2025-04-28

From standalone devices to integrated systems, the PowerFlex 520-series AC drives deliver a flexible, cutting-edge approach to motor control in a variety of applications. While its primary capabilities are widely known, the series also includes several advanced features that are often overlooked but can significantly boost the effectiveness and efficiency of business operations. Here, we explore five "hidden gems" of the PowerFlex 520-series drives that can enhance energy efficiency, control precision, and overall productivity.

Enhanced Control Performance with Multiple Motor Control Options

The PowerFlex 520-series drives offer a wide range of motor control options, an extremely powerful but often underutilized feature. The PowerFlex 525, in particular, stands out with multiple control modes:

• Volts-per-Hertz (V/Hz) Control: Reliable and simple, ideal for general applications without critical speed control requirements.

• Sensorless Vector Control (SVC): Provides precise motor control without needing feedback sensors.

• Closed Loop Velocity Vector Control: Exclusive to the PowerFlex 525, it uses encoder feedback for exact speed control in heavy-duty applications.

• Permanent Magnet Motor Control: Supports high-efficiency motor types that are increasingly popular in industrial applications.

• PointStop Function: Allows loads to stop consistently without sensors, critical for precision-required applications like packaging and material handling.

This flexibility ensures that operators can adapt the drive to a wide range of machines without additional hardware.

Advanced PID Control for Application Flexibility

Built-in Proportional-Integral-Derivative (PID) control enhances system performance by maintaining stable process variables like temperature, pressure, and flow.

• PowerFlex 523: Offers a single PID loop for basic control needs.

• PowerFlex 525: Features dual PID loops for simultaneous, independent control of two different process variables.

For example, in a complex pumping system, one PID could manage flow rate while the other controls pressure, all without the need for external controllers, significantly reducing system complexity and cost.

Integrated Communications for Seamless System Integration

PowerFlex 520-series drives provide exceptional communication capabilities essential for modern networked systems:

• Embedded Ethernet Port: Simplifies control system integration and improves diagnostics.

• Dual-port EtherNet/IP Option Card: Supports Device Level Ring (DLR) topologies, maintaining communication even during network cable failures.

• RS485/DSI Communication: Enables simple multi-drop network configurations.

• Optional Communication Cards: Support DeviceNet and PROFIBUS DP protocols, allowing easy integration without overhauling existing systems.

These features reduce setup time and improve troubleshooting, particularly in large installations.

Optimized for Common DC Bus Installations

The 520-series drives are also optimized for common DC bus configurations:

• Shared Energy: Multiple drives can share braking energy, reducing the need for individual braking resistors.

• Simplified Wiring: Enhanced internal precharge control and direct DC bus connections reduce installation complexity and costs.

This configuration is ideal for operations focused on energy efficiency, cost savings, and system simplicity.

Improved Ride-through Capabilities for Critical Operations

For industries where downtime is unacceptable, PowerFlex 520-series drives offer superior ride-through capabilities:

• 1/2 Line Voltage Operation: Maintains continuous output even if incoming supply voltage drops by 50%.

• Enhanced Inertia Ride-through: Utilizes the load's kinetic energy during brief power outages, maintaining stable operations.

These features ensure uninterrupted operation during power disturbances, protecting critical processes like manufacturing lines, HVAC systems, and water treatment plants.

Conclusion

The PowerFlex 520-series drives, especially the PowerFlex 525, offer a range of hidden features that can significantly streamline operations. By leveraging enhanced motor control options, advanced PID loops, integrated communications, optimized DC bus functionality, and superior ride-through capabilities, users can boost system efficiency, reduce costs, and minimize downtime.

At DO Supply, we specialize in Allen-Bradley drives like the PowerFlex 520-series and more. Our team of sales and technical experts is ready to help you find the perfect solution for your automation needs. Visit DoSupply.com today or reach out by phone or email—we're here to support your success. If you enjoyed this article, be sure to check out our blog on installing PowerFlex 520-series drives!

For more information or help selecting the right drive, contact PLG Automation:
Email: sales@plgautomation.com
Phone: 800-906-9271