Allen-Bradley PowerFlex 525 25B-D017N114 7.5 kW AC Drive

The 7.5 kW PowerFlex 525 with integral filter

The Allen-Bradley 25B-D017N114 is a 7.5 kW (10 HP) PowerFlex 525 with 17.0 A output at 380 to 480 V, the top rating of Frame C. For many plants it is the standard drive for 7.5 kW process pumps and fans because it fits the compact 109 mm frame, can still be DIN-rail mounted, and includes an integral EMC filter, EtherNet/IP and Safe Torque Off.

The drive provides closed-loop velocity vector control, permanent magnet motor control and PointStop positioning, so it can serve in light machine automation as well as in utilities. Overload capability is 110 percent for 60 seconds in normal duty.

Technical specifications

Choosing the N114 or N104 version

The N114 in this catalog number means the drive has an integral EMC filter and standard interface module, losing 230 W, while the N104 (25B-D017N104) has no filter and loses 221 W. Select the filtered version when the drive is the only EMC measure in the installation, for example with a shielded motor cable, and the non-filtered version when an external filter or an isolated supply is used.

Protection devices from the table are the 100-E26 contactor, the 140MT-D9E-C20 motor protector and IEC fuses of 25 to 40 A. In a multi-drive panel the heat is concentrated, so check the 230 W loss against the panel size.

Catalog code and family ratings

Reading the catalog number: 25B is the PowerFlex 525, D is the 380…480V 3-phase supply, the next group is the output current code, N is the IP20 open enclosure, 1 is the standard interface, and the following digit is the emission class: 1 means an integral EMC filter and 0 means no filter. The last digit 4 is the version.

Key features for 7.5 kW pump and fan duty

• Modular construction: the control module separates from the power module, so programming and wiring can start before the power section is installed.
• Embedded EtherNet/IP port with integration into Studio 5000 Logix Designer through Add-on Profiles, which reduces separate configuration work on Logix-based systems.
• Safe Torque Off built in, so a safety relay can remove torque without switching the motor supply through a contactor for every stop.
• Several motor control modes in one drive, from simple V/Hz for fans to sensorless vector and closed-loop velocity vector for conveyors and positioning.
• SVC economizer mode, which reduces motor flux at light load to save energy on variable-torque loads.
• Configuration through the integral keypad, Connected Components Workbench software or a USB connection, with the ability to program the control module without mains power through USB.

Sizing considerations

Select the drive on motor full-load current rather than on kilowatts alone. A standard four-pole 7.5 kW motor at 400 V usually draws less than the 17.0 A rating, but high-pole-count, older or special motors may draw more, and the motor nameplate current must stay within the drive output current at the expected duty. For loads that need high starting torque or frequent acceleration, such as loaded conveyors, mixers or positive displacement pumps, check the heavy duty overload rating and consider stepping up a size where repeated peaks are expected.

Above 1000 m altitude, above 50 °C ambient or at high carrier frequency, derating applies; the derating curves in the specifications document should be used when the drive is installed in a hot plant room or an outdoor enclosure.

Panel installation tips

• Keep the minimum clearances above and below the drive given by Rockwell Automation to allow cooling air flow, and remember that side-by-side mounting may require derating.
• Use shielded motor cable with the shield bonded at both ends for best EMC performance with the integral filter.
• Separate power and control wiring, and run analog signals in shielded twisted pair cable.
• For long motor cables, check the manufacturer recommendations on output reactors or dV/dt filters to protect motor insulation.
• Wire the Safe Torque Off terminals as the safety design requires; the factory jumper must be removed when STO is used.

Commissioning and maintenance

Enter the motor nameplate data and run the autotune routine before operating in vector modes. Save the parameter file to a PC or the control module so a replacement drive can be loaded quickly. Periodic maintenance consists of cleaning cooling fins and fan inlets, checking terminal tightness and reviewing the fault log; the cooling fan is a wear item and should be inspected during scheduled shutdowns.

Applications in Oman and GCC conditions

Typical duties include chilled water and condenser water pumps, cooling tower and AHU fans, booster sets, conveyor drives and small compressors. Many panels in the region operate in hot, dusty rooms, so filtered ventilation or air conditioning of the enclosure is often required to keep the drive within its rated ambient range. Where generators supply the plant, the drive input protection should be coordinated with the generator capacity and voltage variations.

What to include in an RFQ

• Catalog number 25B-D017N114 and quantity.
• Motor kW, full-load current and supply voltage.
• Required communication options and any accessories such as keypads or fan kits.

Documents and quotation

Seven Star LLC supplies PowerFlex 525 drives against the full catalog number. The Rockwell Automation PowerFlex 520-series specifications document is attached. Compare with the Allen-Bradley PowerFlex 525 page and see the AC drives category. Confirm the exact catalog number, series letter and firmware or hardware revision on the product label, and the compatibility with your existing system, before ordering. Stock and lead time are confirmed at quotation.