[PROJECT NUMBER] [PROJECT NAME]

[DATE] [PROJECT LOCATION]

ROCKWELL AUTOMATION PROCUREMENT SPECIFICATION

PROCUREMENT SPECIFICATION
PowerFlex 525
Low Voltage AC
Variable Frequency Drive

NOTICE: The specification guidelines in this document are intended to aid in the specification of
products. Specific installations have specific requirements, and Rockwell Automation does not
recommend or intend any specific application based solely upon the guidelines provided here.
Because of the variety of uses for this information, the user of, and those responsible for applying
this information, are responsible for ensuring the acceptability of each application and appropriate
use of the guidelines. In no event will Rockwell Automation be liable for misuse, misapplication or
reliance on these guidelines in connection with any specific application. Rockwell Automation also
disclaims indirect or consequential damages resulting from the use or application of this
information.

Note: To download or view a .doc file version of this procurement specification, please visit:
www.rockwellautomation.com/industries/procurement-specifications

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TABLE OF CONTENTS

PART 1 GENERAL........................................................................................................................... 3
1.01 SUMMARY......................................................................................................................... 3
1.02 RELATED SECTIONS........................................................................................................3
1.03 CERTIFICATIONS/REFERENCES....................................................................................3
1.04 SUBMITTALS..................................................................................................................... 4
1.05 CLOSEOUT SUBMITTALS (OPERATION AND MAINTENANCE MANUALS)...................4
1.06 QUALITY ASSURANCE.....................................................................................................5
1.07 DELIVERY, STORAGE AND HANDLING...........................................................................5
1.08 WARRANTY....................................................................................................................... 5
PART 2 PRODUCTS........................................................................................................................ 5
2.01 MANUFACTURERS........................................................................................................... 5
2.02 RATINGS........................................................................................................................... 5
2.03 CONSTRUCTION.............................................................................................................. 6
2.04 CONFIGURATION/PROGRAMMING.................................................................................8
2.05 COMMUNICATIONS..........................................................................................................8
2.06 CONTROL FEATURES......................................................................................................9
2.07 CONTROL I/O.................................................................................................................... 9
2.08 DIMENSIONS.................................................................................................................. 10
PART 3 EXECUTION..................................................................................................................... 10
3.01 EXAMINATION................................................................................................................. 10
3.02 INSTALLATION................................................................................................................ 10
3.03 START-UP SERVICE.......................................................................................................10

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SECTION XX XX XX
LOW VOLTAGE AC VARIABLE FREQUENCY DRIVE
PART 1 GENERAL
PART 2 SUMMARY

PART 3 The Variable Frequency Drive (VFD) system shall contain all components required to meet
the performance, protection, safety and certification criteria of this specification.

PART 4 RELATED SECTIONS

PART 5 Section 26 05 00 – Common Work Results for Electrical

PART 6 Section 26 00 00 – Electrical – General Provisions

PART 7 CERTIFICATIONS/REFERENCES

PART 8 Certifications and approvals shall include:

PART 9 c-UL-us – UL508C and CAN/CSA-C22.2 No. 14-05

PART 10 C-Tick – Radiocommunications Act: 1992; Std.: 2008; Labeling Notice: 2008
PART 11 CE –

PART 12 In conformity with EMC Directive (2004/108/EC) and Low Voltage Directive (2006/95/EC)
PART 13 Standards EN 61800-3:2004 and EN 61800-5-1:2007

PART 14 TÜV –

PART 15 Standards EN ISO 13849-1:2008, EN ISO 13849-2:2008, EN 61800-5-2:2007, EN 61508

PARTS 1-7:2010, EN 62061:2005 and EN 60204-1:2009
PART 16 With embedded Safe-Torque-Off function, certified to ISO 13849-1 SIL2/PLd and meets
Functional Safety (FS)

PART 17 ATEX – Directive 94/9/EC

PART 18 KCC – Compliant with Article 58-2 of Radio Waves Act, Clause 3
PART 19 GOST-R – Certificate No. POCC US.ME92.H00040
PART 20 AC156
PART 21 EPRI – Semi F47, IEC 61000-4-34
PART 22 RINA – ELE283205CS marine certification
PART 23 Lloyd’s Register Type Approval Certificate 12/10068(E1)
PART 24 RoHS

PART 25 The VFD shall also meet the appropriate portions of the following specifications:

PART 26 NFPA 70 – US National Electrical Code

PART 27 NEMA ICS 3.1 – Safety Standards for Construction and Guide for Selection, Installation
and Operation of Adjustable Speed Drive Systems
PART 28 IEC 146 – International Electrical Code

PART 29 SUBMITTALS

PART 30 Submit under provisions of Section 01 30 00

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PART 31 Shop Drawings – Approval

PART 32 Elevation Drawings: Shall include dimensional information and conduit routing locations.
PART 33 Unit Descriptions: Shall include amperage ratings, enclosure ratings, fault ratings,
nameplate information, etc. as required for approval.
PART 34 Wiring Diagrams:

PART 35 Power Diagram: Shall include amperage ratings, circuit breaker frame sizes, circuit
breaker continuous amp ratings, etc. as required for approval.
PART 36 Control Diagram: Shall include disconnect devices, pilot devices, etc.

PART 37 Major components list.

PART 38 Product Data Sheets

PART 39 VFD publications.

PART 40 Data sheets and publications on all major components.

PART 41 Test procedures shall be per the manufacturer’s standards.

PART 42 CLOSEOUT SUBMITTALS (OPERATION AND MAINTENANCE MANUALS)

PART 43 Submit under provisions of Section 01 30 00

PART 44 Shop Drawings – Final as shipped

PART 45 Elevation Drawings: Shall include dimensional information and conduit routing locations.
PART 46 Unit Descriptions: Shall include amperage ratings, enclosure ratings, fault ratings,
nameplate information, etc. as required for approval.
PART 47 Wiring Diagrams:

PART 48 Power Diagram: Shall include amperage ratings, circuit breaker frame sizes, circuit
breaker continuous amp ratings, etc. as required for approval.
PART 49 Control Diagram: Shall include disconnect devices, pilot devices, etc.

PART 50 Major components list.

PART 51 Product Data Sheets

PART 52 VFD publications.

PART 53 Data sheets and publications on all major components.

PART 54 Test procedures shall be per the manufacturer’s standards.

PART 55 Operation and Maintenance Data

PART 56 Service and Contact information.

PART 57 VFD User Manual.
PART 58 Troubleshooting/Service Manual.

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PART 59 QUALITY ASSURANCE

PART 60 Qualifications:

PART 61 Manufacturers:

PART 62 The VFD and all associated optional equipment shall be UL listed or recognized.
PART 63 The VFD shall contain a UL label attached on the inside of the enclosure cabinet.

PART 64 Suppliers:

PART 65 All inspection and testing procedures shall be developed and controlled under the
guidelines of the supplier’s quality system and must be registered to ISO 9001 and regularly
reviewed and audited by a third party registrar.
PART 66 The VFD shall be factory pre-wired, assembled and tested as a complete package.

PART 67 DELIVERY, STORAGE AND HANDLING

PART 68 Supplier shall coordinate the shipping of equipment with the manufacturer.
PART 69 Supplier shall store the equipment in a clean and dry space at an ambient temperature
range of -40°C to 85°C (-40°F to 185°F).
PART 70 The supplier shall protect the units from dirt, water, construction debris and traffic.

PART 71 WARRANTY

PART 72 The manufacturer shall provide their standard parts warranty for eighteen (18) months
from the date of shipment or twelve (12) months from the date of being energized, whichever
occurs first.
PART 73 This warranty applies to variable frequency drive systems.

PART 74 PRODUCTS
PART 75 MANUFACTURERS

PART 76 Allen-Bradley – PowerFlex 525 Low Voltage AC Variable Frequency Drive (No
substitutions)

PART 77 RATINGS

PART 78 The variable frequency drive (VFD) shall be designed to operate in one of the following
input voltage classes with -15%/+10% voltage tolerance:

PART 79 100 to 120 VAC, 1 phase.

PART 80 200 to 240 VAC, 1 phase.
PART 81 200 to 240 VAC, 3 phase.
PART 82 380 to 480 VAC, 3 phase.
PART 83 525 to 600 VAC, 3 phase.

PART 84 The VFD shall operate from an input frequency range of 47 to 63 Hz.

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PART 85 The VFD shall have a power rating of:

PART 86 100 to 120V: 0.4 to 1.1 kW / 0.5 to 1.5 HP.

PART 87 200 to 240V: 0.4 to 15 kW / 0.5 to 20 HP.
PART 88 380 to 480V: 0.4 to 22 kW / 0.5 to 30 HP.
PART 89 525 to 600V: 0.4 to 22 kW / 0.5 to 30 HP.

PART 90 The displacement power factor of the VFD shall be between 1.0 and 0.95, lagging, over
the entire speed range.
PART 91 The efficiency of the VFD shall be a minimum of 97% at full load and speed.
PART 92 The overload capability shall be:

PART 93 Normal Duty – 110% for up to 1 minute, 150% for up to 3 seconds.

PART 94 Heavy Duty – 150% for up to 1 minute, 180% for up to 3 seconds (200% programmable).

PART 95 The VFD shall have a maximum output frequency of 500 Hz.
PART 96 The VFD shall provide UL Listed Class 10 motor overload protection to comply with
N.E.C. Article 430.
PART 97 The VFD shall be designed to operate in the following environmental conditions:

PART 98 Ambient temperature range –

PART 99 -20°C to 50°C (-4°F to 122°F).

PART 100 -20°C to 60°C (-4°F to 140°F) with current derating.
PART 101 -20°C to 70°C (-4°F to 158°F) with current derating and control module fan kit (option).

PART 102 Relative humidity range – 0% to 95% non-condensing.

PART 103 Elevation –

PART 104 up to 1000 m (3280 ft.).

PART 105 up to 4000 m (13123 ft.) with current derating [2000 m (6561 ft.) for 525 to 600V drives].

PART 106 Shock and vibration –

PART 107 Shock: 15G peak for 11 ms duration (±1.0 ms).

PART 108 Vibration: 1G peak, 5 to 2000 Hz.

PART 109 CONSTRUCTION

A. The variable frequency drive (VFD) shall have a compact footprint and be of modular
design to provide for ease of installation and inventory reduction, consisting of:

1. A power module sized to meet the application.

2. A control module common to all VFD ratings.

3. The VFD shall be IP20/NEMA Open. Optional conduit box in IP21/IP30 NEMA Type
1 shall be available.
4. The VFD shall be able to be mounted in both vertical and horizontal orientation.
Frames A to C shall be able to be installed on a DIN rail. The VFD shall be capable
of side-by-side installation.
5. The VFD shall employ the following power components:

6. Diode or fully gated bridge on the input.

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7. Switching logic power supply operating from the DC bus.

8. MOV protection – phase to phase and phase to ground with jumpers to remove the
phase to ground unit when applicable.
9. Gold plated plug-in connections on printed circuit boards.
10. Microprocessor-based inverter logic isolated from power circuits.
11. Inverter section with no commutation capacitors.

12. The VFD shall have a standard built-in 7th IGBT for use as a dynamic braking
chopper. This IGBT shall be able to provide at least 100% braking torque on a
continuous basis with a properly sized externally-mounted brake resistor.
13. The VFD shall have two EMC options to comply to IEC 61800-3 specification, each
with an optional EMC earthling/grounding plate:

14. Embedded EMC filter – shall achieve 10 m for C2 and 20 m for C3.
15. External EMC filter – shall achieve 30 m for C1 and 100 m for C2 and C3.

16. The VFD shall have a standard USB port that connects to a PC for upgrading
firmware or uploading/downloading parameter configurations.
17. With its RS-485 port, the VFD shall provide an interface for up to 2 independent
peripherals to be connected at one time at 19.2K Bps. Connection and identification
of peripheral interface DSI addresses shall require no user adjustments.
18. The VFD shall have an embedded EtherNet/IP port. A slot shall be available for dual
port EtherNet/IP, DeviceNet and PROFIBUS DP adapter cards.
19. A slot for an optional encoder card shall be available to perform simple positioning
control. Closed loop with encoder feedback shall be available to replace slip
compensation with trim for improved speed range and regulation.
20. The VFD shall have embedded control I/O.
21. The VFD shall have an embedded safe-torque off solution certified to SIL2 / PLd.
This requires the use of an external safety relay to meet ISO 13849-1. The safety
solution shall maximize safety, increase machine up-time and help protect personnel
and equipment. Communications shall be active throughout when safety is initiated.
22. The VFD’s printed circuit board shall be conformal coated, certified to IEC60721-3-2
with 3C2 (Chemical & Gases at the minimum).
23. The VFD’s control module shall have an integral Human Interface Module (HIM).

24. 5-digit LCD display with scrolling text, used to display drive operating conditions,
fault/alarm indications and programming information and capable of showing
multiple languages via selectable mode.
25. Status LED for drive condition.
26. Status LEDs for communications status, including embedded DSI status, adapter
health and communications network status.
27. Keys for navigation, start, stop and reverse.
28. Potentiometer used to control speed of the drive.

29. The VFD shall have an optional external Human Interface Module (HIM) available in
two package styles:

30. A backlit LCD display with graphics capability and rated for IP20/Type 1, used as a
handheld terminal by connecting via a separate cable or used in a bezel kit mounted
to a cabinet/panel. This package style is removable (slides out) without the use of a
tool.

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31. An IP66/UL Type 4X-12 remote-mounted version for cabinet/panel mounting that is
connected via cable.

32. The VFD’s control module shall have available a fan kit to accommodate horizontal
mounting and extreme ambient temperatures.

33. CONFIGURATION/PROGRAMMING

34. The variable frequency drive (VFD) shall be configurable using:

35. The HIM’s keypad and LCD display.

36. Connected Components Workbench™ – This software offers configuration and
programming.
37. Studio 5000™ Logix Designer – This software, a single development environment
for the entire control system, includes add-on profiles which minimize the need to
individually program the required parameters and tags. (Available to VFDs on
EtherNet/IP or ControlNet.)

38. Autogeneration of descriptive tag names and respective tag data types.
39. Wizards available to walk through configuration.
40. Copy and paste function to easily duplicate VFDs.
41. Single development environment – minimizes errors associated with multiple
software tools.
42. Configuring entire system from one environment – minimizes I/O mismatch errors.

43. Through the Studio 5000 Logix Designer, a Logix controller shall be able to use
Automatic Device Configuration (ADC) to detect a replaced VFD and download the
needed firmware and all configuration parameters. (Available to VFDs on
EtherNet/IP.)
44. With Studio 5000 software,

45. VFD configuration settings shall be stored in the project file and in the control
system’s PACs. This VFD I/O packet shall consist of:

46. VFD status and feedback, command and reference.

47. At least 8 data words of inputs and 8 data words of outputs that can be dynamically
configured to access any parameter.

48. VFDs shall be able to be flash-updated directly.

49. COMMUNICATIONS

50. The variable frequency drive (VFD) shall be capable of communications through
standard protocols, and EtherNet/IP and DeviceNet shall be the preferred networks.

51. Through its USB port, the VFD shall be capable of direct connection to a PC.
52. Through its integral RS-485 port, the VFD shall be able to use Modbus RTU:

53. For programming from a PC.

54. In a multi-drop network configuration.

55. Through its integral Ethernet port, the EtherNet/IP network is supported.

56. The VFD shall be able to communicate with at least 2 networks at the same time.

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57. The VFD shall have available adapter cards, including:

58. Dual port EtherNet/IP – to support Device Level Ring topology.

59. DeviceNet.
60. PROFIBUS DP.

61. VFD communications adapters shall have individually selectable fault actions in the
case of a communications loss or if the controller is idle (in program mode or
faulted):

62. Faulting the VFD.

63. Stopping the VFD.
64. Zeroing data written to the VFD.
65. Holding the VFD in its last state.
66. Using a user-selectable fault configuration.

67. CONTROL FEATURES

68. The variable frequency drive (VFD) shall be programmable for the following motor
control modes:

69. Volts per Hertz.

70. Sensorless vector control.
71. Closed loop velocity vector control.
72. Sensorless vector control with Economizer.
73. Permanent magnet motor control (scheduled for a future firmware release).

74. The VFD shall be capable of open loop and closed loop speed regulation
applications.
75. Programmable features shall include:

76. Flying start

77. V/F ratio
78. Bus regulator
79. Process PID
80. Fiber-application-specific features
81. Common DC bus
82. 1/2 DC bus operation
83. Regulation with encoder feedback or analog input
84. Multi-drive connectivity (with communication option card)
85. StepLogic Function (relay and timers)
86. 16 preset speeds

87. The VFD shall include energy cost reduction potential through energy monitoring
features and Economizer and permanent magnet motor control modes.

88. CONTROL I/O

89. The variable frequency drive (VFD) shall have 2 analog inputs (1 unipolar and 1
bipolar), independently isolated from the rest of the drive I/O.
90. The VFD shall have 7 digital inputs (24 VDC, 6 programmable) to provide
application versatility.

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91. The VFD shall have 1 analog output that is scalable, 10-bit, suitable for metering or
as a speed reference for another drive.
92. The VFD shall have 2 digital outputs and 2 relay outputs (1 form A and 1 form B) to
be used to indicate various drive, motor or logic conditions.

93. DIMENSIONS

94. Frame A: 152 mm (5.98 in.) H x 72 mm (2.83 in.) W x 172 mm (6.77 in.) D
95. Frame B: 180 mm (7.08 in.) H x 87 mm (3.42 in.) W x 172 mm (6.77 in.) D
96. Frame C: 220 mm (8.66 in.) H x 109 mm (4.29 in.) W x 184 mm (7.24 in.) D
97. Frame D: 260 mm (10.23 in.) H x 130 mm (5.11 in.) W x 212 mm (8.34 in.) D
98. Frame E: 300 mm (11.81 in.) H x 185 mm (7.28 in.) W x 279 mm (10.98 in.) D

PART 110 EXECUTION

PART 111 EXAMINATION

PART 112 Verify that location is ready to receive equipment.

PART 113 Verify that the building environment can be maintained within the service conditions
required by the manufacturer of the VFD.

PART 114 INSTALLATION

PART 115 Installation shall be in compliance with all manufacturer requirements, instructions and
drawings.

PART 116 START-UP SERVICE

PART 117 At a minimum, the start-up service shall include:

PART 118 Perform pre-power check

PART 119 Megger motor resistances: phase-to-phase and phase-to-ground
PART 120 Verify system grounding per manufacturer’s specifications
PART 121 Verify power and signal grounds
PART 122 Check connections
PART 123 Check environment

PART 124 Drive power-up and commissioning:

PART 125 Measure incoming power phase-to-phase and phase-to-ground

PART 126 Measure DC bus voltage
PART 127 Measure AC current unloaded and loaded
PART 128 Measure output voltage phase-to-phase and phase-to-ground
PART 129 Verify input reference signal

PART 130 All measurements shall be recorded.

PART 131 Drive shall be tuned for system operation.
PART 132 Drive parameter listing shall be provided.

END OF SECTION

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