Allen-Bradley 25B-D6P0N104 PowerFlex 525 2.2 kW (3 Hp) AC Drive

A 2.2 kW PowerFlex 525 for three-phase pumps and fans

The Allen-Bradley 25B-D6P0N104 is a PowerFlex 525 drive rated 3 Hp (2.2 kW) with 6 A output on a 380 to 480V AC three-phase supply. It is the largest of the frame A ratings in this voltage class, and it has no integral EMC filter.

Typical uses are conveyors, pumps, fans and mixers where an embedded Ethernet port and Safe Torque Off save on external modules.

Technical specifications

Catalog number explained

In 25B-D6P0N104, 25B is the PowerFlex 525, D is the 480V AC three-phase supply, and 6P0 is a 6.0 A output current. N is the IP20 NEMA Open Type enclosure, and the digits 1, 0 and 4 stand for the standard interface, no EMC filter and standard braking.

The filtered equivalent is 25B-D6P0N114, which the technical data lists at 88 W of total loss against 86 W for this model.

Motor control options include volts per hertz, sensorless vector, economizer SVC and closed loop vector with an encoder, and the same drive can run permanent magnet motors. Speed regulation is within 0.5% of base speed across a 100:1 range in sensorless vector mode, according to the control table.

For ordering, keep in mind that the drive is supplied as the base unit; keypad variants, conduit boxes, communication cards and brake resistors are listed in the accessories section of the technical data and are quoted separately. Check the motor nameplate current against the 6.0 A output before choosing a lower or higher frame.

Branch circuit sizing

The input rating is 6.9 kVA and 7.5 A maximum. For UL 61800-5-1 applications the table shows a 15 A fuse, a 100-C09 or 100-E09 contactor and a 140MT-C3E-C10 breaker; the IEC fuse range is 10 A to 16 A.

Frame A measures 72 x 152 x 172 mm and weighs 1.1 kg. Even at 3 Hp it fits the same footprint as the 1 Hp model.

Key features of the PowerFlex 525 platform

The PowerFlex 525 is built as a compact component-class drive that still carries features normally found on larger units. For a 2.2 kW motor on a 400 V network, the points that matter most in practice are listed below.

• Embedded EtherNet/IP port – the drive can be connected straight to a Logix controller or an HMI without an add-on communication card, which simplifies panel layout and wiring.
• Safe Torque Off – the built-in STO function is certified to ISO 13849-1 PLd / SIL 2, so a safety relay can remove torque from the motor without opening the main contactor on every stop.
• Several motor control modes – volts per hertz for simple fans and pumps, sensorless vector control for conveyors and mixers that need torque at low speed, an economizer mode that trims energy on lightly loaded machines, closed loop vector with an encoder, and permanent magnet motor control.
• Removable control module – on the PowerFlex 525 the control core separates from the power section, which allows configuration to be prepared while the power section is still being installed.
• Normal and heavy duty at the same rating – this catalog number is rated 2.2 kW in both duty classes, with heavy-duty overload of 150% for one minute and 180% for 3 seconds.

Why the N in the catalog number matters

The 25B-D6P0N104 has no integral EMC filter. That is a sensible choice where the drive feeds a motor over a short cable in an industrial panel supplied from its own transformer, or where an external filter is already planned. Where the installation sits on a public low-voltage network, near sensitive instrumentation, or must meet a specific emission category, the filtered variant of the same rating or an external filter should be considered. It is worth deciding this before ordering, because a different catalog number is involved.

The drive is also IP20 open type, so it needs to be mounted inside an enclosure. The enclosure must remove the 86 W of heat loss listed in the data sheet, together with the heat from other components in the same panel.

Selection guidance for a 2.2 kW motor

A drive is best selected by motor current rather than by kilowatts alone. Check the full-load current on the motor nameplate against the 6.0 A output of this drive at the supply voltage actually used. Four-pole 2.2 kW motors usually fall below this figure at 400 V, but older or high-efficiency designs vary, and two-pole or six-pole motors can differ again.

If the load is a heavy constant-torque machine with frequent starts, or the motor current is close to the drive limit, the next rating up in the PowerFlex 525 range gives margin for overload and for ambient derating.

Installation and maintenance

• Protect the drive with the branch circuit devices listed in the specification table: Class CC, J or T 15 A fuses, or the listed Allen-Bradley motor protection circuit breaker and contactor.
• Mount the drive vertically with the free space above and below it that the user manual specifies, so cooling air can pass through the heat sink.
• Use shielded motor cable where long runs or EMC requirements apply, and bond the shield at both ends to a proper earth.
• Avoid switching a contactor on the drive output while the drive is running.
• Keep filters and heat sink fins clean. Dust buildup is the most common cause of over-temperature faults in small drives.
• Back up the parameter set after commissioning, either with Connected Components Workbench, Studio 5000 or the drive’s own memory, so a replacement unit can be configured quickly.

Using the drive in Oman and GCC conditions

Panels in the region frequently face high summer ambient temperatures, dust and, near the coast, salt-laden humid air. For a small drive like this the practical measures are a well-sealed enclosure, filtered or air-conditioned cooling sized for the heat load, and avoiding direct sun on the enclosure. Where the panel ambient may exceed the rated temperature of the drive, apply the derating given in the PowerFlex 520-series user manual or move to a higher rating. On remote pump stations and water network sites, the embedded Ethernet port makes remote monitoring of current, speed and fault history straightforward through a SCADA or PLC connection.

What to include in your RFQ

• The full catalog number 25B-D6P0N104 and the quantity required.
• Whether you need an EMC-filtered alternative or accessories such as a communication card, a dynamic braking resistor or a line reactor.
• Motor nameplate data and the application, so the rating can be checked.
• Delivery location in Oman or elsewhere in the GCC, and any required certificates of origin or conformity.

Quotation details

Provide the 25B-D6P0N104 reference, motor nameplate and supply. This page uses the frame A family image. Confirm the exact catalog number and suffix before ordering. Related items are in AC Drives and PowerFlex 525 AC drive.