PowerFlex 523

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. 

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.