1. A M E M B E R O F T H E K E N D A L L G R O U P
PowerFlex® 527 AC Drives Kendall Drive HeadQuarters Product Overview

2. Kendall Drive HeadQuarters Product Overview
PowerFlex® 527 AC Drives
Kendall Drive HeadQuarters Product Overview
March15 , 2016

3. PowerFlex 520-Series AC Drives
The Next Generation of Powerful Performance. Flexible Control.
Compact Easy to Use Innovative Design
LEARN MORE ABOUT. . .
Today’s PowerFlex 750-Series drives offers more application flexibility and allows customers to be more connected to their operations optimizing their productivity
PowerFlex 523
PowerFlex 525
PowerFlex 527

4. Compact Market Product Positioning Three Product Lines
Connected Components
Mid-Range Offering
PowerFlex 527
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.
PowerFlex 525
Ideal for networked machines and simple system integration, offering standard features including built-in EtherNet/IP™ and safety.
Value
PowerFlex 523
Ideal for standalone machines that require cost-effective motor control.
Ease of installation with HIM, Application programming groups and Software Tools
Performance / Functionality
PowerFlex 520 Series
The Next Generation of Powerful Performance. Flexible Control.

5. PowerFlex 520-Series AC Drives PowerFlex 527 Overview
First compact PowerFlex drive designed to exclusively use a Logix controller and programmed with Studio 5000 integrated motion instructions
Ideal VFD to complement machines already using Kinetix servo drives
Common Studio 5000 configuration and programming experience saves start up time, and delivers a coordinated and synchronized machine
Built-in dual-port Ethernet
Features Integrated Safety — controller based safety delivered via EtherNet/IP
PowerFlex 523 AC drives provide the power, control, flexibility and features suitable for a wide array of applications – ideal for systems ranging from standalone machines to simple system integration
Power Ratings:
V: 0.4 to 1.1 kW / 0.5 to 1.5 Hp
V: 0.4 to 2.2 kW / 0.5 to 20 Hp
V: 0.4 to 22 kW / 0.5 to 30 Hp
V: 0.4 to 22 kW / 0.5 to 30 Hp
Power Ratings:
V: kW / Hp
V: kW / Hp
V: kW / Hp
V: kW / Hp

6. PowerFlex 520-Series AC Drives PowerFlex 527 Summary
Power Ratings
Input / Output
0.4…22kW (0.5…30HP) at V
4 DI (4 programmable), 2 DO, 2 AI, 1AO, 2 Relay (1 form A, 1 form B)
Motor Control Performance
Energy Saving
V/Hz, SVC, Closed loop velocity vector control
CIP Energy - Energy sensing capability
Positioning
Other Features
Closed loop feedback allows positioning capability
Studio 5000 exclusively – Drive is programmed via embedded motion instructions
Communications
Global Standard
Embedded dual port EtherNet/IP
UL, cUL, CE, C-Tick, RoHS, GOST-R, KCC, REACH, Marine (Lloyds), ATEX, TUV, Semi-F47, ACS 156
Embedded Safety
Built-in Hardwired Safe Torque-Off SIL3/PLe, Cat 3
Built-in Network Safe Torque-Off SIL3/PLe, Cat 3
Offers Premier Integration Experience with Logix Controller, Servo Drive and AC Drive

7. PowerFlex 520-Series AC Drives Common Attributes
Modular Design
Din rail mounting for frames A, B and C and high ambient temperature up to 70oC (158oF)
Removable control module helps speed installation
Energy Saving
Reduce energy costs with Economizer control mode
One control module supports entire power range
CIP Energy - Energy sensing capability (PowerFlex 527 only)
No size penalty when adding option cards
Ease of Programming
Global Voltages
Studio 5000™ Logix Designer: AOPs & ADC
100V, 200V, 400V, 600V
Connected Component Workbench software (PowerFlex 523 and 525 only)
Multiple EMC filtering options
Embedded EMC filtering at 1ph 200V & 3ph 400V class
Dedicated application parameter groups (PowerFlex 523 and 525 only)
Optional external EMC filtering for longer cable length
MainsFree™ programming (PowerFlex 523 and 525 only)
Robustness
Flexible Installation
Allow -15% / +10% input voltage
Requires only 50mm (1.96 in) space for top and bottom
Conformal Coating to 3C2 specification (Chemical Gases only)
Horizontal mounting
Zero Stacking up to 45oC (113oF)
Ideal for standalone and simple-to-standard machine builders and simple system integration

8. PowerFlex 520-Series AC Drives PowerFlex 527
HIM
Multi-lingual LCD display with QuickView scrolling text
Safety – SIL3/PLe
Integrated Safety for safety over EtherNet/IP and embedded Safe Torque-Off for hardwired safety
Terminal Blocks Removable terminal blocks ease installation
The 527 has the same foot print, and control and power module foot print. You’ll find the differences with the HIM, and when you take the cover off the options that you now have.
Removable terminal blocks feature applied to PF 527 based on feedback from the PF 527. Current PF 525 design doesn’t allow space for this currently.
Control & Programming
Configure, control, and monitor PowerFlex drives in a single control platform
Communications
Embedded dual port EtherNet/IP

9. PowerFlex 520-Series AC Drives
Innovative Design
Modular design helps reduce installation and configuration time
Compact footprint
No penalty for adding option cards
Small mounting clearances at the top and bottom of drive
High ambient temperature operation up to 70°C (158°F)
Flexible installation with both vertical and horizontal and side- by-side installation
PowerFlex 525 has built in: single port for EtherNet/IP and Safe Torque-off
PowerFlex 527 has built in: dual port for EtherNet/IP, hardwire Safe Torque-off and Network safety
The PowerFlex 525 AC drives feature an innovative modular design. As you can see the control module can be removed from the power module. This feature allows you to install the power module onto your machine while someone else simultaneously configures the control module. This feature can help you get your machines out the door faster,
Reduce spare parts with same control module for entire power range
Talk about the rest of the features of this design

10. Compact Market Product Positioning Three Product Lines
Connected Components
Mid-Range Offering
PowerFlex 527
Integrated Motion
30HP
Communication: Embedded Dual Port Ethernet/IP
Safety: Embedded Safe Torque Off SIL3/Ple for both hardwired and Integrated Network Safety
Motor control Option: V/Hz, SVC, Closed Loop Velocity Vector, PM*
Incremental Encoder Option
Removable terminal blocks
Programmed via embedded motion instructions
PowerFlex 525
30HP
Standard USB connectivity
Comms: Embedded DSI + Single port Ethernet/IP
Comms Options: Dual port EtherNet/IP with DLR, DeviceNet, Profibus
Safety: Embedded Safe Torque Off SIL2/PLd
Motor Control options: V/Hz, SVC, Economizer SVC, Closed Loop Velocity Vector, PM*
Incremental Encoder Option
AppView & CustomView Application Configuration
CCW Programming Software
Value
PowerFlex 523
30HP
Standard USB connectivity
Comms: Embedded DSI
Comm Options: Dual port EtherNet/IP with DLR, DeviceNet, Profibus
Motor Control options: V/Hz, SVC, Economizer SVC
AppView & CustomView Application Configuration
CCW Programming Software
* Future Firmware Release
Performance / Functionality
PowerFlex 520 Series: Common Attributes
Innovative Design
Simplified Configuration
Modularity design
Common Power Module
Smallest clearance requirement
Zero-stack
Extreme ambient temperatures
Simplified programming
QuickView HIM
Seamless integration into Logix with add-on-profiles for Studio 5000

11. PowerFlex 527 AC Drives Integrated Motion Offering
● The PowerFlex 525 provides value with, embedded safe torque-off, positioning control, wide variety of motor control including permanent magnet motor control, Economizer mode for greater energy savings, ease of programming, PowerFlex 525 aligns with the Midrange Campaign with AOPs, ADC, DLR. PM motor control and datalinks.

12. GuardLogix Controller
Gantry Application
Kinetix® 5500 used for precise control of linear axes for product transfer
PowerFlex® 527 controls induction motors on in-feed and out-feed conveyors
Kinetix® 5500 used for precision control of conveyors where product is transferred or inserted
PowerFlex®
527
Kinetix®
5500
Kinetix®
5500
Kinetix®
5500
PowerFlex®
527
Kinetix®
5500
Kinetix®
5500
Integrated Motion and CIP Sync provide common instruction set and coordinated motion for all drives in system
GuardLogix Controller

13. PowerFlex 520-Series AC Drives EtherNet/IP™ Topologies
Linear
Star
Ring
Linear: All devices are connected on the network which has exactly two endpoints
Star: Each device is connected to a central hub with a point-to-point connection
Ring: Each device is set up in a circular model in which data travels around the ring in one direction and each device on the right acts as a repeater.
Star, linear, Ring—talk about DLR, hybrid
DLR is a differentiator for us
Rockwell Automation supports rings at the device level (DLR)

14. PowerFlex 520-Series AC Drives Automatic Device Configuration (ADC)
ADC allows a user to configure their Logix system to automatically download a drive’s configuration
Ideal for drive replacement
ADC is a version 20 and above feature
Also compliments:
Stratix 6000 & 8000 and 5700 switches
Automatically assigns IP Address
Firmware Supervisor
Flashes the drive and peripherals
Download
button
Add-On Profile (AOP)
of desired drive in
RSLogix 5000
ADC is a v20 Logix-based feature that allows a user to configure their Logix system to automatically download a “large” device’s configuration – typically after it has been replaced
Configuration data for “large” devices resides in the ACD file and the Logix controller, but the download was a manual process in v16-v19
Also compliments:
Stratix 6000 & 8000 and 5700 switches
Automatically assigns IP Address (if desired for the application)
Firmware Supervisor
Flash the drive and/or peripherals (if desired for the application)
Attribute
PF523
PF525
PF527
Automatic Device Configuration (ADC)
Optional with dual Port Ethernet/IP Card
Embedded single port EtherNet/IP as part of the architecture
Embedded dual port EtherNet/IP as part of the architecture

15. PowerFlex 520-Series AC Drives Automatic Device Configuration (ADC)
Example
2:00 AM
Configuration
Flash
Stratix 6000 /
8000 / 5700
IP Address
EtherNet/IP
Automatic Device Configuration (ADC) is another productivity enhancing feature available with Studio 5000 software and PowerFlex 525 drives. This feature,
enabled by EtherNet/IP, allows a Logix controller to automatically detect a replaced PowerFlex 525 drive and download firmware and all configuration parameters, minimizing the need for manual reconfiguration.
Only PowerFlex drives with embedded EtherNet/IP networking can help reduce maintenance time and increase productivity with Automatic Device Configuration.
* Dual port EtherNet/IP supports DLR topology
Helps save the user time and money by reducing downtime

16. PowerFlex 527 Common Integrated Motion Experience
Kinetix 5500
PowerFlex 527
Common Tabs for Configuration, Common Information in Each Tab

17. PowerFlex 527 Common Integrated Safety Experience
Kinetix 5500
PowerFlex 527
For “Like Functions” (e.g. Safety) the CIP Motion Interface is Identical

18. Logix - CIP Motion Motion instruction set
Instruction Based Programming
Motion instruction set
Broad range of functionality from single axis drive control to complex coordinated drive control
Supported in Ladder, ST, and SFC
Examples:
MDS – Motion Drive Start
Enable drive and ramp to speed
MAPC – Motion Axis Position Cam
Slave drive to master axis via defined profile
Static and dynamic profile definition, graphical CAM editor, import for Motion Analyzer
Many options including lock position, registration, phase correction, clutching
CAM from 1 drive to 100’s of drives
Having a common programming experience means:
The same motion instruction set is used – this means that powerful motion instructions, such as coordinated motion moves, can now be used with PowerFlex 755 drives.
The only exception is the Motion Drive Start (MDS) instruction, which was created specifically for drive applications allowing a ramped start with “flying start” capability. 18

19. Premier Integration with Add-on Profiles How Do You Solve This?
Ladder Logic (and maybe some parameters?)
There are two ways to tackle the diverter line with a controller, and the first one I want to point out is Premier Integration with AOPs. If you think about how you would solve this, you may configure some parameters in the drive, write some control code to execute a start and stop maybe fault clearing. This is a good approach, but let’s take it one step further with the PF527.

20. Premier Integration with Embedded Motion Instructions How Do You Solve This?
Ladder Logic and some parameters
Premier Integration with Embedded Motion instructions introduces an intelligent motion instruction such as the Motion Drive Start command. This gives us both a consistent programming experience from our Kinetix axes to the PowerFlex axes and some enhanced diagnostics.

21. Diagnostics Cont’d
Extensive list of status and fault/alarms attributes (via Axis tag)
Drive fault/alarm action options
Faults/alarms event logging
Time stamp date/time
Logix Designer access
Programmatic access
Read up to 10 attributes per drive
Cyclical update rate
Dynamic list configuration
This information is also time stamped. This is especially useful when a fault occurs as can simplify troubleshooting when a user knows when and where the problem occurred. We will get into this in more detail in our applications section of this presentation.

22. Diagnostics Meaningful and Informative
Push “Start” while Safe Torque-off is still active
What I mean by diagnostics is for example, if my start command does not execute while safe torque off is active, I can build some meaningful and informative intelligence in my control system to read the error code and announce the error along with corrective actions on a HMI for example.

23. PowerFlex 520-Series AC Drives
Safety
Safe Torque-off can help increase safety and machine uptime
PowerFlex 525 AC drives: Built-in hardwired safety
Certified to SIL2 / PLd
Requires the use of any external safety relay to meet ISO
PowerFlex 527 AC drives: Choice of safety options
Built-in Hardwired Safe Torque-off SIL3/PLe, Cat 3
Built-in Network Safe Torque-off SIL3/PLe, Cat 3
Help protect your personnel and assets with standard built-in Safe Torque-off
Helps with faster start ups and reduces wear on motor assets
Reduce wiring and installation space with built in safety or integrated safety-- safety over the network

24. PowerFlex 520-Series AC Drives Safety Solutions
External
PowerFlex 523
Hardwired
PowerFlex 525
SIL2 / PLd
PowerFlex 527
SIL3 / PLe
Network
PowerFlex 527
SIL3 / PLe (Network)
The PowerFlex 520-Series of AC drives offers the flexibility in safety solutions from hardwired to a fully integrated solution. So with any of the 520 drives, your customers can implement a safety solution:
<CLICK>
PF 523 external safety application
A safety option that is externally wired requires the maximum about of panel space and depending on the safety category you are required to meet, could mean even more hardware than we have pictured in this example.
This option also requires the most hardware, wire or cable, and take the longest time to install and even troubleshoot. This option can require approximately 83 pieces of hardware which not only can be costly, also can reduce your system reliability with more parts that can fault.
Lastly this option has no communications resulting in no diagnostics.
<CLICK> (Hardwired SIL2/PLd Safe Torque-Off – PowerFlex 525)
This solution requires less panel space than the external safety options, fewer pieces of hardware—consider a reduction by approx. 75%--and with that faster installation time and reduced hardware this can result in lower labor costs.
With fewer pieces of hardware required reliability improves here and with this option we do start to get diagnostics: Nothing more than basic fault information – Drive detects something is wrong, 440R also reports faults in components but reasons for safety demand require further investigation.
<CLICK> (Networked SIL3/PLe Safe Torque-Off – PowerFlex 527)
And now with Integrated safety—safety in the controller and delivered via EtherNet/IP—You can see already how the hardware count is greatly reduced which not only reduces the hardware required, you know get the lowest level of panel space required, low parts greatly reduces the installation and wiring time required. This also can be configured entirely within Studio 5000—something that you don’t have to use additional software, or use any additional configuration tools to set the safety system up.
Thanks to safety over the network, you know get an advanced level of diagnostics: Specific information on what component faulted/experienced safety demand and why. And quite frankly with fewer parts, you’ll have a lot fewer faults or failures. 24
Safety solutions to meet your needs

25. Integrated Safety on EtherNet/IP
Kinetix® 5500 and PowerFlex® 527
with Integrated Safety
GuardLogix® Integrated
Safety System Controller
PointGuard
Safety I/O
Stratix 5700™
Industrial Ethernet switch
A closer look at the topology that has GuardLogix controlling motion and Safety for the drive system. The safety devices,(e-stop, Light curtain etc..) input to the PointGuard Safety I/O and communicate on the EhterNet/IP network to the guardLogix which monitors for STO request. If STO is requested, The Safety connection to the drive system will communicate to the drives and Execute the safe torque off request.
Integrated Safety Enhances Machine Performance and Flexibility

26. Any Questions? Now More Safety on the PF527