowerFlex 527 drives feature drive configuration that is stored in the Logix controller, supporting fast, automatic device replacement.
PowerFlex 527 Drive Family
(a) Studio 5000 Logix Designer application (formerly RSLogix 5000®) version 24 or later is required.
6Rockwell Automation Publication 520-TD002D-EN-E - October 2020
PowerFlex 527 AC Drive Specifications
CodeType
25CPowerFlex 527
(1) Normal and Heavy Duty ratings are available for drives above 15 HP / 11 kW.
(2) 110% Overload capability for up to 60 s, 150% for up to 3 s.
Rockwell Automation Publication 520-TD002D-EN-E - October 20207
PowerFlex 527 AC Drive Specifications
Technical Specifications
Protection
SpecificationsPowerFlex 527
Bus Overvoltage Trip
100...120V AC Input:
200...240V AC Input:
380...480V AC Input:
525...600V AC Input:
Bus Undervoltage Trip
100...120V AC Input:
200...240V AC Input:
380...480V AC Input:
525...600V AC Input
Power Ride-Thru:100 ms
Logic Control Ride-Thru:0.5 s min, 2 s typical
Electronic Motor Overload Protection:
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
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)
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)
Provides class 10 motor overload protection according to NEC article 430 and motor over-temperature protection according to
NEC article 430.126 (A) (2). UL 508C File 29572.
SpecificationsPowerFlex 527
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
Short Circuit Rating, max:100,000 Amps Symmetrical
Actual Short Circuit Rating:Determined by AIC Rating of installed fuse/circuit breaker
Transistor Type:Insulated gate bipolar transistor (IGBT)
Internal DC Bus Choke
200…240V AC Input:
380…480V AC Input:
525…600V AC Input:
Only for Frame E drive ratings
11 kW (15 HP)
15…18.5 kW (20…25 HP) — Heavy Duty
15…18.5 kW (20…25 HP) — Heavy Duty
Control
SpecificationsPowerFlex 527
• Frequenc y Control:
– Basic Volts/Hertz
– Fan/Pump Volts/Hertz
– Sensorless Vector Control (SVC)
Method
Carrier Frequency2...8 kHz, Drive rating based on 4 kHz
Frequency AccuracyWithin ±0 .05% of set output frequency
Performance
V/Hz (Volts per Hertz):
SVC (Sensorless Vector):
SVC Economizer:
Performance with Encoder
Closed Loop Velocity Vector Control:±0.1% of base speed across a 100:1 speed range
Output Voltage Range:0V to rated motor voltage
Output Frequency Range:0…590 Hz (programmable)
Efficiency:97.5% (typical)
– Sensorless Vector Control (SVC) Economizer
• Position Loop:
– Closed Loop Position Vector Control (with optional encoder card)
±1% of base speed across a 60:1 speed range
±0.5% of base speed across a 100:1 speed range
±0.5% of base speed across a 100:1 speed range
8Rockwell Automation Publication 520-TD002D-EN-E - October 2020
PowerFlex 527 AC Drive Specifications
Control (Continued)
SpecificationsPowerFlex 527
Stop Modes:Multiple programmable stop modes including – Disable and Coast, Current Decel and Disable, and Ramped Decel and Disable
Accel/Decel:
Intermittent Overload
Normal Duty:
Heavy Duty:
“REAL” tag programmable with Studio 5000 motion instructions.
For more information, see the Logix 5000 Controllers Motion Instructions Reference Manual, publication MOTION-RM002
110% Overload capability for up to 60 s, 150% for up to 3 s
Applies to the following drives:
•25C-B048*
•25C-B062*
•25C-D030*
•25C-D030*
•25C-D037*
•25C-D043*
• 25C-E022*
•25C-E027*
•25C-E032*
150% Overload capability for up to 60 s, 180% for up to 3 s
Applies to following drives:
• 25C-V2P5*
• 25C-V4P8*
•25C-V6P0*
• 25C-A2P5*
• 25C-A4P8*
• 25C-A8P0*
•25C-A011*
• 25C-B2P5*
•25C-B5P0*
•25C-B8P0*
•25C-B011*
•25C-B017*
•25C-B024*
•25C-B032*
•25C-D1P4*
• 25C-D2P3*
•25C-D4P0*
•25C-D6P0*
• 25C-D010*
•25C-D013*
•25C-D017*
•25C-D024*
•25C-E0P9*
•25C-E1P7*
•25C-E3P0*
• 25C-E4P2*
•25C-E6P6*
•25C-E9P9*
•25C-E012*
•25C-E019*
.
Rockwell Automation Publication 520-TD002D-EN-E - October 20209
PowerFlex 527 AC Drive Specifications
Control Inputs
SpecificationsPowerFlex 527
Quantity:(4) Programmable
Digital
Analog
Safety
(per channel)
Current:6 mA
Type
Source Mode (SRC):
Sink Mode (SNK):
Quantity:(2) Isolated, ±10V and 4…20 mA
Specification
Resolution:
±10V DC Analog:
4…20 mA Analog:
External Pot:
Input Current:<10 mA
Input ON Voltage, max:18…26.4V DC
Input OFF Voltage, max:5V DC
Input ON Current:10 mA
Input OFF Current:500 µA
Pulse Rejection Width:700 µs
External Power Supply:SELV/PELV
Input Type:Optically isolated and reverse voltage protected
18…24V = ON, 0…6V = OFF
0…6V = ON, 18…24V = OFF
10-bit
100k ohm input impedance
250 ohm input impedance
1…10k ohm, 2 W min
Control Outputs
SpecificationsPowerFlex 527
Quantity:(2) 1 Programmable Form A and 1 Programmable Form B
Relay
Opto
Analog
Specification
Resistive Rating:
Inductive Rating:
Quantity:(2) Programmable
Specification:30V DC, 50 mA Non-inductive
Quantity:(1) Non-Isolated 0…10V or 4…20 mA
Specification
Resolution:
0…10V DC Analog:
4…20 mA Analog:
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
10-bit
1 kΩ min
525 Ω max
Encoder
SpecificationsPowerFlex 527
Type:Incremental, dual channel
Supply:5V, 12V, 250 mA
Quadrature:
Duty Cycle:50%, +10%
Requirements:
90°, ±27° @ 25 °C
Encoders must be line driver type, quadrature (dual 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.
10Rockwell Automation Publication 520-TD002D-EN-E - October 2020
Environmental Specifications
IMPORTANT
Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive
gas, vapors vapors, or dust. If the drive is not going to be installed for a period of time, it must be
stored in an area where it will not be exposed to a corrosive atmosphere.
Fram e
Size
Operating and NonoperatingNonoperating (Transportation)
Force (Shock/Vibration)Mounting TypeForce (Shock/Vibration)Mounting Type
A15 g / 2 gDIN rail or screw30 g/ 2.5 gScrew only
B15 g / 2 gDIN rail or screw30 g/ 2.5 gScrew only
C15 g / 2 gDIN rail or screw30 g/ 2.5 gScrew only
D15 g / 2 gScrew only30 g/ 2.5 gScrew only
E15 g / 1.5 gScrew only30 g/ 2.5 gScrew only
SpecificationsPowerFlex 527
Altitude
Without derating:
With derating:
Surrounding Air Temperature, max.
Without derating:
With derating:
Storage Temperature
Frame A...D:
Frame E:
Atmosphere:
Relative Humidity:0…95% noncondensing
Shock:
Vibration:
See Current Derating Curves on page 16 for derating guidelines.
1000 m (3300 ft) max.
Up to 4000 m (13,200 ft) max., except for 600V drives at 2000 m (6600 ft) max.
See Current Derating Curves
°C (-4…+122 °F)
-20…+50
°C (-4…+140 °F) or -20…+70 °C (-4…+158 °F) with optional Control Module Fan kit.
-20…+60
°C (-40…+185 °F)
-40…+85
°C (-40…+158 °F)
-40…+70
Complies with IEC 60068-2-27
Complies with IEC 60068-2-6:2007
PowerFlex 527 AC Drive Specifications
on page 16 for derating guidelines.
Conformal Coating:
Surrounding Environment Pollution
Degree
Pollution Degree 1 & 2:
Sound Pressure Level (A-weighted)
Frame A & B:
Frame C:
Frame D:
Frame E:
Complies with:
IEC 60721-3-3 to level 3C2 (chemical and gases only)
All enclosures acceptable.
Measurements are taken 1 m from the drive.
53 dBA max
57 dBA max
64 dBA max
68 dBA max
Rockwell Automation Publication 520-TD002D-EN-E - October 202011
PowerFlex 527 AC Drive Specifications
Functional
Safety
Type
Approved
www.tuv.com
ID 0600000000
Certifications
CertificationPowerFlex 527
c-UL-us
Listed to UL508C and CAN/CSA-C22.2 No. 14-05.
Australian Communications and Media Authority
RCM
CE
Functional Safety
KCC
EAC
AC 156
SEMI F47
ODVAODVA conformance tested to EtherNet/IP specifications
Lloyd’s RegisterLloyd’s Register Type Approval Certificate 15/80016(E1)
IEEE P1668Product meets the requirements of IEEE P1668
RoHSCompliant with the European “Restriction of Hazardous Substances” 2011/65/EU Directive
The drive is also designed to meet the appropriate portions of the following specifications:
NFPA 70 - US National Electrical Code
NEMA ICS 7.1 - Safety standards for Construction and Guide for Selection, Installation, and Operation of Adjustable Speed Drive Systems.
In conformity with the following:
Radiocommunications Act: 1992 (including amendments up to 2018)
Radiocommunications Standard: 2017
Radiocommunications Labelling Notice: 2017
Standards applied:
EN 61800-3
In conformity with the following European Directives:
2014/35/EU Low Voltage Directive (LVD)
2014/30/EU EMC Directive (EMC)
2006/42/EC Machinery Directive (MD)
2011/65/EU RoHS Directive (RoHS)
Standards applied:
EN 61800-3
EN 61800-5-1
TÜV Rheinland
Standards applied:
EN ISO 13849-1
EN 61800-5-2
EN 62061
EN 60204-1
IEC 61508 Part 1-7
Certified to ISO 13849-1 SIL3/PLe with embedded Safe Torque Off function
Certified to ISO 61800-5-2 and EN 62061 SIL3/PLe with Network Torque 0ff function
Meets Functional Safety (FS) when used with embedded Safe Torque Off function
Korean Registration of Broadcasting and Communications Equipment
Compliant with the following standards:
Article 58-2 of Radio Waves Act, Clause 3
Customs Union:
Low Voltage TP CU 004/2011
EMC TP CU 020/2011
Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification Testing of Nonstructural Components and 2003
International Building Code for worst-case seismic level for USA excluding site class F
Certified compliant with the following standards:
SEMI F47
IEC 61000-4-11
IEC 61000-4-34
12Rockwell Automation Publication 520-TD002D-EN-E - October 2020
(1) A non-filtered drive is not available for 380…480V AC 25 HP (18.5 kW) and 30 HP (22.0 kW) ratings. Filtered drives are available, however you must verify that the application will support a
filtered drive.
(2) Catalogs 25C-037N114 and 25C-043N114 come with an EMC filter.
Input Voltage RangeTotal Watts LossFrame SizeNormal DutyHeavy Duty
Drive Dimensions and Weights
Dimensions are in mm and (in.). Weights are in kg and (lb).
•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 Drive Dimensions and Weights on page 14 for mounting dimensions.
PowerFlex 527 AC Drive Specifications
50 mm
(2.0 in.)
50 mm
(2.0 in.)
25 mm
(1.0 in.)
50 mm
(2.0 in.)
25 mm
(1.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
(1)
50 mm
(2.0 in.)
(2)
(2.0 in.)
50 mm
50 mm
(1)
(2.0 in.)
25 mm
(1.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
(1)
50 mm
(1)
(2.0 in.)
(2)
(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.
Rockwell Automation Publication 520-TD002D-EN-E - October 202015
PowerFlex 527 AC Drive Specifications
Single DriveZero Stacking
Ambient Temperature (°C)
40
100
90
110
120
80
70
60
50
45403530
60 65 70 75 80
5550
Percentage of Rated Current (%)
with Control
Module Fan Kit
IP 20/Open Type
Ambient Temperature (°C)
40
100
90
110
120
80
70
60
50
45403530
60 65 70 75 80
5550
Percentage of Rated Current (%)
IP 30/NEMA 1
with Control
Module Fan Kit
IP 20/Open Type
Single DriveZero Stacking
Ambient Temperature (°C)
40
100
90
120
110
80
70
60
50
30 35
70 75 80
60 6550 5540 45
Percentage of Rated Current (%)
with Control
Module Fan Kit
IP 20/Open Type
Ambient Temperature (°C)
40
100
90
120
110
80
70
60
50
30 35
70 75 80
60 6550 5540 45
Percentage of Rated Current (%)
with Control
Module Fan Kit
IP 20/Open Type
Ambient Operating Temperatures
See Accessories on page 30 for option kits.
Ambient Temperature
Mounting
Vertic al
Enclosure Rating
IP 20/Open Type
IP 30/NEMA 1/UL Type 145 °C (113 °F)55 °C (131 °F)—
Vertical, Zero StackingIP 20/Open Type45 °C (113 °F)—65 °C (149 °F)
Horizontal
with Control Module Fan Kit
Horizontal, Zero Stacking
with Control Module Fan Kit
(1) 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.
(2) For catalogs 25C-D1P4N104 and 25C-E0P9N104, the temperature that is listed under the Max (Derate) column is reduced by 5 °C (9 °F) for all mounting methods.
(3) For catalogs 25C-D1P4N104 and 25C-E0P9N104, the temperature that is 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.
(4) Requires installation of the PowerFlex 520-Series Control Module Fan Kit, catalog number 25-FANx-70C.
(5) Catalogs 25C-D1P4N104 and 25C-E0P9N104 cannot be mounted using either of the horizontal mounting methods.
IP 20/Open Type50 °C (122 °F)—70 °C (158 °F)
(4)(5)
IP 20/Open Type45 °C (113 °F)—65 °C (149 °F)
(4)(5)
(1)
MinMax (No Derate)
-20 °C (-4 °F)
Max (Derate)
(2)
Max with Control Module
Fan Kit (Derate)
50 °C (122 °F)—70 °C (158 °F)
(3)(4)
Current Derating Curves
Vertical Mounting
Horizontal Mounting/Floor
16Rockwell Automation Publication 520-TD002D-EN-E - October 2020
PowerFlex 527 AC Drive Specifications
Altitude (m)
Percentage of Rated Current (%)
40
90
100
110
120
80
70
60
50
0
4000
300020001000
Altitude (m)
Ambient Temperature (°C)
20
50
60
40
30
0
4000
300020001000
Derating Guidelines for High Altitude
The drive can be used without derating at a maximum altitude of 1000 m (3300 ft).
If the drive is used above 1000 m (3300 ft):
•Derate the maximum ambient temperature by 5 °C (41 °F) for every additional 1000 m (3300 ft), subject to limits listed in the Altitude
Limit (Based on Voltage) table below.
Or
•Derate the output current by 10% for every additional 1000 m (3300 ft), subject to limits listed in the Altitude Limit (Based on Voltage)
table below.
Altitude Limit (Based on Voltage)
Drive RatingCenter Ground (Wye Neutral)
100…120V 1-Phase6000 m6000 m
200…240V 1-Phase2000 m2000 m
200…240V 3-Phase6000 m2000 m
380…480V 3-Phase4000 m2000 m
525…600V 3-Phase2000 m2000 m
Corner Ground, Impedance
Ground, or Ungrounded
High Altitude
Debris Protection
Take precautions to prevent debris from falling through the vents of the drive housing during installation.
Storage
•Store within an ambient temperature range of -40…+85 °C
•Store within a relative humidity range of 0
•Do not expose to a corrosive atmosphere.
(a) The maximum ambient temperature for storing a Frame E drive is 70 °C.
(a)
.
…95%, noncondensing.
Rockwell Automation Publication 520-TD002D-EN-E - October 202017
PowerFlex 527 AC Drive Specifications
Power Module
AC Supply Source Considerations
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-to-line voltage. To disconnect these
devices, remove the jumper that is shown in the following diagrams.
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)
IMPORTANTTighten screw after jumper removal.
Phase to Ground MOV Removal
AC Input
R/L1
S/L2
T/L3
Jumper
1234
Three-Phase
18Rockwell Automation Publication 520-TD002D-EN-E - October 2020
PowerFlex 527 AC Drive Specifications
SHLD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
Esc
Sel
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated voltage of the drive (see Input Power Conditions on page 19). Listed
in the Input Power Conditions table below are certain input power conditions, which may cause component damage or reduction in product
life. If any of these conditions exist, install one of the devices that are listed under the heading Corrective Action on the line side of the drive.
IMPORTANT Only one device per branch circuit is required. It should be mounted closest to the branch and sized to handle the total
current of the branch circuit.
Input Power Conditions
Input Power ConditionCorrective Action
Low Line Impedance (less than 1% line reactance)
Greater than 120 kVA supply 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
240V open delta configuration (stinger leg)
(1) See Accessories on page 30 for accessory ordering information.
(2) 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,” and so on. 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 Bulletin 1321-3R Series Line Reactors
(2)
• Install Line Reactor
• or Isolation Transformer
• Install Line Reactor
• or Isolation Transformer
• Remove MOV jumper to ground.
• or Install Isolation Transformer with grounded secondary if necessary.
• Install Line Reactor
on page 35 for specific line reactor part numbers.
(1)
(1)
(1)
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
Ground Fault Monitoring
If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping.
Safety Ground - (PE)
Rockwell Automation Publication 520-TD002D-EN-E - October 202019
This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder,
joist), a floor ground rod or busbar. Grounding points must comply with national and local industrial safety regulations and/or electrical
codes.
PowerFlex 527 AC Drive Specifications
Motor Ground
The motor ground must be connected to one of the ground terminals on the drive.
Shield Termination - SHLD
Either of the safety ground terminals that are 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). Use a shield
terminating or EMI clamp to connect the shield to the safety ground terminal. The earthing plate or conduit box option may be used with a
cable clamp for a grounding point for the cable shield.
When shielded cable is used for control and signal wiring, the shield should be grounded at the source end only, not at the drive end.
RFI Filter Grounding
Using a drive with filter may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations with
grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground.
Verify that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not
rely on flexible cables and should exclude any form of plug or socket that would permit inadvertent disconnection. Some local codes may
require redundant ground connections. The integrity of all connections should be periodically checked.
Power Wiring
ATTENTION: National Codes and standards (NEC, VDE, BSI, and so on) and local codes outline provisions for safely
installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch
circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.
ATTENTION: To avoid a possible shock hazard that is caused by induced voltages, unused wires in the conduit must be
grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this
conduit should be disabled. This will help minimize the possible shock hazard from “cross coupled” power leads.
Motor Cable Types Acceptable for 100...600 Volt Installations
Various cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3 m (1 ft) for every 10 m (32.8 ft) of length. In all cases, long parallel runs
must be avoided. Do not use cable with an insulation thickness fewer than 15 mils (0.4 mm/0.015 in.). Do not route more than three sets of
motor leads in one conduit to minimize “cross talk”. If more than three drive/motor connections per conduit are required, shielded cable
must be used.
UL installations above 50 °C ambient must use 600V, 90 °C wire.
UL installations in 50 °C ambient must use 600V, 75 °C or 90 °C wire.
UL installations in 40 °C ambient should use 600V, 75 °C or 90 °C wire.
Use copper wire only. Wire gauge requirements and recommendations are based on 75 °C. Do not reduce wire gauge when using higher
temperature wire.
ATTENTION: The distance between the drive and motor must not exceed the maximum cable length that is stated in the
Motor Cable Length Restrictions Tables in “Wiring and Grounding for Pulse Width Modulated (PWM) AC Drives,” publication
DRIVES-IN001
20Rockwell Automation Publication 520-TD002D-EN-E - October 2020
.
PowerFlex 527 AC Drive Specifications
Unshielded Cable
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 that is chosen must have a minimum insulation thickness of 15 mils and should not have large variations
in insulation concentricity.
ATTENTION: Do not use THHN or similarly coated wire in wet areas.
Shielded/Armored Cable
Shielded cable contains all the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain
much of the noise that is generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with
sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the
distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of
communications / networking are also good candidates for shielded cable.
Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance
of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices
such as terminator networks. See Reflected Wave in “Wiring and Grounding for Pulse Width Modulated (PWM) AC Drives,”
publication DRIVES-IN001
.
Consideration should be given to all general specifications dictated by the environment of the installation, including temperature, flexibility,
moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable
manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment.
A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has four XLPE insulated conductors with a 100%
coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket.
Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the
newer cables twist four conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable
charging current required and reduce the overall drive performance. Unless specified in the individual distance tables as tested with the
drive, these cables are not recommended and their performance against the lead length limits supplied is not known.
Recommended Shielded Wire
LocationRating/TypeDescription
• Four tinned copper conductors with XLPE insulation.
• Three tinned copper conductors with XLPE insulation.
• 5 mil single helical copper tape (25% overlap min) with three bare copper grounds
in contact with shield.
• PVC jacket.
• Three bare copper conductors with XLPE insulation and impervious corrugated
continuously welded aluminum armor.
• Black sunlight resistant PVC jacket overall.
• Three copper grounds on #10 AWG and smaller.
Standard (Option 1)
Standard (Option 2)
Class I and II;
Division I and II
600V, 90 °C (194 °F) XHHW2/RHW-2
Anixter B209500…B209507, Belden 29501…29507, or
equivalent
Tray rated 600V, 90 °C (194 °F)
RHH/RHW-2 Anixter OLF-7xxxxx or equivalent
Tray rated 600V, 90 °C (194 °F)
RHH/RHW-2 Anixter 7V-7xxxx-3G or equivalent
Rockwell Automation Publication 520-TD002D-EN-E - October 202021
PowerFlex 527 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). See Reflected Wave in “Wiring and Grounding for Pulse Width
Modulated (PWM) AC Drives,” publication DRIVES-IN001
.
The reflected wave data applies to all carrier frequencies 2…8 kHz.
For 240V ratings and lower, reflected wave effects do not need to be considered.
Output Disconnect
The drive is intended to be commanded by control input signals that will start and stop the motor. A device that routinely disconnects then
reapplies output power to the motor for the purpose of starting and stopping the motor should not be used. If it is necessary to disconnect
power to the motor with the drive outputting power, use Logix Designer application to disable the drive (Aux Fault or Coast-to-Stop).
Power Terminal Block Wire Specifications
Fram e
A
B
C
D
E
(1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations.
Wire Size max
5.3 mm
8.4 mm
8.4 mm
13.3 mm
26.7 mm
(1)
2
(10 AWG)0.8 mm2 (18 AWG)
2
(8 AWG)2.1 mm2 (14 AWG)
2
(8 AWG)2.1 mm2 (14 AWG)
2
(6 AWG)5.3 mm2 (10 AWG)
2
(3 AWG)8.4 mm2 (8 AWG)
Wire Size min
(1)
Tor qu e
1.76…2.16 N•m (15.6…19.1 lb•in)
1.76…2.16 N•m (15.6…19.1 lb•in)
1.76…2.16 N•m (15.6…19.1 lb•in)
1.76…2.16 N•m (15.6…19.1 lb•in)
3.09…3.77 N•m (27.3…33.4 lb•in)
Common Bus/Precharge Notes
If drives are used with a disconnect switch to the common DC bus, then an auxiliary contact on the disconnect must be connected to a
digital input of the drive.
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.
Important points to remember about I/O wiring:
•Always use copper wire.
•Wire with an insulation rating of 600V or greater is recommended.
•Control and signal wires should be separated from power wires by at least 0.3 m (1 ft).
IMPORTANTI/O terminals labeled “Common” are not referenced to the safety ground (PE) terminal and are designed to greatly
reduce common mode interference.
ATTENTION: Driving the 4…20 mA analog input from a voltage source could cause component damage. Verify proper
configuration before applying input signals.
22Rockwell Automation Publication 520-TD002D-EN-E - October 2020
ATTENTION: Due to its control circuitry difference from the PowerFlex 523 and PowerFlex 525 drives, connecting
Terminals 01 and 11 on the PowerFlex 527 drive causes an internal short and results in some internal components incurring
damage to the control module I/O circuitry.
Signal and Control Wire Types
Recommendations are for 50 °C ambient temperature.
75 °C wire must be used for 60 °C ambient temperature.
90 °C wire must be used for 70 °C ambient temperature.
Recommended Signal Wire
PowerFlex 527 AC Drive Specifications
Signal Type/Where Used
Analog I/O8760/9460
Remote Pot8770
Encoder9728/9730
(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.
Belden Wire Types (or equivalent)
(1)
DescriptionInsulation Rating min
0.750 mm2 (18 AWG), twisted-pair, 100% shield with drain
2
0.750 mm
0.196 mm
(18 AWG), 3 conductor, shielded
2
(24 AWG), individually shielded pairs
(2)
300V,
60 °C (140 °F)
Recommended Control Wire for Digital I/O
TypeWire TypesDescriptionInsulation Rating min
Unshielded
Shielded
Per US NEC or applicable national or local
code
Multi-conductor shielded cable such as
Belden 8770 (or equivalent)
–
0.750 mm
2
(18 AWG), 3 conductor, shielded.
300V,
60 °C (140 °F)
Maximum Control Wire Recommendation
Do not exceed control wiring length of 30 m (100 ft). Control signal cable length is highly dependent on electrical environment and installation
practices. To improve noise immunity, the I/O terminal Common may be connected to ground terminal/protective earth. When using the
embedded Ethernet ports, terminal C1 is the connection for the Ethernet shield, and a ground wire must be connected to a clean ground.
Control I/O Terminal Block Wire Specifications
Fram e
A…E
(1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations.
Wire Size max
1.3 mm
(1)
2
(16 AWG)0.13 mm2 (26 AWG)
Wire Size min
(1)
Tor qu e
0.71…0.86 N•m (6.2…7.6 lb•in)
Machinery Directive (2006/42/EC)
•EN ISO 13849-1:2008+AC:2009 – Safety of machinery – Safety-related parts of control systems -Part 1: General principles for design.
•EN 62061:2005+A1:2013 – Safety of machinery – Functional safety of safety-related electrical, electronic, and programmable electronic
control systems.
•EN 60204-1:2006+A1:2009 – Safety of machinery – Electrical equipment of machines - Part 1: General requirements.
•EN 61800-5-2:2007 – Adjustable speed electrical power drive systems - Part 5-2: Safety requirement – Functional.
Rockwell Automation Publication 520-TD002D-EN-E - October 202023
PowerFlex 527 AC Drive Specifications
R/L1
S/L2
T/L3
U/T1
V/T2
W/T3
EMI ttings and metal conduit
IP 30/NEMA 1/UL Type 1
option kit or EMC kit
Shielded enclosure
(1)
Building structure steel
Enclosure ground connection
EMI lter
L1'
L2'
L3'
L1
L2
L3
Shielded motor cable
Esc
Sel
Connections and Grounding
(1) Some installations require a shielded enclosure. Keep wire length as short as possible between the enclosure entry point and the EMI filter.
PowerFlex 527 RF Emission Compliance and Installation Requirements
Standard/Limits
Filter Type
EN61800-3 Category C1
EN61000-6-3
CISPR11 Group 1 Class B
Internal—10 m (33 ft)20 m (66 ft)
(1)
External
(1) See Accessory Dimensions on page 36 for more information on optional external filters.
30 m (16 ft)100 m (328 ft)100 m (328 ft)
EN61800-3 Category C2
EN61000-6-4
CISPR11 Group 1 Class A
(Input power ≤ 20 kVA)
EN61800-3 Category C3 (I ≤ 100 A)
CISPR11 Group 1 Class A
(Input power > 20 kVA)
24Rockwell Automation Publication 520-TD002D-EN-E - October 2020
PowerFlex 527 AC Drive Specifications
Fuses and Circuit Breaker Ratings
The PowerFlex 527 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.
The tables on pages 26
…29 provide drive ratings and recommended AC line input fuse and circuit breaker information. Both types of short
circuit protection are acceptable for UL and IEC requirements. Sizes that are listed are the recommended sizes based on 40 °C (104 °F) and
the U.S. N.E.C. Other country, state, or local codes may require different ratings.
Fusing
The recommended fuse types are listed in the tables that are found on pages 26…29. If available current ratings do not match those listed in
the tables that are provided, choose the next higher fuse rating.
•IEC – BS88 (British Standard) Parts 1 & 2
(a)
, EN60269-1, Parts 1 & 2, type GG or equivalent should be used.
•UL – UL Class CC, T, RK1, or J should be used.
Circuit Breakers
The “non-fuse” listings in the tables found on pages 26…29 include inverse time circuit breakers, instantaneous trip circuit breakers (motor
circuit protectors) and 140M self-protected combination motor controllers. If one of these is chosen as the desired protection method, the
following requirements apply:
•IEC – Both types of circuit breakers and 140M self-protected combination motor controllers are acceptable for IEC installations.
•UL – Only inverse time circuit breakers and the specified 140M self-protected combination motor controllers are acceptable for UL
installations.
When using Bulletin 140M or UL489 rated circuit breakers, the following guidelines that are listed must be followed to meet the NEC
requirements for branch circuit protection.
•Bulletin 140M can be used in single motor applications.
•Bulletin 140M can be used up stream from the drive without the need for fuses.
If the DC Bus terminals or the Dynamic Brake terminals are used, the drive must be installed in an enclosure and fuses must be used for
input protection (for CE applications only). The ventilated enclosure must be IP 20 rating or higher and at least 1.5x size larger than the drive.
(a) Typical designations include, but may not be limited to the following;
26Rockwell Automation Publication 520-TD002D-EN-E - October 2020
(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.
(2) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.
(3) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See the Use of Motor Protection Circuit Breakers with Variable-Frequency Drives Application Techniques, publication 140M-AT002
(4) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.
(5) 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.
1.00.75 1.00.75 5.02.7 5.8A100-C091015140U-D6D3-B80 140M-C2E-B63CLASS RK5, CC, J, or T / DLS-R-15140U-D6D3-B80 140M-C2E-B63
2.01.52.01.58.04.3 9.5A100-C121520140U-D6D3-C10140M-C2E-C10CLASS RK5, CC, J, or T / DLS-R-20 140U-D6D3-C10 140M-C2E-C10
3.02.23.02.211.06.3 13.8A100-C232030140U-D6D3-C15140M-C2E-C16CLASS RK5, CC, J, or T / DLS-R-30 140U-D6D3-C15 140M-C2E-C16
5.04.05.04.017.59.6 21.1B100-C233045140U-D6D3-C25 140M-F8E-C25CLASS CC, J, or T / 45140U-D6D3-C25 140M-F8E-C25
7.55.57.55.524.012.2 26.6C100-C373560140U-H6C3-C35 140M-F8E-C32CLASS CC, J, or T / 60140U-H6C3-C35 140M-F8E-C32
10.0 7.510.0 7.532.215.9 34.8D100-C434570140U-H6C3-C60 140M-F8E-C45CLASS RK5, CC, J, or T / DLS-R-70 –140M-F8E-C45
15.0 11.015.0 11.048.320.1 44.0E100-C606090140U-H6C3-C70 140M-F8E-C45CLASS CC, J, or T / 90–140M-F8E-C45
20.0 15.0 15.0 11.062.125.6 56.0E100-C7270125140U-H6C3-C90 140M-H8P-C70CLASS CC, J, or T / 125–140M-H8P-C70
(1)
(1)
25C-B5P0N104
(1)
25C-B8P0N104
25C-B011N104
(1)
(1)
25C-B017N104
25C-B024N104
(2)
(1)
(2)
25C-B048N104
25C-B032N104
25C-B062N104
(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.
(2) 110% Overload capability for up to 60 s, 150% for up to 3 s.
(3) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.
(4) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See the Use of Motor Protection Circuit Breakers with Variable-Frequency Drives Application Techniques, publication 140M-AT002
(5) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.
(6) 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.
Rockwell Automation Publication 520-TD002D-EN-E - October 202027
28Rockwell Automation Publication 520-TD002D-EN-E - October 2020
20.0 15.0 15.0 11.030.030.2 33.0D100-C434570140U-H6C3-C50 140M-F8E-C45CLASS CC, J, or T / 70–140M-F8E-C45
20.0 15.0 15.0 11.030.030.2 33.0D100-C434570140U-H6C3-C50 140M-F8E-C45CLASS CC, J, or T / 70–140M-F8E-C45
(2)
(2)
25C-D030N104
25.0 18.5 20.0 15.0 37.030.8 33.7E100-C434570140U-H6C3-C50 140M-F8E-C45CLASS CC, J, or T / 70–140M-F8E-C45
30.0 22.0 25.0 18.5 43.035.6 38.9E100-C605080140U-H6C3-C60 140M-F8E-C45CLASS CC, J, or T / 80–140M-F8E-C45
(2)
(2)
25C-D030N114
25C-D037N114
25C-D043N114
(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.
(2) 110% Overload capability for up to 60 s, 150% for up to 3 s.
(3) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.
(4) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See the Use of Motor Protection Circuit Breakers with Variable-Frequency Drives Application Techniques, publication 140M-AT002
(5) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.
(6) 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.
1.00.75 1.00.75 1.72.6 2.3A100-C0936140U-D6D3-B30 140M-C2E-B25CLASS RK5, CC, J, or T / DLS-R-6–140M-C2E-B25
2.01.52.01.53.04.3 3.8A100-C09610140U-D6D3-B50 140M-C2E-B40CLASS RK5, CC, J, or T / DLS-R-10 –140M-C2E-B40
3.02.23.02.24.26.15.3A100-C091015140U-D6D3-B80 140M-C2E-B63CLASS RK5, CC, J, or T / DLS-R-15–140M-D8E-B63
5.04.05.04.06.69.18.0B100-C091020140U-D6D3-C10140M-C2E-C10CLASS RK5, CC, J, or T / DLS-R-20 –140M-D8E-C10
7.55.57.55.59.912.8 11.2C100-C161525140U-D6D3-C15140M-C2E-C16CLASS RK5, CC, J, or T / DLS-R-25 –
10.0 7.510.0 7.512.015.4 13.5C100-C232030140U-D6D3-C20 140M-C2E-C16CLASS RK5, CC, J, or T / DLS-R-30 –140M-D8E-C16
15.0 11.015.0 11.019.027.4 24.0D100-C303050140U-H6C3-C30 140M-F8E-C25CL ASS CC, J, or T / 50–140M-F8E-C25
20.0 15.0 15.0 11.022.031 .2 27.3D100-C303560140U-H6C3-C35 140M-F8E-C32CLASS CC, J, or T / 60–140M-F8E-C32
25.0 18.5 20.0 15.0 27.028.2 24.7E100-C303550140U-H6C3-C35 140M-F8E-C32CLASS CC, J, or T / 50–140M-F8E-C32
30.0 22.0 25.0 18.5 32.033.4 29.2E100-C374060140U-H6C3-C50 140M-F8E-C32CLASS CC, J, or T / 60–140M-F8E-C32
(1)
25C-E1P7N104
(1)
(1)
(1)
25C-E3P0N104
(1)
(1)
25C-E4P2N104
25C-E6P6N104
25C-E9P9N104
25C-E012N104
(1)
25C-E019N104
(2)
25C-E022N104
(2)
(2)
25C-E027N104
25C-E032N104
(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.
(2) 110% Overload capability for up to 60 s, 150% for up to 3 s.
(3) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.
(4) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See the Use of Motor Protection Circuit Breakers with Variable-Frequency Drives Application Techniques, publication 140M-AT002
(5) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.
(6) 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.
(7) When used with the 140M circuit breaker, the 25C-E9P9N104 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.).
Rockwell Automation Publication 520-TD002D-EN-E - October 202029
(1) The resistors that are listed in this table are rated for 5% duty cycle.
(2) Use of Rockwell Automation resistors is always recommended. The resistors that are listed have been carefully selected for optimizing performance in various applications. Alternative
resistors may be used, however, care must be taken when making a selection. See the PowerFlex Dynamic Braking Resistor Calculator, publication PFLEX-AT001
(3) Requires two resistors that are wired in parallel.
(4) Requires three resistors that are wired in parallel.
(1) EMC Line Filter size is based on the input current of the drive. See the tables on page 28 and page 29 for more information.
(2) This 600V drive rating must be matched with a frame B EMC Line Filter.
For use with 3.7 kW (5HP) and below drives.1204-TFA1
For use with 1.5 kW (2HP) and above drives.1204-TFB2
IP 30/NEMA 1/UL Type 1 Kit
ItemDescriptionFrame SizeCatalog No.
A25-JBAA
B25-JBAB
C25-JBAC
D25-JBAD
E25-JBAE
IP 30/NEMA 1/UL Type 1 Kit
Field installed kit. Converts drive to IP 30/NEMA 1/UL Type 1 enclosure. Includes conduit
box with mounting screws and plastic top panel.
Control Module Fan Kit
ItemDescriptionFrame SizeCatalog No.
Control Module Fan Kit
For use with drive in environments with ambient temperatures up to 70 °C or horizontal
mounting.
A…D25-FAN1-70C
E25-FAN2-70C
Incremental Encoder Input Option
ItemDescriptionCatalog No.
Incremental Encoder BoardInterface to an external incremental encoder.25-ENC-2
Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate
ItemDescription
Mounting Adapter Plate
For use with drive when replacing Bulletin 160 drives in existing installations to a
PowerFlex 520-Series drive. Select the catalog number based on the frame size of your
Bulletin 160 drive.
B160
Frame Size
A25-MAP-FA
B25-MAP-FB
Catalog No.
32Rockwell Automation Publication 520-TD002D-EN-E - October 2020
PowerFlex 527 AC Drive Specifications
Replacement Parts
PowerFlex 527 Power Module
ItemDescription
Replacement power module for use with PowerFlex 527 drives. Includes:
(1) Normal Duty and Heavy-Duty ratings for 15 HP / 11 kW and below are identical.
(2) Catalog numbers that are listed are for 3% impedance at 60 Hz. 5% impedance reactor types are also available.
See 1321 Power Conditioning Products Technical Data, publication 1321-TD001
(3) Input line reactors were sized based on the NEC fundamental motor amps. Output line reactors were sized based on the VFD rated output currents.
1321-3R25-B (ND)
1321-3R18-B (HD)
1321-3R35-C (ND)
1321-3R25-B (HD)
1321-3R35-B (ND)
1321-3R35-C (HD)
.
1321-3RA25-B (ND)
1321-3RA18-B (HD)
1321-3RA35-C (ND)
1321-3RA25-B (HD)
1321-3RA35-B (ND)
1321-3RA35-C (HD)
1321-3R25-B1321-3RA25-B
1321-3R35-C1321-3RA35-C
1321-3R35-B1321-3RA35-B
Rockwell Automation Publication 520-TD002D-EN-E - October 202035
PowerFlex 527 AC Drive Specifications
C
F
G
51.1 (2.01)
21.0 (0.82)
135.4 (5.33)
111.9 (4.41)
88.2 (3.47)
64.7 (2.55)
ø21.5 (ø0.85)
66.1 (2.60)
63.1 (2.48)
33.5 (1.32)
23.9 (0.94)
128.5 (5.06)
108.5 (4.27)
88.3 (3.48)
67.3 (2.65)
ø21.5 (ø0.85)
ø27.5 (ø1.08)
123.3 (4.85)
82.2 (3.24)
80.5 (3.17)
66.5 (2.62)
34.5 (1.36)
26.5 (1.04)
ø21.5 (ø0.85)
ø27.5 (ø1.08)
109.8 (4.32)
153.3 (6.04)
96.0 (3.78)
44.0 (1.73)
30.0 (1.18)
70.0 (2.76)
ø21.5 (ø0.85)
ø33.5 (ø1.32)
127.5 (5.02)
82.5 (3.25)
62.5 (2.46)
42.5 (1.67)
212.0 (8.35)
181.0 (7.13)
164.0 (6.46)
ø21.5 (ø0.85)
ø43.7 (ø1.72)
A
15.0 (0.59)
H
E
B
D
Frame A
Frame B
Frame C
Frame D
Frame E
Accessory Dimensions
IP 30/NEMA 1/UL Type 1 Kit – Dimensions are in mm and (in.).
38Rockwell Automation Publication 520-TD002D-EN-E - October 2020
PowerFlex 527 AC Drive Specifications
Safe Torque Off Function
The PowerFlex 527 Safe Torque Off (STO) function, when used with other safety components, helps provide protection according to EN ISO
13849 and EN62061 for STO and protection against restart. The PowerFlex 527 STO function is just one component in a safety control system.
Components in the system must be chosen and applied appropriately to achieve the desired level of operator safeguarding.
PowerFlex 527 Safe Torque Off Overview
The PowerFlex 527 Safe Torque Off function:
•Provides the Safe Torque Off (STO) function that is defined in EN IEC 61800-5-2.
•Blocks gate-firing signals from reaching the insulated gate bipolar transistor (IGBT) output devices of the drive. This prevents the
IGBTs from switching in the sequence necessary to generate torque in the motor.
•Can be used in combination with other safety devices to fulfill the requirements of a system “Safe Torque Off” function which satisfies
Category 3 / PLe according to EN ISO 13849-1 and SIL CL 3 according to EN/IEC 62061, IEC 61508, and EN/IEC 61800-5-2.
IMPORTANTThe function is suitable for performing mechanical work on the drive system or affected area of a machine only. It
does not provide electrical safety.
EC Type Examination Certification
TÜV Rheinland has certified the PowerFlex 527 Safe Torque Off function compliant with the requirements for machines that are defined in
Annex I of the EC Directive 2006/42/EC, and that it complies with the requirements of the relevant standards that are listed below:
•EN ISO 13849-1:2008+AC:2009 Safety of machinery – Safety-related parts of control systems – Part 1: General principles for design.
(PowerFlex 527 STO achieves Category 3 / PLe)
•EN 61800-5-2:2007 Adjustable speed electrical power drive systems – Part 5-2 Safety requirements – Functional. (PowerFlex 527 STO
achieves SIL CL 3)
•EN 62061:2005+A1:2013 Safety of machinery – Functional safety of safety-related electrical, electronic, and programmable electronic
control systems.
•EN 60204-1:2006+A1:2009 – Safety of machinery – Electrical equipment of machines - Part 1: General requirements
•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 527 STO may be used in applications up to Category 3/ PLe according to EN ISO 13849-1 and SIL 3
according to EN 62061 / EN 61800-5-2 / IEC 61508.
The TÜV Rheinland certificate may be found at rok.auto/certifications
.
Safety Concept
The PowerFlex 527 Safe Torque Off function is suitable for use in safety applications up to and including Category 3 / PLe according to
EN ISO 13849-1 and SIL 3 according to EN 62061 / EN 61800-5-2 / IEC 61508.
In addition, the PowerFlex 527 STO function may be used together with other components in a safety application to achieve an overall
Category 3 / PLe according to EN ISO 13849-1 and SIL 3 according to EN 62061 and IEC 61508.
Safety requirements are based on the standards current at the time of certification.
The PowerFlex 527 STO function is intended for use in safety-related applications where the de-energized state is considered to be the safe
state. All examples that are shown here are based on achieving de-energization as the safe state for typical Machine Safety and Emergency
Shutdown (ESD) systems.
Rockwell Automation Publication 520-TD002D-EN-E - October 202039
PowerFlex 527 AC Drive Specifications
Probability of Dangerous Failure Per Hour (PFH) Data
This PFH calculation is based on the equations from EN 61508 and show worst-case values.
Determination of safety parameters is based on the assumption that the system operates in High demand mode and that the safety function
is requested at least once a year.
This table provides data for a 20-year proof test interval and demonstrates the worst-case effect of various configuration changes on the
data.
IMPORTANT Determination of safety parameters is based on the assumption that the system operates in High demand mode and
that the safety function is requested at least once every three months.
PFD and PFH Data
AttributeValue
PFD (average)1.53E-4
PFH1.7E-9
SIL CL3
PLe
Category3
MTTFd (years) 166166
DCavg (%)90 (medium)
HFT1 (1oo2)
Mission time (years)20
Safety Reaction Time
The safety reaction time from an input signal condition that triggers a safe stop, to the initiation of the configured Stop Type, is less than
12 ms.
40Rockwell Automation Publication 520-TD002D-EN-E - October 2020
PowerFlex 527 AC Drive Specifications
Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.
ResourceDescription
Describes how to configure and use the PowerFlex 527 drive in a Studio 5000 Logix Designer
PowerFlex 527 Adjustable Frequency AC Drive User Manual, 520-UM002
GuardLogix 5570 Controllers User Manual, 1756-UM022
GuardLogix 5570 and Compact GuardLogix 5370 Reference Manual,
1756-RM099
ControlLogix 5580 and GuardLogix 5580 Controllers User Manual, 1756-UM543
CompactLogix 5370 Controllers User Manual, 1769-UM021
Compact GuardLogix 5370 Controllers User Manual, 1769-UM022
Wiring and Grounding for Pulse Width Modulated (PWM) AC Drives Installation
Instructions, DRIVES-IN001
Preventive Maintenance Checklist of Industrial Control and Drive System
Equipment, publication, DRIVES-TD001
Integrated Motion on the EtherNet/IP Network: Configuration and Startup
User Manual, MOTION-UM003
.Provides declarations of conformity, certificates, and other certification details.
application.
Describes how to configure and use the GuardLogix 5570 controller in a Studio 5000 Logix
Designer application.
Contains detailed requirements for achieving and maintaining SIL 3/PLe with the
GuardLogix 5570 and Compact GuardLogix 5370 controller system, using the Studio 5000
Logix Designer application.
Describes how to configure and use the ControlLogix 5580 and GuardLogix 5580 controllers
in a Studio 5000 Logix Designer application.
Describes how to configure and use the CompactLogix 5370 controller in a Studio 5000
Logix Designer application.
Describes how to configure and use the Compact GuardLogix 5370 controller in a Studio
5000 Logix Designer application.
Provides basic information to install, protect, wire, and ground pulse-width modulated
(PWM) AC drives
Provides a checklist as a guide in performing preventive maintenance.
Details how to configure an Integrated Motion on EtherNet/IP networks application system.
Provides programmers with details about the motion instructions that are available for a
Logix5000 controller.
Detailed information on axis control modes and attributes for Integrated Motion on
EtherNet/IP networks.
Provides information on dynamic braking and how to determine dynamic brake
requirements for your drive.
Provides information on how to guard against the effects of ESD.
Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
Provides guidance on how to conduct security assessments, implement Rockwell
Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
Provides a quick reference tool for Allen-Bradley industrial automation controls and
assemblies.
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies incorporating solid-state
components.
Provides general guidelines for installing a Rockwell Automation industrial system.
You can view or download publications at rok.auto/literature.
Rockwell Automation Publication 520-TD002D-EN-E - October 202041
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Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec.
Allen-Bradley, CompactLogix, ControlLogix, expanding human possibility, FactoryTalk, GuardLogix, Kinetix, Logix 5000, PowerFlex, Rockwell Automation, RSLogix 5000, RSNetWorx, Studio 5000,
Studio 5000 Logix Designer, and TechConnect are trademarks of Rockwell Automation, Inc.
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