PowerFlex 523

Allen-Bradley 25A PowerFlex 523 Low-Voltage AC Drive

Allen-Bradley PowerFlex 523 Drives

Technical Specifications

  • PowerFlex 523 Drives horsepower ratings rage from 0.25-1.5HP, 0.25-20HP, 0.5-30HP, or 0.5-30HP
  • Input-voltage range from 100-120V, 200-240V, 380-480V, or 525-600V
  • Output voltage range is adjustable from 0V to input voltage 
  • Enclosure types include IP20 NEMA/Open, IP30 NEMA/UL Type 1
  • Maximum output frequency is 500Hz

Overview

  • Mounting and Packaging Choices
    • Two detachable modules for seperate and concurrent wiring and software configuration 
    • Side-by-side mounting permissible with 50mm spacing at bottom and top of the drive
    • DIN rail mounting for frames A, B, and C
  • Simple Set-up and Operation
    • Integral Human Interface Module languages include English, Spanish, French, German, Italian, Portuguese, Polish, Turkish and Czech
  • Network Solutions and Easy Programming
    • Application specific parameter tools avaliable
    • Configure over open industrial networks such as DeviceNet or EtherNet/IP

Frame Sizing (in millimeters)

  • Frame A: 152 x 72 x 172
  • Frame B: 180 x 87 x 172
  • Frame C: 220 x 109 x 184
  • Frame D: 260 x 130 x 212
  • Frame E: 300 x 185 x 279

 

Allen-Bradley PowerFlex 523 Drives

Technical Specifications

  • PowerFlex 523 Drives horsepower ratings rage from 0.25-1.5HP, 0.25-20HP, 0.5-30HP, or 0.5-30HP
  • Input-voltage range from 100-120V, 200-240V, 380-480V, or 525-600V
  • Output voltage range is adjustable from 0V to input voltage 
  • Enclosure types include IP20 NEMA/Open, IP30 NEMA/UL Type 1
  • Maximum output frequency is 500Hz

Overview

  • Mounting and Packaging Choices
    • Two detachable modules for seperate and concurrent wiring and software configuration 
    • Side-by-side mounting permissible with 50mm spacing at bottom and top of the drive
    • DIN rail mounting for frames A, B, and C
  • Simple Set-up and Operation
    • Integral Human Interface Module languages include English, Spanish, French, German, Italian, Portuguese, Polish, Turkish and Czech
  • Network Solutions and Easy Programming
    • Application specific parameter tools avaliable
    • Configure over open industrial networks such as DeviceNet or EtherNet/IP

Frame Sizing (in millimeters)

  • Frame A: 152 x 72 x 172
  • Frame B: 180 x 87 x 172
  • Frame C: 220 x 109 x 184
  • Frame D: 260 x 130 x 212
  • Frame E: 300 x 185 x 279

 

Troubleshooting Your PowerFlex 523

This page outlines information you will need to troubleshoot your PowerFlex 523 Drive. 

PowerFlex 523 Faults

There are two types of Faults that can affect your PowerFlex 523 Drive: Auto-Reset/Run and Non-Resettable. An Auto-Reset/Run fault, the drive will try to automatically reset the fault. If the fault's cause is not present at the time of reset, the fault will reset and the drive will restart. A Non-Resettable fault will likely require a drive or motor repair. However, this kind of fault can also be caused by wiring or programming errors. Once the cause of the fault is corrected, the fault may be cleared. 

When the drive detects a fault you will see a flashing fault number and a flashing fault indicator on the front of the drive. You must press Escape to regain control of the keypad. 

Power Flex 523 Fault Codes - AutoReset/Run

Code No. Fault Meaning  Action
F00 No Fault No Fault None
F002 Aux. Input External trip auxiliary inupt Check remote wiring. Ensure communications programming is correct.
F004 UnderVoltage DC Bus voltage below minimum value  Watch for low voltage/line power interruption on the incoming AC line. 
F005 OverVoltage DC Bus voltage over maximum value Watch for high line voltage/ transient conditions on the AC line. Note: Motor generation can cause bus overvoltage. Extend decel time/install dynamic brake
F006 Motor Stalled Drive cannot accelerate/decelerate the motor Verify there is not overhauling load. Increase the Accell Time x parameters or reduce the load. The output current cannot exceed the current set in the parameter Current Limit x. 
F007 Motor Overload Internal electronic overload trip  Check the Boost Select Setting. Reduce the load. The drive's output current cannot exceed the current set in the parameter Motor OL Current. 
F008 Heatsink OvrTmp Power Module/Heatsink temperature over predetermined value  Ensure the fan is operational. Ensure there the heat sink fins are not dirty or blocked. Ambient temperatures should not exceed the rated ambient temperatures. 
F009 CC OvrTemp Control Module temperature over predetermined value  Ensure the fan is operational and that there is no debris or dirt. Ensure nothing is blocking the airflow. Ensure the ambient temperature does not exceed the rated ambient temperature for this product. 
F013 Ground Fault Current path to earth ground detected from at least one of the drive output terminals Look for a grounded condition for the motor and external wiring to drive output terminals
F021 Output Ph Loss Output phase loss may be enabled. Configure this with Out Phas Loss En Check the motor and motor wiring. 
F029 Analog In Loss  Analog input configured to fault on signal loss/ a signal loss has occurred. Configure with Anlg In V Loss or Anlg In mA Loss Review parameters and look for loose or broken connections at inputs 
F048 Params Defaulted Drive was commanded to write default values to EEPROM Clear fault/cycle drive power. Reprogram parameters as necessary. 
F063 SW Over Current The Shear Pin x Level programmed values exceeded for a longer than the value programmed in Shear Pin x Time Check the connections between the motor and the load. Check the level and time requirements

 

PowerFlex 523 Fault Codes - Non-Resettable

Code No. Fault Meaning Action
F003 Power Loss Single phase operation with excessive load detected  Watch for low voltage/line power interruption on the incoming AC line. Reduce the load and examine input fuses.
F012 HW Over Current  Drive's output current exceeds hardware current limit Check the programming and look for excess load, an improper Boost Select setting, and verify the DC brake volts are not set too high.
F033 Auto Rstrt Tries  Drive fault reset attempt failed. Correct the fault source and manually clear the fault. See "How to Manually Clear Faults" below.
F038 Phase U to Gnd  Detected phase to ground fault between drive and motor in phase U, V or W Examine the wiring between the motor and the drive. Look for a grounded phase in the motor. If you cannot clear the fault, replace the drive. 
F039 Phase V to Gnd 
F040 Phase W to Gnd 
F041 Phase UV Short Detected excessive current between two output terminals Examine motor and drive output terminal wiring. Look for a shorted condition. If you cannot clear the fault, the drive must be replaced. 
F042 Phase UW Short
F043 Phase VW Short
F064 Drive Overload  Overload exceeds the drive's overload rating  Either reduce the load or extend the Accel Time parameter. 
F070 Power Unit Detected failure in drive power section  Verify maximum ambient temperatures have not been exceeded. Cycle terminal power. If you cannot clear the fault, the drive must be replaced. 
F071 DSI Net Loss Interrupted control over the Modbus or DSI communication link Cycle the power then check the communication cabling and the Modbus/DSI settings and status. 
F072 Opt Net Loss Interrupted control over network option card's remote network  Cycle the power then check the communication cabling, the network adapter settings and the external network status.
F080 Autotune Failure Autotune function failed or canceled by a user  Restart the procedure.
F081 DSI Comm Loss Interrupted communication between the drive and the Modbus/DSI master device Cycle the power then check the communication cabling, Modbus/DSI settings and status. Adjust the Comm Loss Action parameter. You may need to replace the port expander, option card, wiring or the control module.
F082 Opt Comm Loss Interrupted communications between the drive and network option card Cycle the power and reinstall the option card in the drive. Adjust the Comm Loss Action parameter. If necessary, replace the port expander, wiring, option card or the control module.
F094 Function Loss Funciton Loss input inactivated. The input to the programmed terminal is open Close the input to the terminal and cycle the terminal power.
F100 Parameter Checksum Drive's parameter non-volatile storage corrupted

Reset to Factory Default.

F101 External Storage External non-volatile storage failure Reset to Factory Default.
F105 C Connect Err Drive powered during control module disconnection Clear the fault and check all parameter settings. Do not install/remove a control module while the drive is powered.
F107 Replaced C-P Control module did not recognize power module - hardware failure Change the power module. If this does not resolve the error, replace the control module.
F109 Mismatch C-P Control module mounted to a different drive type power module Set Reset To Defaults to Power Reset.
F110 Keypad Membrane  Keypad membrane disconnected or failed Cycle the power. If this does not resolve the fault, you must replace the control module.
F114 uC Failure Microprocessor failed Cycle the power and ensure the grounding requirements are met. If you cannot clear the fault, replace the control module.
F122 I/O Board Fail Detected failure in the drive control and I/O section Cycle the power. If you cannot clear the fault, replace the control module.
F125 Flash Update Req Corrupt, mismatched or incompatible firmware Load a valid firmware set via a firmware flash update operation.
F126 NonRecoverablErr Non-recoverable firmware/hardware error detected.  Clear the fault/cycle drive power. If you cannot clear the fault, replace the drive or control module.
F127 DSIFlashUPdatReq Critical firmware issue detected. The drive is running and using backup firmware. only DSI communications currently supported.  Load a valid firmware set via a firmware flash update operation.

 

How to Manually Clear Faults

  1. Press Escape to regain control of the keypad. To view the most recent fault information, access d007 Fault 1 Code.
  2. Take corrective action to address the cause of the fault. The cause of the fault must be resolved before clearing the fault. See the table above.
  3. To clear the fault either:
    1. Restart the drive (cycle power)
    2. Select Stop if Stop Mode is set between 0 and 3
    3. Set Fault Clear to 1 or 2
    4. OR cycle digital input if the Digital Inx Select is set to option 7 - "Clear Fault"

To automatically clear a fault and reset the drive set the AutoRstrt Tries to any value other than 0. Then, set Auto Rstrt Delay to any value other than 0. Follow the same process to clear a Heatsink OvrTemp, OverVoltage or UnderVoltage fault, just do not restart the drive. 

Common Issues - PowerFlex 523

Drive Power-Up Failure

If your PowerFlex 523 Drive will not power up, always check the power circuit first. Ensure the drive is receiving the proper supply voltage and check all fuses and disconnects. The drive will not power up if the control module is incorrectly connected to the power module. In this instance, remove the power, ensure the two modules are properly installed, then reapply the power. 

Drive Cannot Reverse Motor Direction

First, verify that reverse has not been disabled by checking the Reverse Disable parameter and check that all motor and digital input wiring is properly phased for reverse. If the motor wiring is not phased for reverse, switch the two motor leads. Finally, ensure the digital input is selected for reversing control. If it is not, simply check DigIn TermBlk and choose the correct input and program for reverse mode. 

Drive Non-Responsive to Speed Change Command

If the drive "Run" indicator is on and the output is 0 Hz, there is no value coming from the command source. To correct this, check Control Source for the correct source and ensure all wiring is correct. Also, check Command Freq to verify the command is correct. 

If no indicator light is on, the reference source selected is incorrect. Check and verify the settings in the following parameters: Control Source, Dig In Status, DigIn TermBlk xx and Speed Reference x. 

Drive Will Not Start From Start/Run Inputs

If the red status indicator light is flashing, the drive is faulted. Clear the fault, see "How to Manually Clear Faults" above for more information. Verify the programming is correct by checking the parameters Start Source x and DigIn TermBlk 02/03 settings. Verify all input wiring is correct and that the sink/source jumper setting is correct.

Failed Motor Start

Always check the power circuit first; the motor may not be receiving output voltage. Ensure the motor is connected properly and check the control input signals. When checking the input signals, confirm that a start signal is present. If you are using a 2-Wire control, ensure only Run Forward or Run Reverse is active. Both should not be simultaneously active. The I/O Terminal 1 should be active and the Start Source should match your configuration. Finally, ensure Reverse Disable is not inhibiting movement and that the safety inputs are active.

A failed start can also be caused by an improper boost setting at initial startup. In response, set Boost Select to 35.0,VT (option 2). Additionally, incorrectly setting the Start Source x parameter or incorrectly wiring the sink/source jumper setting can cause a failed start.

If a red status light is flashing, the drive is faulted. See "How to Manually Clear Faults" above to clear the fault. 

Unstable Motor Operation

The motor data was entered incorrectly. Enter motor nameplate data into Motor NP Volts, Motor NP Hertz, and Motor OL Current. Then enable Compensation and use Boost select to reduce the boost level.

Motor Rotation 0Hz/ Incorrect Slip Frequency

Improper speed indicates there is an incorrect speed calculation. Under this circumstance, check the Motor NP Hertz parameter and reduce the boost in the Boost Select parameter. Finally set the Motor NP RPM parameter to motor synchronous speed. 

Motor/Drive Not Accelerating to Command Speed

First, check the acceleration. If this value is excessive, adjust the value. Programming may be preventing the drive output from exceeding limiting values. To check this, look at Maximum Freq and ensure the programming is not limiting the speed. It is also possible that the speed command source or speed command value do not align with the Command Freq or the Control Source. Check both these parameters. 

The excess load or short acceleration times can force the drive into a current limit which results in decreased or stopped acceleration. Compare the Output Current to the Current Limit and remove the excess load. If you do not want to remove the excess load, you can reprogram the Accel 1 or 2 parameters. Be sure to check for an improper Boost Select setting. 

It is also possible this issue is caused by the torque performance not matching the motor characteristics. Set the motor nameplate full load amps in the parameter Motor NP FLA and perform the Autotune procedure. Finally, set the torque Perf Mode Parameter to 0 V/Hz

Repair Your PowerFlex 523 Drive

Here at DO Supply, we offer repair services for your Allen-Bradley products, such as the Allen-Bradley PowerFlex 523 Drive. Please click here for more information or to request a quote.


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PowerFlex 523DescriptionStock Level
PowerFlex 523DescriptionStock Level
25A-A011N104Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 11 Amperes Output
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25A-A011N114Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 11 Amperes Output
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25A-A1P6N104Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 1.6 Amperes Output
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25A-A1P6N114Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 1.6 Amperes Output
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25A-A2P5N104Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 2.5 Amperes Output
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25A-A2P5N114Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 2.5 Amperes Output
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25A-A4P8N104Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 4.8 Amperes Output
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25A-A4P8N114Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 4.8 Amperes Output
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25A-A8P0N104Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 8 Amperes Output
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25A-A8P0N114Allen-Bradley PowerFlex 523 AC Drive has One Phase, 240 VAC voltage and 8 Amperes Output
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25A-B011N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 11 Amperes Output
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25A-B017N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 17.5 Amperes Output
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25A-B024N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 24 Amperes Output
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25A-B032N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 32 Amperes Output
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25A-B048N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 48.3 Amperes Output
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25A-B062N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 62.1 Amperes Output
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25A-B1P6N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 1.6 Amperes Output
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25A-B2P5N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 2.5 Amperes Output
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25A-B5P0N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 5.0 Amperes Output
In Stock
25A-B8P0N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 240 VAC voltage and 8.0 Amperes Output
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25A-D010N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 10.5 Amperes Output
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25A-D010N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 10.5 Amperes Output
In Stock
25A-D013N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 13 Amperes Output
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25A-D013N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 13 Amperes Output
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25A-D017N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 17 Amperes Output
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25A-D017N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 17 Amperes Output
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25A-D024N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 24 Amperes Output
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25A-D024N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 24 Amperes Output
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25A-D030N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 30 Amperes Output
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25A-D030N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 30 Amperes Output
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25A-D037N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 37 Amperes Output
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25A-D043N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 43 Amperes Output
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25A-D1P4N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 1.4 Amperes Output
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25A-D1P4N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 1.4 Amperes Output
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25A-D2P3N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 2.3 Amperes Output
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25A-D2P3N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 2.3 Amperes Output
In Stock
25A-D4P0N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 4 Amperes Output
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25A-D4P0N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 4 Amperes Output
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25A-D6P0N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 480 VAC voltage and 6 Amperes Output
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25A-D6P0N114Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 6 Amperes Output
In Stock
25A-E012N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 12 Amperes Output
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25A-E019N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 19 Amperes Output
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25A-E022N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 22 Amperes Output
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25A-E027N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 27 Amperes Output
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25A-E032N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 32 Amperes Output
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25A-E0P9N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 0.9 Amperes Output
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25A-E1P7N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 1.7 Amperes Output
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25A-E3P0N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 3 Amperes Output
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25A-E4P2N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 4.2 Amperes Output
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25A-E6P6N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 6.6 Amperes Output
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25A-E9P9N104Allen-Bradley PowerFlex 523 AC Drive has Three Phase, 600 VAC voltage and 9.9 Amperes Output
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25A-V1P6N104Allen-Bradley PowerFlex 523 AC Drive has One Phase, 120 VAC voltage and 1.6 Amperes Output
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25A-V2P5N104Allen-Bradley PowerFlex 523 AC Drive has One Phase, 120 VAC voltage and 2.5 Amperes Output
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25A-V4P8N104Allen-Bradley PowerFlex 523 AC Drive has One Phase, 120 VAC voltage and 4.8 Amperes Output
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25A-V6P0N104Allen-Bradley PowerFlex 523 AC Drive has One Phase, 120 VAC voltage and 6 Amperes Output
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