Allen-Bradley 25B-D4P0N104 PowerFlex 525 1.5 kW (2 Hp) AC Drive

A 1.5 kW PowerFlex 525 drive without filter

The Allen-Bradley 25B-D4P0N104 is a PowerFlex 525 AC drive for 2 Hp (1.5 kW) motors. It takes a 380 to 480V three-phase supply and delivers 4 A to the motor. It is the unfiltered variant, so the emission class position in the catalog number is 0.

The drive is a frame A unit, the same compact housing used for the 0.75 kW and 2.2 kW ratings, which lets a panel builder standardise mounting holes across three powers.

Technical specifications

How the catalog number is built

The code reads as 25B for PowerFlex 525, D for 480V AC, 4P0 for 4.0 A, N for the IP20 enclosure, then 1 for the standard interface module, 0 for no EMC filter and 4 for standard braking. The decimal point in current ratings is written as P, so 4P0 is 4.0 A.

The same current with a filter is 25B-D4P0N114. The technical data lists its total loss at 63 W against 62 W for this unfiltered drive.

On the control side there are six programmable digital inputs, a dedicated stop input, two analog inputs (one of them 0 to 10V or 4 to 20 mA) and two relay and two optocoupler outputs. Carrier frequency is adjustable from 2 to 16 kHz, with the drive rating based on 4 kHz. Output frequency is programmable up to 500 Hz, and stop modes include ramp, coast and DC brake, so the drive can be matched to fans, pumps or conveyors without extra hardware.

Input ratings and short circuit protection

Input is 5.2 kVA and 5.7 A maximum. UL 61800-5-1 guidance is a 15 A Class CC, J or T fuse, a 100-C09 or 100-E09 contactor and a 140MT-C3E-B63 breaker. Under IEC the fuse range runs from 10 A to 16 A.

The drive does not provide branch short circuit protection, so a fuse or breaker must always be installed ahead of it. Overload capability is 150% for 60 seconds.

Key features of the PowerFlex 525 platform

• Embedded EtherNet/IP: the built-in Ethernet port allows control and monitoring from a Logix controller without an extra communication card.
• Safe Torque Off: the integrated STO function (PLd) removes torque from the motor without disconnecting the supply, which simplifies safety circuits.
• Several motor control modes: V/Hz, vector control and permanent-magnet motor support in one drive.
• Modular design: the control module and power module are separate, so the control module can be configured while the power module is installed.
• Programming options: configuration via the integral keypad, Connected Components Workbench or Studio 5000.

When to choose the unfiltered version

The 25B-D4P0N104 has no integral EMC filter. This is commonly chosen where the drive is installed in a panel with an external filter, where the supply network is an IT (ungrounded or impedance grounded) system, or where local EMC requirements do not call for an integral filter. On IT networks, filters with capacitors to earth can be problematic, so an unfiltered drive is often preferred there. If the installation must meet a specific emission category on a grounded supply, compare it with the filtered 25B-D4P0N114 or an external filter.

Selecting by current and duty

The drive is rated 4.0 A output. Check the motor nameplate full-load current at the actual supply voltage; it should not exceed this value. Normal and heavy duty ratings are both 2 Hp for this catalog number, and the heavy-duty overload of 150% for 60 s and 180% for 3 s gives enough reserve for conveyors and mixers that start under load. For pumps and fans the drive will usually run well below its overload limits.

Installation and maintenance

• Install in an enclosure suitable for the environment, since the drive is IP20 / Open Type.
• Provide the recommended fuse or breaker ahead of the drive, as listed above.
• Use shielded motor cable and correct grounding to limit interference with other equipment.
• Raising the carrier frequency above 4 kHz reduces motor noise but increases drive losses; check derating in the user manual.
• Keep heatsink and fan clear of dust, and back up parameters to software for quick replacement.

Use in Oman and GCC conditions

Small drives of this size are widely used for conveyors, packaging machines, ventilation fans and dosing pumps in the region. With 62 W total loss the heat load is modest, but in hot, unconditioned panels the ambient temperature limits and derating given in the user manual must be respected. In sandy and dusty locations a filtered or air-conditioned enclosure protects the cooling path. The EtherNet/IP port makes it easy to bring motor status into plant SCADA systems used in utilities and oil and gas facilities.

What to include in your RFQ

Along with the catalog number, it helps to state the network type of the supply (grounded or IT), whether an external EMC filter, line reactor or brake resistor is needed, the communication method to the PLC, and any requirement for the Safe Torque Off function to be wired into the machine safety circuit. This allows the full drive package to be checked in one quotation.

Quote details

For a quotation provide the 25B-D4P0N104 reference, motor nameplate, supply voltage and quantity. Photo shown is the frame A family image, not this exact unit. Confirm the exact catalog number before ordering. See AC Drives and PowerFlex 525 AC drive for related items.