Allen-Bradley PowerFlex 525 25B-D6P0N114 2.2 kW AC Drive

A 2.2 kW PowerFlex 525 for pumps and fans

The Allen-Bradley 25B-D6P0N114 is a 2.2 kW (3 HP) PowerFlex 525 drive for 380 to 480 V supplies, delivering 6.0 A in the same compact Frame A as the 0.4 kW unit. It is the largest Frame A rating, which makes it popular for small pumps, ventilation fans, mixers and conveyor sections where a 4 pole 2.2 kW motor is used. It carries normal and heavy duty ratings of the same size.

The drive has embedded EtherNet/IP, six programmable digital inputs, two analog inputs, two relay outputs and a Safe Torque Off function. The integral EMC filter is fitted, so the drive can be placed near other equipment in a cabinet without an extra line filter in many installations.

Technical specifications

Application and protection notes

With 6.0 A output the drive loses 88 W, about three times the loss of the 1.4 A model, so leave the clearances in the user manual or use zero stacking only up to 45 °C. The input current of 6.9 to 7.5 A calls for IEC fuses between 10 and 16 A, with the 100-E09 contactor and the 140MT-C3E-C10 breaker in the UL protection table.

Many of these drives drive pumps, where the PID function of the 525 can hold a pressure or level set point directly from an analog transmitter. Use the second PID loop or the economizer vector mode to reduce energy on variable-torque loads.

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 of the 25B-D6P0N114

• Embedded EtherNet/IP: the drive connects directly to Logix controllers and can be added to a Studio 5000 project with its parameters, reducing the need for separate communication cards.
• Safe Torque Off: hardwired STO removes torque-producing power to the motor without disconnecting the drive supply, which simplifies machine safety circuits.
• Several motor control methods: V/Hz, sensorless vector, economizer, closed-loop velocity vector and permanent-magnet motor control are all in one unit.
• Dual duty rating: 2.2 kW in both normal and heavy duty, with heavy-duty overload of 150% for 60 s.
• Modular design: the control module separates from the power module, so configuration can be done before the power section is installed.

Normal duty or heavy duty?

Normal duty suits variable-torque loads such as centrifugal pumps and fans, which seldom need more than modest overload. Heavy duty applies to constant-torque machinery such as conveyors, mixers and positive-displacement pumps, where starting torque and short overloads are higher. Because this catalogue number carries the same 2.2 kW rating for both, the important check is the motor full-load current against the 6.0 A output, together with the expected overload profile.

Programming and commissioning

Initial set-up can be done from the built-in keypad and LCD, through Connected Components Workbench software, or over EtherNet/IP from the controller. A practical sequence is to enter the motor nameplate data, run an autotune, select the start and speed reference source, set ramps and then verify the STO circuit. Keeping a saved copy of the parameter file makes swapping a failed unit much faster.

Protecting the drive and motor

Use the fuse or breaker values given in the specification table, and follow the Rockwell grounding and shielding recommendations for the motor cable. For long cable runs, check whether a load reactor or dv/dt filter is needed to protect motor insulation. Where several drives run from one transformer, line reactors help reduce harmonic current and protect against supply transients.

Using the drive in Gulf conditions

In Omani water pumping stations, building services and food processing, drives are often housed in cabinets exposed to heat and dust. Size the enclosure cooling around the 88 W loss of this drive plus the other components in the panel, and verify cabinet temperature against the drive’s ambient rating, applying derating if it is exceeded. Fit filtered fans or air conditioning where dust and sand are present, and clean filters regularly.

RFQ details

• Catalog number 25B-D6P0N114 and the required quantity.
• Accessories: line reactor, IP30/NEMA 1 kit, communication adapters or spare control modules.
• Motor rating and load type if you want sizing reviewed.
• Delivery location and project schedule.

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.