Allen-Bradley 25B-D010N104 PowerFlex 525 4 kW (5 Hp) AC Drive

A 4 kW (5 Hp) PowerFlex 525 in a frame B housing

The Allen-Bradley 25B-D010N104 is a PowerFlex 525 drive for 5 Hp (4 kW) motors on a 380 to 480V three-phase supply. Rockwell lists 10.5 A of output current, which is the first rating in the 480V range that moves up to frame B.

It has no integral EMC filter, the embedded EtherNet/IP port and Safe Torque Off, and it is catalogued as a Preferred product on the Rockwell product page.

Technical specifications

Ordering code for 25B-D010N104

The code is 25B for PowerFlex 525, D for 480V AC, 010 for a 10.5 A rating, N for the IP20 enclosure, and then 1, 0 and 4. Those last digits are the standard interface, emission class 0 (no filter) and standard braking.

Three-digit current codes like 010 are used from 10 A upward, while smaller drives use the P decimal style such as 6P0. The filtered version is 25B-D010N114, which has 133 W of loss against 129 W here.

The drive offers an embedded EtherNet/IP port and an RS485 DSI port, so it can be configured and monitored over the network. Efficiency is 97.5% typical, the sound pressure is up to 53 dBA for frames A and B, and ambient limits are 50 °C vertical or 45 °C with zero stacking in the open-type form.

Mounting hardware matters at this size. Frame B uses the same M5 screw size as frames A and C, with a torque of 1.56 to 1.96 N-m, and its mass of 1.6 kg is small enough for DIN rail use. Allow the clearances shown in the manual above and below the drive for airflow.

Frame B dimensions and protection

Frame B measures 87 x 180 x 172 mm and weighs 1.6 kg, and it can be mounted on DIN rail or by screws. Input is 12.6 kVA with 13.8 A maximum. The UL 61800-5-1 table recommends a 30 A fuse, a 100-C23 or 100-E26 contactor and a 140MT-D9E-C16 circuit breaker, while the IEC fuse range is 20 A to 32 A.

Overload ratings are 150% for 60 seconds and 180% for 3 seconds in the heavy-duty description.

Panel installation and wiring practice

As an IP20 open-type drive, the 25B-D010N104 has to be installed inside an enclosure that provides the protection required on site. Plan the panel layout so that the drive is mounted vertically with the clearances given in the PowerFlex 520-series user manual, and keep heat sources such as transformers and braking resistors away from the air path below and above it. When several drives share a panel, check that the enclosure ventilation or cooling can remove the combined watts loss of all devices, not only that of this drive.

Separate power and control wiring. Run motor cables, supply cables and low-voltage control or network cables in different ducts, cross them at right angles where they must meet, and use shielded motor cable terminated according to the manual. Because this catalog number has no integral EMC filter, decide early whether the installation needs an external filter to meet the emission requirements of the site, particularly where the drive shares a supply with sensitive instruments or communication equipment.

Protection and the Safe Torque Off circuit

Select the branch-circuit protection from the fuse, contactor and breaker recommendations listed above rather than from a general table. If Safe Torque Off is used as part of a safety function, design and validate that circuit according to the safety reference manual and the risk assessment for the machine. If it is not used, leave the factory jumper in place as the manual describes, otherwise the drive will not run.

Commissioning the drive

Before energising, check the motor nameplate against the drive rating, confirm the supply voltage at the terminals and verify that all covers are fitted. Enter the motor data in the basic program group, select the control method that suits the load, and run an autotune where the motor and machine allow it. Set acceleration and deceleration times to values the mechanics and the supply can tolerate, and confirm the stop mode required by the process.

For network control, assign an IP address to the embedded EtherNet/IP port and add the drive to the controller project with the correct profile. Connected Components Workbench or Studio 5000 Logix Designer can be used to save the finished parameter set, and keeping a copy of that file with the panel documents makes a future replacement much faster.

Operating in hot and dusty Omani sites

Many electrical rooms and outdoor panels in Oman run close to the ambient limits quoted above during summer. Measure the actual temperature inside the enclosure on a hot day after commissioning, not only at the design stage. Where the air is dusty, fit filters on panel fans and clean them on a fixed schedule, since a blocked filter quickly raises the internal temperature and can cause nuisance trips or shorten component life.

During routine maintenance, read the fault queue, check terminal tightness after thermal cycling, and inspect the heat sink for dust buildup. Keeping the saved parameter file current after every change avoids guesswork when a drive has to be replaced during a shutdown.

Quotation details

Send the 25B-D010N104 reference, motor nameplate and supply voltage. Confirm the exact catalog number before ordering. Related items are in AC Drives and PowerFlex 525 AC drive.