Modernizing PowerFlex 520 Drives with Communication Option Cards

Unlocking Real-Time Control, Diagnostics, and Flexibility

In today’s industrial automation landscape, simply controlling a motor isn’t enough. Engineers expect full access to performance data, diagnostics, and configuration tools—all in real-time and over the network.

Enter the Allen-Bradley PowerFlex 520 Series—a popular family of AC drives with a huge install base across the globe. Whether you’re designing a new system or modernizing an existing one, these drives are perfect candidates for network connectivity upgrades.

This guide walks you through:

• The differences between PowerFlex 523, 525, and 527 drives

• Which models support communication cards

• Features of the three available communication option cards: EtherNet/IP, DeviceNet, and PROFIBUS

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🔧 PowerFlex 520 Series at a Glance

🔍 Note: Only the PowerFlex 523 and 525 support external communication adaptor cards.

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📡 Why Add a Communication Card?

Upgrading your drives with a communication adaptor provides:

• Real-time access to drive data

• Remote configuration and diagnostics

• Reduced wiring complexity

• Flexible network topologies (like Device Level Ring)

This is especially valuable for:

• OEMs seeking scalable solutions

• System integrators managing complex machine networks

• Maintenance teams aiming for faster issue resolution

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🔌 PowerFlex 520 Communication Option Cards

Allen-Bradley offers three plug-in communication cards for PowerFlex 523 and 525 drives:

Each card installs into the drive’s control module, is powered by the drive itself, and supports Device Serial Interface (DSI) communication.

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🔄 Card-by-Card Breakdown

1. EtherNet/IP Dual-Port Card

(Part #: 25-COMM-E2P)
Perfect for network upgrades or adding redundancy to PF 523/525 drives.

🔹 Top Features:

• Dual RJ45 ports for DLR, linear, or star topologies

• IP address setup via DIP switch, BOOTP, DHCP, or drive parameters

• 4 input / 4 output 16-bit Datalinks

• Multi-drive mode – 1 node, up to 5 drives

• Explicit Messaging support

• User-defined fault actions for communication loss or idle controller

• Built-in switch—no need for external hardware

📘 Reference: User Manual #820COM-UM003A-EN-E

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2. DeviceNet Adaptor Card

(Part #: 25-COMM-D)
Best for installations where DeviceNet is already in place or where wiring simplicity is critical.

🔹 Top Features:

• Shared power and data over a single 4-wire trunk

• Supports up to 64 nodes per network

• Datalinks: 4 in, 4 out (16-bit)

• Supports Polled, Cyclic, and Change-of-State (COS) data exchange

• Faulted Node Recovery compatible

• Multi-drive sharing: 5 drives on one DeviceNet address

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3. PROFIBUS DP Adaptor Card

(Part #: 25-COMM-P)
Designed for legacy systems running on PROFIBUS DP infrastructure.

🔹 Top Features:

• DIP switch or parameter configuration

• Supports acyclic messaging

• Compatible with HIM modules and built-in keypads

• Multi-drive mode: 5 drives per PROFIBUS node

• User-defined fault handling (e.g., comm failure, idle mode)

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✅ Choosing the Right Card

Still unsure which option suits your application? Ask these questions:

• Are you already using Logix PACs and EtherNet/IP?

• Is your plant built around DeviceNet or PROFIBUS?

• Do you need ring topology or plan for future scaling?

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🚀 Final Thoughts

The PowerFlex 520 Series offers robust motor control—and with the right communication card, it becomes a modern, networked powerhouse.

Whether you’re upgrading standalone drives or integrating them into a full automation platform, these cards give you:

• Easier troubleshooting

• Remote configuration

• Scalable, future-ready connectivity