Powerflex 525 Ac Drive Specifications: Technical Data

Technical Data
PowerFlex 525 AC Drive Specifications

Original Instructions
Topic Page
Product Overview 2
Catalog Number Explanation 8
Technical Specifications 9
Environmental Specifications 11
Certifications 12
Dimensions and Weights 13
Design Considerations 15
Fuses and Circuit Breaker Ratings 25
Accessories and Dimensions 30
Safe-Torque-Off Function 39
Additional Resources 43
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Product Overview
The PowerFlex® 525 AC drive delivers an innovative design that is remarkably
versatile and can accommodate systems ranging from standalone machines to
simple system integration. The PowerFlex 525 provides general purpose control
for applications ranging up to 30 HP and 22 kW.
By combining a variety of motor control options, communications, energy

savings and standard safety features in a cost-effective drive, the PowerFlex 525
drive is suitable for a wide array of applications.
Maximize your system performance and productivity by taking advantage of

the following key features offered in a PowerFlex 525 drive.
PowerFlex 525 Drive Features

Modular Design
• Standard control module used across the entire power range.
• Detachable control module and power module allow simultaneous configuration and installation.
• MainsFree™ configuration allows you to simply connect your control module to a PC with a standard USB cable
and quickly upload, download, and flash the drive with new settings.
• Simultaneous support for two accessory cards without affecting footprint.
Packaging and Mounting

• Installation can be quick and easy using the DIN rail mounting feature on A, B, and C frame drives. Panel mounting
is also available, providing added flexibility.
• Zero Stacking™ is allowed for ambient temperatures up to 45 °C, saving valuable panel space.
• Integral filtering is available on all 200V and 400V ratings, providing a cost-effective means of meeting EN61800-3
Category C2 and C3 EMC requirements. External filters provide compliance to EN61800-3 Category C1, C2, and
C3 EMC requirements for all PowerFlex 525 ratings.
• An optional IP 30, NEMA/UL Type 1 conduit box is easily adapted to the standard IP 20 (NEMA Type Open)
product, providing increased environmental ratings.
Optimized Performance
• Removable MOV to ground provides trouble-free operation when used on ungrounded distribution systems.
• A relay pre-charge limits inrush current.
• Integral brake transistor, available on all ratings, provides dynamic braking capability with simple low cost brake
resistors.
• A jumper to switch between 24V DC sink or source control for control wiring flexibility.
• Dual Overload Rating available for drives above 15 HP/11 kW. Normal duty: 110% overload for 60 seconds or
150% for 3 seconds. Heavy duty: 150% overload for 60 seconds or 180% overload (200% programmable) for
3 seconds provides robust overload protection.
• Adjustable PWM frequency up to 16 kHz ensures quiet operation.
2 Rockwell Automation Publication 520-TD001B-EN-E - June 2013

PowerFlex 525 Advanced Features

Control Performance
• Variety of motor control options, including:
• Volts per hertz
• Sensorless Vector Control (SVC)
• Closed loop velocity vector control
• Variety of Positioning Control, including:
• PointStop™ stops motor load in a consistent position without encoder feedback
• Closed loop feedback with an optional encoder card
• Point-to-point positioning mode
• 2 Integral PID functionality enhance application flexibility.
I/O Wiring
• Two (2) Analog Inputs (one unipolar and one bipolar) 01
Stop
(1)
Typical
SRC wiring
Typical
SNK wiring
Safety 1 DigIn TermBlk 02/(2)
are independently isolated from the rest of the drive I/O. Safety 2
S1
S2
Safe-Torque-Off 02
Start/Run FWD
DigIn TermBlk 03/
These inputs can be toggled via a digital input. Safety +24V
S+
03
Direction/Run REV
Digital Common
SNK SRC 04
• Seven (7) Digital Inputs (6 programmable) provide 05
DigIn TermBlk 05
DigIn TermBlk 06
application versatility. 06
DigIn TermBlk 07/Pulse
07
• One (1) Analog Output is jumper selectable between 08
DigIn TermBlk 08
for either 0-10V or 0-20 mA. This scalable, 10-bit Relay 1 N.O.
R1
+24V
11
+24V DC
+10V +10V DC
output is suitable for metering or as a speed reference for Relay 1 Common
R2
12
0-10V (or ±10V) Input
13
another drive. Relay 2 Common
R5 14
Analog Common
Relay 2 N.C. Pot must be
R6 4-20mA Input 1...10 k ohm
• Two (2) Opto Outputs and two (2) Relay Outputs 0-10V
15
Analog Output
2 W min.
0/4-20 mA 16
(one form A and one form B) can be used to indicate 17
Opto Output 1
24V
(3)
Common
various drive, motor or logic conditions. 30V DC
50 mA
18
Opto Output 2
Non-inductive Opto Common

19
RJ45 Shield
C1
Comm Common
C2
DigIn TermBlk 07 Sel
0/4-20mA Pulse In SNK

Analog Out
Digital In
0-10V Digital SRC

Input
R1 R2 R5 R6 01 02 03 04 05 06 07 08 C1 C2
S1 S2 S+ 11 12 13 14 15 16 17 18 19
Rockwell Automation Publication 520-TD001B-EN-E - June 2013 3

Communications
• Embedded EtherNet/IP™ port allows easy configuration, control, and collection of drive data over the network.
• Dual port EtherNet/IP option card supports Device Level Ring (DLR) topologies, providing fault-tolerant
connectivity for optimum drive availability.
• Integral RS485/DSI communications enable the drives to be used in a multi-drop network configuration.
• Optional communication cards such as DeviceNet™, and PROFIBUS DP™ can improve machine performance.
• Field installed option allows for future addition of stand-alone drives to a network.
• Online EDS file creation with RSNetWorx™ providing ease of set-up on a network.
Closed Loop
Encoder/Pulse Train Input Standard
The PowerFlex 525 drive allows for configurable closed loop control with an optional encoder card for either speed or
position feedback for improved speed regulation, basic position control, or other pulse inputs for motor control.
• Improved speed regulation
• Basic position control
Basic Position Control

Local Position Control
• Position regulator with StepLogic™
• 8 positions (local logic)
Outer Position Control Loop

• Analog input bipolar mode offers improved zero-cross performance.
• Simple motion control applications with more complex position profiles.
• Speed reference supplied to drive via Analog Input or multiple field bus network options.
• Speed ratio available for simple draw applications.
Feedback Details
• Line Driver Type Incremental Encoder I/O Connection Example I/O Connection Example
Quadrature (dual channel) or Single Channel. Encoder +12V DC Encoder
(250 mA)
Power – +V Power –
Common
• 5V/12V DC supply, 10 mA min per channel Internal Drive Cm

B-
Common External to
+
SHLD
Power B Power External
• Single Ended or Differential (A, B Channel) Internal (drive)
A-
to SHLD
Source
Power
Supply
A
• Duty Cycle of 50%, +10% 12V DC, 250 mA
• Pulse Train Input Encoder to Power Supply

Common
Encoder
Signal – +V Signal – +V to SHLD
• Configurable Input Voltage 5V/12V/24V Single-Ended, Cm
B-
B NOT Differential, Cm
B-
B NOT
Dual Channel B
B Dual Channel B
B
DC autodetect A-
A NOT
A
A- A NOT
A
A A
• Frequency controlled PWM to SHLD
• Allowable Pulse Frequency DC to 250 kHz.

Improved Ride Through
Operation Down to 1/2 Line Voltage
The PowerFlex 525 drive allows for the selection of 1/2 DC Bus operation, for use in critical applications where continued
drive output is desired even in the event of brown out or low voltage conditions. The PowerFlex 525 drive also supports
enhanced inertia ride through for additional low voltage mitigation.
• Selectable 1/2 line voltage operation.
• Increased power loss ride through.
Optimized for Common DC Bus Installations
Enhanced Control of Internal Pre-charge
Common DC Bus offers additional inherent breaking capabilities by utilizing all the drives/loads on the bus for energy
absorption offering higher efficiency and cost savings. The PowerFlex 525 drive has been optimized for use in Common
DC Bus or Shared DC Bus installations.
• Configurable pre-charge control using digital inputs.
• Direct DC Bus connection to power terminal blocks.
Safety Inside using Safe-Torque-Off Function
Safe Torque-Off is a standard safety feature of the PowerFlex 525 drive to help protect personnel and equipment. Safe
Torque-off allows you to restart your application faster after a safety-related situation.
• Safe Torque-Off functionality removes rotational power without powering down the drive.
• Embedded safety reduces wiring and saves on installation space.
• Meets ISO 13849-1 standards and provides safety ratings up to and including SIL 2/PLd.

Communications and Software

Versatile Programming and Network Solutions
• PowerFlex 525 is compatible with any device that
acts as a RTU Master and supports standard 03
RTU
and 06 RTU commands.
up to 31 PowerFlex 525, PowerFlex 4, or PowerFlex 40 drives
• A network can be configured using Network Communication
PowerFlex 525 drives for high performance and
Node 1 Node 2 Node 3
flexible configuration capabilities.
• EtherNet/IP standard
(Dual port option available) PowerFlex 40 PowerFlex 40 PowerFlex 40
with Comms card with Comms card with Comms card
• DeviceNet
DeviceNet to EtherNet/IP
• PROFIBUS DP
• PowerFlex 525 is compatible with any device that
acts as a RTU Master and supports standard 03
and 06 RTU commands. RTU
• A multi-drive solution can be reached using a up to 4 PowerFlex 525, PowerFlex 4, or PowerFlex 40 drives
single PowerFlex 525 drive, with the ability for
up to five (5) drives to reside on one (1) node.
• Integral RS485 communications enable the DF1 RTU
drives to be used in a multi-drop network
configuration. A serial converter module (SCM) SCM up to 31 PowerFlex 525, PowerFlex 4, or PowerFlex 40 drives
provides connectivity to any controller with a
DF1 port. The SCM can be eliminated if the controller acts as a RTU Master.
PC Programming Software
Connected Components Workbench™

• Supports plug-and-play connectivity through a standard USB connection.
• AppView™ tool provides parameter groups for several of the most common applications.
• Create and save custom parameter groups using the CustomView™ tool.
• Supports PowerFlex drives, Micro800™ controllers and PanelView™ component graphic terminals.
Studio 5000™ Logix Designer

• Add-on profiles (AOPs) for PowerFlex 525 AC drives provide seamless integration into the Logix environment.
• Configuration files from Studio 5000 Logix Designer(1) can be transferred directly to the PowerFlex 525 drive over
EtherNet/IP.
• Automatic Device Configuration (ADC) uploads configuration parameters to a replaced drive, minimizing the need
for a manual reconfiguration.
(1) The Logix Designer application is the rebranding of RSLogix 5000 software. You can also use RSLogix 5000 version 17 or greater.

PowerFlex 525 Drive Family
Frame A Frame B Frame C Frame D Frame E

Catalog Number Explanation

1-3 4 5 6-8 9 10 11 12 13 14
25B - B 2P3 N 1 1 4 – –
Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash
Code Braking
4 Standard
Code Type
25B PowerFlex 525 Code EMC Filter
0 No Filter
1 Filter
Code Voltage Phase
V 120V AC 1 Code Interface Module
A 240V AC 1 1 Standard
B 240V AC 3
D 480V AC 3
E 600V AC 3 Code Enclosure
N IP20 NEMA/Open
Output Current @ 1 Phase, 100...120V Input Output Current @ 3 Phase, 380...480V Input
Code Amps Frame ND HD Code Amps Frame ND HD
HP kW HP kW HP kW HP kW
2P5 2.5 A 0.5 0.4 0.5 0.4 1P4 1.4 A 0.5 0.4 0.5 0.4
4P8 4.8 B 1.0 0.75 1.0 0.75 2P3 2.3 A 1.0 0.75 1.0 0.75
6P0 6.0 B 1.5 1.1 1.5 1.1 4P0 4.0 A 2.0 1.5 2.0 1.5
6P0 6.0 A 3.0 2.2 3.0 2.2
Output Current @ 1 Phase, 200...240V Input
010 10.5 B 5.0 4.0 5.0 4.0
Code Amps Frame ND HD
013 13.0 C 7.5 5.5 7.5 5.5
HP kW HP kW
017 17.0 C 10.0 7.5 10.0 7.5
2P5 2.5 A 0.5 0.4 0.5 0.4
024 24.0 D 15.0 11.0 15.0 11.0
4P8 4.8 A 1.0 0.75 1.0 0.75 * Normal and Heavy duty ratings are
030 30.0 D 20.0 15.0 15.0 11.0
8P0 8.0 B 2.0 1.5 2.0 1.5 available for drives above 15 HP / 11 kW.
037 37.0 E 25.0 18.5 20.0 15.0
011 11.0 B 3.0 2.2 3.0 2.2
043 43.0 E 30.0 22.0 25.0 18.5
Output Current @ 3Phase, 200...240V Input
Output Current @ 3 Phase, 525...600V Input
HP kW HP kW
HP kW HP kW
2P5 2.5 A 0.5 0.4 0.5 0.4
0P9 0.9 A 0.5 0.4 0.5 0.4
5P0 5.0 A 1.0 0.75 1.0 0.75
1P7 1.7 A 1.0 0.75 1.0 0.75
8P0 8.0 A 2.0 1.5 2.0 1.5
3P0 3.0 A 2.0 1.5 2.0 1.5
011 11.0 A 3.0 2.2 3.0 2.2
4P2 4.2 A 3.0 2.2 3.0 2.2
017 17.5 B 5.0 3.7 5.0 3.7
6P6 6.6 B 5.0 3.7 5.0 3.7
024 24.0 C 7.5 5.5 7.5 5.5
9P9 9.9 C 7.5 5.5 7.5 5.5
032 32.2 D 10.0 7.5 10.0 7.5
012 12.0 C 10.0 7.5 10.0 7.5
048 48.3 E 15.0 11.0 15.0 11.0
019 19.0 D 15.0 11.0 15.0 11.0
062 62.1 E 20.0 15.0 15.0 11.0
022 22.0 D 20.0 15.0 15.0 11.0
027 27.0 E 25.0 18.5 20.0 15.0
032 32.0 E 30.0 22.0 25.0 18.5

Technical Specifications
Category Specifications
Protection Bus Overvoltage Trip
100...120V AC Input: 405V DC bus (equivalent to 150V AC incoming line)
Bus Undervoltage Trip
525...600V AC Input
P038 = 3 “600V”: 487V DC bus (equivalent to 344V AC incoming line)
P038 = 2 “480V”: 390V DC bus (equivalent to 275V AC incoming line)
Power Ride-Thru: 100 ms
Logic Control Ride-Thru: 0.5 s minimum, 2 s typical
Electronic Motor Overload Protection: Provides class 10 motor overload protection according to NEC article 430 and motor over-temperature protection
according to NEC article 430.126 (A) (2). UL 508C File 29572.
Overcurrent: 200% hardware limit, 300% instantaneous fault
Ground Fault Trip: Phase-to-ground on drive output
Short Circuit Trip: Phase-to-phase on drive output
Electrical Voltage Tolerance: -15% / +10%
Frequency Tolerance: 47...63 Hz
Input Phases: Three-phase input provides full rating. Single-phase input provides 35% rating on three-phase drives.
Displacement Power Factor: 0.98 across entire speed range
Maximum Short Circuit Rating: 100,000 Amps Symmetrical
Actual Short Circuit Rating: Determined by AIC Rating of installed fuse/circuit breaker
Transistor Type: Isolated Gate Bipolar Transistor (IGBT)
Control Method Sinusoidal PWM, Volts/Hertz, Sensorless Vector Control, Economizer SVC motor control, and Closed Loop Velocity
Vector Control
Carrier Frequency 2...16 kHz, Drive rating based on 4 kHz
Frequency Accuracy
Digital Input: Within ±0.05% of set output frequency
Analog Input: Within 0.5% of maximum output frequency, 10-Bit resolution
Analog Output: ±2% of full scale, 10-Bit resolution
Speed Regulation
Open Loop with Slip Compensation: ±1% of base speed across a 80:1 speed range
With Encoder: ±0.3% of base speed across a 80:1 speed range
±0.05% of base speed across a 20:1 speed range
Output Voltage Range: 0V to rated motor voltage
Output Frequency Range: 0...500 Hz (programmable)
Efficiency: 97.5% (typical)
Stop Modes: Multiple programmable stop modes including – Ramp, Coast, DC-Brake, and Ramp-to-Stop
Accel/Decel: Four independently programmable accel and decel times. Each time may be programmed from 0...600 s in 0.01 s
increments.
Intermittent Overload Normal and Heavy Duty ratings are available for drives above 15 HP/ 11 kW
Normal Duty: 110% Overload capability for up to 60 s, 150% for up to 3 s
Heavy Duty: 150% Overload capability for up to 60 s, 180% for up to 3 s (200% programmable)

Control Inputs Digital Bandwidth: 10 Rad/s for open and closed loop
Quantity: (1) Dedicated for stop
(6) Programmable
Current: 6 mA
Type
Source Mode (SRC): 18...24V = ON, 0...6V = OFF
Sink Mode (SNK): 0...6V = ON, 18...24V = OFF
Analog Quantity: (2) Isolated, -10-10V and 4-20mA
Specification
Resolution: 10-bit
0-10V DC Analog: 100k ohm input impedance
4-20 mA Analog: 250 ohm input impedance
External Pot: 1...10k ohm, 2 W minimum
Encoder Type: Incremental, dual channel
Supply: 12V, 250 mA
Quadrature: 90°, ±27° @ 25 °C
Duty Cycle: 50%, +10%
Requirements: Encoders must be line driver type, quadrature (dual channel) or pulse (single channel), 3.5...26V DC output, single-
ended or differential and capable of supplying a minimum of 10 mA per channel. Allowable input is DC up to a
maximum frequency of 250 kHz. The encoder I/O automatically scales to allow 5V, 12V and 24V DC nominal
voltages.
Control Relay Quantity: (2) 1 Programmable Form A and 1 Programmable Form B
Outputs Specification
Resistive Rating: 3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC
Inductive Rating: 0.5 A @ 30V DC, 0.5 A @ 125V, 0.5 A @ 240V AC
Opto Quantity: (2) Programmable
Specification: 30V DC, 50 mA Non-inductive
Analog Quantity: (1) Non-Isolated 0-10V or 4-20 mA
Specification
Resolution: 10-bit
0-10V DC Analog: 1 k ohm minimum
4-20 mA Analog: 525 ohm maximum

Environmental Specifications
Altitude
Without derating: 1000 m (3300 ft) max.
With derating: Up to 4000 m (13,200 ft) max., with the exception of 600V drives at 2000 m (6600 ft) max. See Current Derating Curves on page 16 for
derating guidelines.
Surrounding Air Temperature, max.
Without derating: -20...50 °C (-4...122 °F)
With derating: -20...60 °C (-4...140 °F) or -20...70 °C (-4...158 °F) with optional Control Module Fan kit. See Current Derating Curves on page 16 for
derating guidelines.
Storage Temperature
Frame A...D: -40...85 °C (-40...185 °F)
Frame E: -40...70 °C (-40...158 °F)
Atmosphere:
IMPORTANT Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors
or dust. If the drive is not going to be installed for a period of time, it must be stored in an area where it will not
be exposed to a corrosive atmosphere.
Relative Humidity: 0...95% noncondensing

Shock: Complies with IEC 60068-2-27
Vibration: Complies with IEC 60068-2-6:1995
Frame Operating and Nonoperating Nonoperating (Transportation)
Size Force (Shock/Vibration) Mounting Type Force (Shock/Vibration) Mounting Type
A 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only
B 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only
C 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only
D 15 g / 2 g Screw only 30 g/ 2.5 g Screw only
E 15 g / 1.5 g Screw only 30 g/ 2.5 g Screw only
Conformal Coating: Complies with:
IEC 60721-3-3 to level 3C2 (chemical gases only)
Surrounding Environment Pollution Degree
Pollution Degree 1 & 2: All enclosures acceptable.
Sound Pressure Level (A-weighted) Measurements are taken 1 m from the drive.
Frame A & B: Maximum 53 dBA
Frame C: Maximum 57 dBA
Frame D: Maximum 64 dBA
Frame E: Maximum 68 dBA

Certifications
Certification PowerFlex 525
c-UL-us Listed to UL508C and CAN/CSA-C22.2 No. 14-05.
C-Tick Australian Communications and Media Authority

In conformity with the following:
Radiocommunications Act: 1992
N223 Radiocommunications Standard: 2008
Radiocommunications Labelling Notice: 2008
Standards applied:
EN 61800-3:2004
CE In conformity with the following European Directives:
EMC Directive (2004/108/EC)
Low Voltage Directive (2006/95/EC)
Standards applied:
EN 61800-3:2004
EN 61800-5-1:2007
TUV TÜV Rheinland
Bauart geprüft
Functional
Standards applied:
..
TUV
Rheinland
Safety EN ISO 13849-1:2008
Type approved
EN ISO 13849-2:2008
EN 61800-5-2:2007
EN 61508 PARTS 1-7:2010
EN 62061:2005
EN 60204-1:2009
Certified to ISO 13849-1 SIL2/PLd with embedded Safe-Torque-Off function
Meets Functional Safety (FS) when used with embedded Safe-Torque-Off function
ATEX Certified to ATEX directive 94/9/EC
Group II Category (2) GD Applications with ATEX Approved Motors
II (2) G D
KCC Korean Registration of Broadcasting and Communications Equipment
Compliant with the following standards:
Article 58-2 of Radio Waves Act, Clause 3
GOST-R Russian GOST-R Certificate no.
POCC US.ME92.H00040
AC 156 Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification Testing of Nonstructural Components and 2003 International
Building Code for worst-case seismic level for USA excluding site class F
EPRI Electric Power Research Institute
Certified compliant with the following standards:
SEMI F47
IEC 61000-4-34
Lloyds Register Lloyd’s Register Type Approval Certificate 12/10068(E1)
RoHS Compliant with the European “Restriction of Hazardous Substances” Directive
The drive is also designed to meet the appropriate portions of the following specifications:
NFPA 70 - US National Electrical Code
NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable Speed Drive Systems.
IEC 146 - International Electrical Code

Dimensions and Weights

Frame/Rating Cross-Reference
Catalog Number Description
25B - V 2P5 N 1 0 4
Drive Voltage Rating Rating Enclosure HIM Emission Class Version
PowerFlex 525 Drive Ratings

Output Ratings
Normal Duty Heavy Duty
Catalog No. HP kW HP kW Output Current (A) Input Voltage Range Total Watts Loss Frame Size
100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
25B-V2P5N104 0.5 0.4 0.5 0.4 2.5 85...132 27.0 A
25B-V4P8N104 1.0 0.75 1.0 0.75 4.8 85...132 53.0 B
25B-V6P0N104 1.5 1.1 1.5 1.1 6.0 85...132 67.0 B
25B-A2P5N104 0.5 0.4 0.5 0.4 2.5 170...264 29.0 A
25B-A4P8N104 1.0 0.75 1.0 0.75 4.8 170...264 50.0 A
25B-A8P0N104 2.0 1.5 2.0 1.5 8.0 170...264 81.0 B
25B-A011N104 3.0 2.2 3.0 2.2 11.0 170...264 111.0 B
200...240V AC (-15%, +10%) – 1-Phase Input with EMC Filter, 0...230V 3-Phase Output
25B-A2P5N114 0.5 0.4 0.5 0.4 2.5 170...264 29.0 A
25B-A4P8N114 1.0 0.75 1.0 0.75 4.8 170...264 53.0 A
25B-A8P0N114 2.0 1.5 2.0 1.5 8.0 170...264 84.0 B
25B-A011N114 3.0 2.2 3.0 2.2 11.0 170...264 116.0 B
25B-B2P5N104 0.5 0.4 0.5 0.4 2.5 170...264 29.0 A
25B-B5P0N104 1.0 0.75 1.0 0.75 5.0 170...264 50.0 A
25B-B8P0N104 2.0 1.5 2.0 1.5 8.0 170...264 79.0 A
25B-B011N104 3.0 2.2 3.0 2.2 11.0 170...264 107.0 A
25B-B017N104 5.0 3.7 5.0 3.7 17.5 170...264 148.0 B
25B-B024N104 7.5 5.5 7.5 5.5 24.0 170...264 259.0 C
25B-B032N104 10.0 7.5 10.0 7.5 32.2 170...264 323.0 D
25B-B048N104 15.0 11.0 15.0 11.0 48.3 170...264 584.0 E
25B-B062N104 20.0 15.0 15.0 11.0 62.1 170...264 708.0 E
380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output(1)
25B-D1P4N104 0.5 0.4 0.5 0.4 1.4 323...528 27.0 A
25B-D2P3N104 1.0 0.75 1.0 0.75 2.3 323...528 37.0 A
25B-D4P0N104 2.0 1.5 2.0 1.5 4.0 323...528 80.0 A
25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 323...528 86.0 A
25B-D010N104 5.0 4.0 5.0 4.0 10.5 323...528 129.0 B
25B-D013N104 7.5 5.5 7.5 5.5 13.0 323...528 170.0 C
25B-D017N104 10.0 7.5 10.0 7.5 17.0 323...528 221.0 C
25B-D024N104 15.0 11.0 15.0 11.0 24.0 323...528 303.0 D
25B-D030N104 20.0 15.0 15.0 11.0 30.0 323...528 387.0 D
25B-D037N114(2) 25.0 18.5 20.0 15.0 37.0 323...528 602.0 E
25B-D043N114(2) 30.0 22.0 25.0 18.5 43.0 323...528 697.0 E

Output Ratings
Catalog No. HP kW HP kW Output Current (A) Input Voltage Range Total Watts Loss Frame Size
25B-D1P4N114 0.5 0.4 0.5 0.4 1.4 323...528 27.0 A
25B-D2P3N114 1.0 0.75 1.0 0.75 2.3 323...528 37.0 A
25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 323...528 81.0 A
25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 323...528 88.0 A
25B-D010N114 5.0 4.0 5.0 4.0 10.5 323...528 133.0 B
25B-D013N114 7.5 5.5 7.5 5.5 13.0 323...528 175.0 C
25B-D017N114 10.0 7.5 10.0 7.5 17.0 323...528 230.0 C
25B-D024N114 15.0 11.0 15.0 11.0 24.0 323...528 313.0 D
25B-D030N114 20.0 15.0 15.0 11.0 30.0 323...528 402.0 D
25B-D037N114 25.0 18.5 20.0 15.0 37.0 323...528 602.0 E
25B-D043N114 30.0 22.0 25.0 18.5 43.0 323...528 697.0 E
25B-E0P9N104 0.5 0.4 0.5 0.4 0.9 446...660 22.0 A
25B-E1P7N104 1.0 0.75 1.0 0.75 1.7 446...660 32.0 A
25B-E3P0N104 2.0 1.5 2.0 1.5 3.0 446...660 50.0 A
25B-E4P2N104 3.0 2.2 3.0 2.2 4.2 446...660 65.0 A
25B-E6P6N104 5.0 3.7 5.0 3.7 6.6 446...660 95.0 B
25B-E9P9N104 7.5 5.5 7.5 5.5 9.9 446...660 138.0 C
25B-E012N104 10.0 7.5 10.0 7.5 12.0 446...660 164.0 C
25B-E019N104 15.0 11.0 15.0 11.0 19.0 446...660 290.0 D
25B-E022N104 20.0 15.0 15.0 11.0 22.0 446...660 336.0 D
25B-E027N104 25.0 18.5 20.0 15.0 27.0 446...660 466.0 E
25B-E032N104 30.0 22.0 25.0 18.5 32.0 446...660 562.0 E
(1) A non-filtered drive is not available for 380...480V AC 25 HP (18.5 kW) and 30 HP (22.0 kW) ratings. Filtered drives are available, however you must verify that the application will support a filtered drive.
(2) Catalogs 25B-037N114 and 25B-043N114 come with an EMC filter.
Drive Dimensions and Weight

Dimensions are in mm and (in.). Weights are in kg and (lb).
A C
D
Esc Sel B
Frame Size A B C D E Weight

A 72.0 (2.83) 152.0 (5.98) 172.0 (6.77) 57.5 (2.26) 140.0 (5.51) 1.1 (2.4)
B 87.0 (3.43) 180.0 (7.09) 172.0 (6.77) 72.5 (2.85) 168.0 (6.61) 1.6 (3.5)
C 109.0 (4.29) 220.0 (8.66) 184.0 (7.24) 90.5 (3.56) 207.0 (8.15) 2.3 (5.0)
D 130.0 (5.12) 260.0 (10.24) 212.0 (8.35) 116.0 (4.57) 247.0 (9.72) 3.9 (8.6)
E 185.0 (7.28) 300.0 (11.81) 279.0 (10.98) 160.0 (6.30) 280.0 (11.02) 12.9 (28.4)

Design Considerations
Mounting Considerations
• Mount the drive upright on a flat, vertical and level surface.
Frame Screw Size Screw Torque
A M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.)
B M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.)
C M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.)
D M5 (#10...24) 2.45...2.94 Nm (22...26 lb-in.)
E M8 (5/16 in.) 6.0...7.4 Nm (53...65 lb-in.)
• Protect the cooling fan by avoiding dust or metallic particles.

• Do not expose to a corrosive atmosphere.
• Protect from moisture and direct sunlight.
Minimum Mounting Clearances
See Dimensions and Weights on page 13 for mounting dimensions.

Vertical Vertical, Zero Stacking Vertical with Control Module Fan Kit Vertical, Zero Stacking with
No clearance between drives. Control Module Fan Kit
No clearance between drives.
50 mm 50 mm 50 mm 50 mm
(2.0 in.) 25 mm (2.0 in.) (2.0 in.)(1) (2.0 in.)(1)
(1.0 in.)
Esc Sel Esc Sel Esc Sel Esc Sel

Esc Sel Esc Sel Esc Sel Esc Sel
25 mm (2)
50 mm 50 mm 50 mm (1.0 in.) 50 mm
(2.0 in.) (2.0 in.) (2.0 in.) (2.0 in.)
50 mm 50 mm
(2.0 in.) 50 mm (2.0 in.)
(2.0 in.)(1) 50 mm
50 mm (2.0 in.)(1)
Esc
50 mm
Esc
Sel
(2.0 in.) (2.0 in.)

Sel
(2)
Esc
Esc
Sel
25 mm
Sel
(1.0 in.)
50 mm 50 mm
(2.0 in.) (2.0 in.)
Horizontal with Control Module Fan Kit Horizontal, Zero Stacking with Control Module Fan Kit
No clearance between drives.
(1) For Frame E with Control Module Fan Kit only, clearance of 95 mm (3.7 in.) is required.
(2) For Frame E with Control Module Fan Kit only, clearance of 12 mm (0.5 in.) is required.

Ambient Operating Temperatures
See Accessories and Dimensions on page 30 for option kits.

Ambient Temperature
Maximum with Control Module
Mounting Enclosure Rating(1) Minimum Maximum (No Derate) Maximum (Derate)(2) Fan Kit (Derate)(3)(5)
Vertical IP 20/Open Type 50 °C (122 °F) 60 °C (140 °F) 70 °C (158 °F)
IP 30/NEMA 1/UL Type 1 45 °C (113 °F) 55 °C (131 °F) –
Vertical, Zero Stacking IP 20/Open Type 45 °C (113 °F) 55 °C (131 °F) 65 °C (149 °F)
IP 30/NEMA 1/UL Type 1 -20 °C (-4 °F) 40 °C (104 °F) 50 °C (122 °F) –
Horizontal IP 20/Open Type 50 °C (122 °F) – 70 °C (158 °F)
with Control Module Fan Kit(4)(5)
Horizontal, Zero Stacking IP 20/Open Type 45 °C (113 °F) – 65 °C (149 °F)
with Control Module Fan Kit(4)(5)
(1) IP 30/NEMA 1/UL Type 1 rating requires installation of the PowerFlex 520-Series IP 30/NEMA 1/UL Type 1 option kit, catalog number 25-JBAx.
(2) For catalogs 25B-D1P4N104 and 25B-E0P9N104, the temperature listed under the Max. (Derate) column is reduced by 5 °C (9 °F) for all mounting methods.
(3) For catalogs 25B-D1P4N104 and 25B-E0P9N104, the temperature listed under the Max. with Control Module Fan Kit (Derate) column is reduced by 10 °C (18 °F) for vertical and vertical with zero stacking
mounting methods only.
(4) Catalogs 25B-D1P4N104 and 25B-E0P9N104 cannot be mounted using either of the horizontal mounting methods.
(5) Requires installation of the PowerFlex 520-Series Control Module Fan Kit, catalog number 25-FANx-70C.
Current Derating Curves

Vertical Mounting
Single Drive Zero Stacking
120 IP 30/NEMA 1 with Control 120 IP 30/NEMA 1 with Control
Percentage of Rated Current (%)
110 Module Fan Kit 110 Module Fan Kit

100 100
90 IP 20/Open Type 90 IP 20/Open Type
80 80
70 70
60 60
50 50
40 40
30 35 40 45 50 55 60 65 70 75 80 30 35 40 45 50 55 60 65 70 75 80
Ambient Temperature (°C) Ambient Temperature (°C)
Horizontal Mounting/Floor
Single Drive Zero Stacking
120 with Control 120 with Control
110 Module Fan Kit 110 Module Fan Kit

100 100
90 90
80 IP 20/Open Type 80 IP 20/Open Type
70 70
60 60
50 50
40 40
30 35 40 45 50 55 60 65 70 75 80 30 35 40 45 50 55 60 65 70 75 80
Ambient Temperature (°C) Ambient Temperature (°C)

Derating Guidelines for High Altitude
The drive can be used without derating at a maximum altitude of 1000 m (3300 ft).
If the drive is used above 1000 m (3300 ft):
• Derate the maximum ambient temperature by 5 °C (41 °F) for every additional 1000 m (3300 ft), subject to limits
listed in the Altitude Limit (Based on Voltage) table below.
Or
• Derate the output current by 10% for every additional 1000 m (3300 ft), subject to limits listed in the Altitude Limit
(Based on Voltage) table below.
Altitude Limit (Based on Voltage)
Corner Ground, Impedance
Drive Rating Center Ground (Wye Neutral) Ground, or Ungrounded
100...120V 1-Phase 6000 m 6000 m
200...240V 1-Phase 2000 m 2000 m
200...240V 3-Phase 6000 m 2000 m
380...480V 3-Phase 4000 m 2000 m
525...600V 3-Phase 2000 m 2000 m
High Altitude
120 60
110
Ambient Temperature (°C)
100 50
90
80 40
70
60 30
50
40 20
0 1000 2000 3000 4000 0 1000 2000 3000 4000
Altitude (m) Altitude (m)
Debris Protection
Take precautions to prevent debris from falling through the vents of the drive housing during installation.
Storage
• Store within an ambient temperature range of -40...85 °C(1).
• Store within a relative humidity range of 0...95%, noncondensing.
• Do not expose to a corrosive atmosphere.
(1) The maximum ambient temperature for storing a Frame E drive is 70 °C.
AC Supply Source Considerations
Ungrounded Distribution Systems
ATTENTION: PowerFlex 525 contains protective MOVs that are referenced to ground. These devices must be disconnected if the
drive is installed on an ungrounded or resistive grounded distribution system.
ATTENTION: Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground.

Disconnecting MOVs
To prevent drive damage, the MOVs connected to ground shall be disconnected if the drive is installed on an ungrounded
distribution system (IT mains) where the line-to-ground voltages on any phase could exceed 125% of the nominal line-to-
line voltage. To disconnect these devices, remove the jumper shown in the diagrams below.
1. Turn the screw counterclockwise to loosen.

2. Pull the jumper completely out of the drive chassis.
3. Tighten the screw to keep it in place.
Jumper Location (Typical)

Power Module
IMPORTANT Tighten screw after jumper removal.
Phase to Ground MOV Removal

R/L1
Three-Phase
AC Input S/L2
T/L3
Jumper 1 2 3 4
Input Power Conditioning

The drive is suitable for direct connection to input power within the rated voltage of the drive (see Input Power Conditions
on page 19). Listed in the Input Power Conditions table below are certain input power conditions which may cause
component damage or reduction in product life. If any of these conditions exist, install one of the devices listed under the
heading Corrective Action on the line side of the drive.
IMPORTANT Only one device per branch circuit is required. It should be mounted closest to the branch and sized to handle the total current of
the branch circuit.

Input Power Conditions

Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) • Install Line Reactor(2)
Greater than 120 kVA supply transformer • or Isolation Transformer
Line has power factor correction capacitors • Install Line Reactor(2)
Line has frequent power interruptions • or Isolation Transformer
Line has intermittent noise spikes in excess of 6000V (lightning)
Phase to ground voltage exceeds 125% of normal line to line voltage • Remove MOV jumper to ground.
Ungrounded distribution system • or Install Isolation Transformer with grounded secondary if necessary.
240V open delta configuration (stinger leg)(1) • Install Line Reactor(2)
(1) For drives applied on an open delta with a middle phase grounded neutral system, the phase opposite the phase that is tapped in the middle to the neutral or earth is referred to as the “stinger leg,” “high
leg,” “red leg,” etc. This leg should be identified throughout the system with red or orange tape on the wire at each connection point. The stinger leg should be connected to the center Phase B on the
reactor. See Bulletin 1321-3R Series Line Reactors on page 35 for specific line reactor part numbers.
(2) See Accessories and Dimensions on page 30 for accessory ordering information.
General Grounding Requirements
The drive Safety Ground - (PE) must be connected to system ground. Ground impedance must conform to the
requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground
connections should be periodically checked.
Typical Grounding
Esc Sel
R/L1 U/T1
S/L2 V/T2
T/L3 W/T3
SHLD
Ground Fault Monitoring
If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance
tripping.
Safety Ground - (PE)
This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building
steel (girder, joist), a floor ground rod or bus bar. Grounding points must comply with national and local industrial safety
regulations and/or electrical codes.
Motor Ground
The motor ground must be connected to one of the ground terminals on the drive.

Shield Termination - SHLD
Either of the safety ground terminals located on the power terminal block provides a grounding point for the motor cable
shield. The motor cable shield connected to one of these terminals (drive end) should also be connected to the motor
frame (motor end). Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal. The
earthing plate or conduit box option may be used with a cable clamp for a grounding point for the cable shield.
When shielded cable is used for control and signal wiring, the shield should be grounded at the source end only, not at the
drive end.
RFI Filter Grounding
Using a drive with filter may result in relatively high ground leakage currents. Therefore, the filter must only be used in
installations with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the
building power distribution ground. Ensure that the incoming supply neutral is solidly connected (bonded) to the same
building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or
socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The
integrity of all connections should be periodically checked.
Power Wiring
ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical
equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and
disconnect devices. Failure to do so may result in personal injury and/or equipment damage.
ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both
ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled.
This will help minimize the possible shock hazard from “cross coupled” power leads.
Motor Cable Types Acceptable for 100...600 Volt Installations
A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided
it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 m (1 ft) for every 10 m (32.8 ft)
of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than 15 mils
(0.4 mm/0.015 in.). Do not route more than three sets of motor leads in a single conduit to minimize “cross talk”. If more
than three drive/motor connections per conduit are required, shielded cable must be used.
UL installations above 50 °C ambient must use 600V, 90 °C wire.
UL installations in 50 °C ambient must use 600V, 75 °C or 90 °C wire.
UL installations in 40 °C ambient should use 600V, 75 °C or 90 °C wire.
Use copper wire only. Wire gauge requirements and recommendations are based on 75 °C. Do not reduce wire gauge when
using higher temperature wire.

Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space
and/or conduit fill rates limits are provided. Any wire chosen must have a minimum insulation thickness of 15 mils and
should not have large variations in insulation concentricity.
ATTENTION: Do not use THHN or similarly coated wire in wet areas.
Shielded/Armored Cable
Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided
shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should
be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that
may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar
location, imposed EMC regulations or a high degree of communications / networking are also good candidates for shielded
cable.
Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the
increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without
the addition of motor protective devices such as terminator networks. Refer to Reflected Wave in “Wiring and Grounding
Guide, (PWM) AC Drives,” publication DRIVES-IN001.
Consideration should be given to all of the general specifications dictated by the environment of the installation, including
temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included
and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve
noise containment.
A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has four (4) XLPE insulated
conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC
jacket.
Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly,
some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can
greatly increase the cable charging current required and reduce the overall drive performance. Unless specified in the
individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead
length limits supplied is not known.
Location Rating/Type Description

Standard (Option 1) 600V, 90 °C (194 °F) XHHW2/RHW-2 • Four tinned copper conductors with XLPE insulation.
Anixter B209500-B209507, Belden 29501-29507, or equivalent • Copper braid/aluminum foil combination shield and tinned copper drain wire.
• PVC jacket.
Standard (Option 2) Tray rated 600V, 90 °C (194 °F) • Three tinned copper conductors with XLPE insulation.
RHH/RHW-2 Anixter OLF-7xxxxx or equivalent • 5 mil single helical copper tape (25% overlap min.) with three bare copper grounds in
contact with shield.
• PVC jacket.
Class I & II; Tray rated 600V, 90 °C (194 °F) • Three bare copper conductors with XLPE insulation and impervious corrugated
Division I & II RHH/RHW-2 Anixter 7V-7xxxx-3G or equivalent continuously welded aluminum armor.
• Black sunlight resistant PVC jacket overall.
• Three copper grounds on #10 AWG and smaller.

Reflected Wave Protection
The drive should be installed as close to the motor as possible. Installations with long motor cables may require the addition
of external devices to limit voltage reflections at the motor (reflected wave phenomena). Refer to Reflected Wave in
“Wiring and Grounding Guide, (PWM) AC Drives,” publication DRIVES-IN001.
The reflected wave data applies to all carrier frequencies 2...16 kHz.
For 240V ratings and lower, reflected wave effects do not need to be considered.
Output Disconnect
The drive is intended to be commanded by control input signals that will start and stop the motor. A device that routinely
disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not be
used. If it is necessary to disconnect power to the motor with the drive outputting power, an auxiliary contact should be
used to simultaneously disable drive (Aux Fault or Coast-to-Stop).
Power Terminal Block Wire Specifications
Frame Maximum Wire Size(1) Minimum Wire Size(1) Torque
A 5.3 mm2 (10 AWG) 0.8 mm2 (18 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.)
B 8.4 mm2 (8 AWG) 2.1 mm2 (14 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.)
C 8.4 mm2 (8 AWG) 2.1 mm2 (14 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.)
D 13.3 mm2 (6 AWG) 5.3 mm2 (10 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.)
E 26.7 mm2 (3 AWG) 8.4 mm2 (8 AWG) 3.09...3.77 Nm (27.3...33.4 lb-in.)
(1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations.
Common Bus/Precharge Notes
If drives are used with a disconnect switch to the common DC bus, then an auxiliary contact on the disconnect must be
connected to a digital input of the drive.

I/O Wiring
Motor Start/Stop Precautions
ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the
motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If
used, the input device must not exceed one operation per minute or drive damage can occur.
ATTENTION: The drive start/stop control circuitry includes solid-state components. If hazards due to accidental contact with
moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to
remove the AC line to the drive. When the AC line is removed, there will be a loss of any inherent regenerative braking effect that
might be present - the motor will coast to a stop. An auxiliary braking method may be required. Alternatively, use the drive’s safety
input function.
Important points to remember about I/O wiring:

• Always use copper wire.
• Wire with an insulation rating of 600V or greater is recommended.
• Control and signal wires should be separated from power wires by at least 0.3 m (1 ft).
IMPORTANT I/O terminals labeled “Common” are not referenced to the safety ground (PE) terminal and are designed to greatly reduce common
mode interference.
ATTENTION: Driving the 4-20 mA analog input from a voltage source could cause component damage. Verify proper configuration
prior to applying input signals.
Signal and Control Wire Types
Recommendations are for 50 °C ambient temperature.

75 °C wire must be used for 60 °C ambient temperature.
90 °C wire must be used for 70 °C ambient temperature.
Recommended Signal Wire

Signal Type/Where Used Belden Wire Type(s)(or equivalent)(1) Description Min. Insulation Rating
Analog I/O & PTC 8760/9460 0.750 mm2 (18 AWG), twisted pair, 100% shield with drain(2) 300V,
Remote Pot 8770 0.750 mm2 (18 AWG), 3 conductor, shielded 60 °C (140 °F)
Encoder/Pulse I/O 9728/9730 0.196 mm2 (24 AWG), individually shielded pairs
(1) Stranded or solid wire.
(2) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.
Recommended Control Wire for Digital I/O

Type Wire Type(s) Description Min. Insulation Rating
Unshielded Per US NEC or applicable national or local code – 300V,
Shielded Multi-conductor shielded cable such as 0.750 mm2 (18 AWG), 3 conductor, shielded. 60 °C (140 °F)
Belden 8770 (or equivalent)

Maximum Control Wire Recommendation
Do not exceed control wiring length of 30 m (100 ft). Control signal cable length is highly dependent on electrical
environment and installation practices. To improve noise immunity, the I/O terminal block Common may be connected to
ground terminal/protective earth. If using the RS485 (DSI) port, I/O Terminal C1 should also be connected to ground
terminal/protective earth. Additionally, communication noise immunity can also be improved by connecting I/O Terminal
C2 to ground terminal/protective earth.
Control I/O Terminal Block Wire Specifications

Frame Maximum Wire Size(1) Minimum Wire Size(1) Torque
A...E 1.3 mm2 (16 AWG) 0.13 mm2 (26 AWG) 0.71...0.86 Nm (6.2...7.6 lb-in.)
(1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations.
Machinery Directive (2006/42/EC)

• EN ISO 13849-1:2008 – Safety of machinery – Safety related parts of control systems -Part 1: General principles for
design.
• EN ISO 13849-2:2008 – Safety of machinery – Safety related parts of control systems -Part 2: Validation.
• EN 62061:2005 – Safety of machinery – Functional safety of safety-related electrical, electronic and programmable
electronic control systems.
• EN 60204-1:2006 – Safety of machinery – Electrical equipment of machines - Part 1: General requirements.
• EN 61800-5-2:2007 – Adjustable speed electrical power drive systems - Part 5-2: Safety requirement – Functional.
Connections and Grounding

Shielded enclosure(1)
Esc Sel IP 30/NEMA 1/UL Type 1

option kit or EMC kit
EMI fittings and metal conduit

EMI filter
L1 L1' R/L1 U/T1
L2 L2' S/L2 V/T2
L3 L3' T/L3 W/T3
Enclosure ground connection Shielded motor cable
Building structure steel
(1) Some installations require a shielded enclosure. Keep wire length as short as possible between the enclosure entry point and the EMI filter.
PowerFlex 525 RF Emission Compliance and Installation Requirements

Standard/Limits
EN61800-3 Category C2
EN61800-3 Category C1 EN61000-6-4 EN61800-3 Category C3 (I ≤ 100 A)
EN61000-6-3 CISPR11 Group 1 Class A CISPR11 Group 1 Class A
Filter Type CISPR11 Group 1 Class B (Input power ≤ 20 kVA) (Input power > 20 kVA)
Internal – 10 m (33 ft) 20 m (66 ft)
External(1) 30 m (16 ft) 100 m (328 ft) 100 m (328 ft)
(1) See Accessory Dimensions on page 37 for more information on optional external filters.

Fuses and Circuit Breaker Ratings

The PowerFlex 525 drive does not provide branch short circuit protection. This product should be installed with either
input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may
determine additional requirements for these installations.
The tables on the following pages provide recommended AC line input fuse and circuit breaker information. See Fusing
and Circuit Breakers below for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 °C (104 °F)
and the U.S. N.E.C. Other country, state or local codes may require different ratings.
Fusing
The recommended fuse types are listed below. If available current ratings do not match those listed in the tables provided,
choose the next higher fuse rating.
• IEC – BS88 (British Standard) Parts 1 & 2(1), EN60269-1, Parts 1 & 2, type gG or equivalent should be used.
• UL – UL Class CC, T, RK1, or J should be used.
Circuit Breakers
The “non-fuse” listing in the following tables include inverse time circuit breakers, instantaneous trip circuit breakers
(motor circuit protectors) and 140M self-protected combination motor controllers. If one of these is chosen as the desired
protection method, the following requirements apply:
• IEC – Both types of circuit breakers and 140M self-protected combination motor controllers are acceptable for IEC
installations.
• UL – Only inverse time circuit breakers and the specified 140M self-protected combination motor controllers are
acceptable for UL installations.
(1) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.

26
100...120V 1-Phase Input Protection Devices – Frames A...B
Output Ratings Input Ratings IEC (Non-UL Applications) UL Applications
Normal Duty Heavy Duty Frame Contactor Fuses Circuit Breakers Fuses (Max. Rating) Circuit Breakers
Catalog No. HP kW HP kW Amps kVA Amps Size Catalog No. Min. Rating Max. Rating 140U 140M Class / Catalog No. UL 489 (140U) UL 140 (140M)(1)(2)
25B-V2P5N104 0.5 0.4 0.5 0.4 2.5 1.3 9.6 A 100-C12 15 20 140U-D6D2-C12 140M-C2E-C10 CLASS RK5, J or T / DLS-R-20 140U-D6C2-C12 140M-C2E-C10
25B-V4P8N104 1.0 0.75 1.0 0.75 4.8 2.5 19.2 B 100-C23 25 40 140U-D6D2-C25 140M-D8E-C20 CLASS RK5, J or T / DLS-R-40 140U-D6D2-C25 140M-D8E-C20
25B-V6P0N104 1.5 1.1 1.5 1.1 6.0 3.2 24.0 B 100-C23 30 50 140U-D6D2-C30 140M-F8E-C25 CLASS RK5, J or T / DLS-R-50 140U-D6D2-C30 140M-F8E-C25
200...240V 1-Phase Input Protection Devices – Frames A...B


Catalog No. HP kW HP kW Amps kVA Amps Size Catalog No. Min. Rating Max. Rating 140U 140M Class / Catalog No. UL 489 (140U) UL 140 (140M)(1)(2)
25B-A2P5N104 0.5 0.4 0.5 0.4 2.5 1.7 6.5 A 100-C09 10 15 140U-D6D2-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-15 140U-D6D2-C10 140M-C2E-C10
25B-A8P0N104 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 25 40 140U-D6D2-C25 140M-F8E-C25 CLASS J or T / 40 140U-D6D2-C25 140M-F8E-C25
25B-A8P0N114 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 25 40 140U-D6D2-C25 140M-F8E-C25 CLASS J or T / 40 140U-D6D2-C25 140M-F8E-C25
25B-A011N104 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 30 50 140U-H6C2-C35 140M-F8E-C25 CLASS J or T / 50 140U-H6C2-C35 140M-F8E-C25
25B-A011N114 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 30 50 140U-H6C2-C35 140M-F8E-C25 CLASS J or T / 50 140U-H6C2-C35 140M-F8E-C25
(1) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection Circuit Breakers Application Ratings.
(2) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/277 or 600Y/347. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems.
Rockwell Automation Publication 520-TD001B-EN-E - June 2013

200...240V 3-Phase Input Protection Devices – Frames A...E
Catalog No.(1) HP kW HP kW Amps kVA Amps Size Catalog No. Min. Rating Max. Rating 140U 140M Class / Catalog No. UL 489 (140U) UL 140 (140M)(2)(3)
25B-B2P5N104 0.5 0.4 0.5 0.4 2.5 1.2 2.7 A 100-C07 6 6 140U-D6D3-B40 140M-C2E-B40 CLASS RK5, J or T / DLS-R-6 140U-D6D3-B40 140M-C2E-B40
25B-B5P0N104 1.0 0.75 1.0 0.75 5.0 2.7 5.8 A 100-C09 10 15 140U-D6D3-B80 140M-C2E-B63 CLASS RK5, J or T / DLS-R-15 140U-D6D3-B80 140M-C2E-B63
25B-B8P0N104 2.0 1.5 2.0 1.5 8.0 4.3 9.5 A 100-C12 15 20 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-20 140U-D6D3-C10 140M-C2E-C10
25B-B011N104 3.0 2.2 3.0 2.2 11.0 6.3 13.8 A 100-C23 20 30 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-30 140U-D6D3-C15 140M-C2E-C16
25B-B017N104 5.0 3.7 5.0 3.7 17.5 9.6 21.1 B 100-C23 30 45 140U-D6D3-C25 140M-F8E-C25 CLASS J or T / 45 140U-D6D3-C25 140M-F8E-C25
25B-B024N104 7.5 5.5 7.5 5.5 24.0 12.2 26.6 C 100-C37 35 60 140U-H6C3-C35 140M-F8E-C32 CLASS J or T / 60 140U-H6C3-C35 140M-F8E-C32
25B-B032N104 10.0 7.5 10.0 7.5 32.2 15.9 34.8 D 100-C43 45 70 140U-H6C3-C60 140M-F8E-C45 CLASS RK5, J or T / DLS-R-70 – 140M-F8E-C45

25B-B048N104 15.0 11.0 15.0 11.0 48.3 20.1 44.0 E 100-C60 60 90 140U-H6C3-C70 140M-F8E-C45 CLASS J or T / 90 – –
25B-B062N104 20.0 15.0 15.0 11.0 62.1 25.6 56.0 E 100-C72 70 125 140U-H6C3-C90 140M-H8P-C70 CLASS J or T / 125 – –
(1) Normal and Heavy duty ratings are available for drives above 15 HP / 11 kW.

27
25B-D1P4N104 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C07 3 6 140U-D6D3-B30 140M-C2E-B25 CLASS RK5, J or T / DLS-R-6 – 140M-C2E-B25
25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 15 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-C10

25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 15 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-C10
25B-D010N104 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 30 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-30 – 140M-C2E-C16
25B-D010N114 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 30 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-30 – 140M-C2E-C16
25B-D013N104 7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 20 35 140U-D6D3-C25 140M-D8E-C20 CLASS J or T / 35 – 140M-D8E-C20
25B-D024N104 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 60 140U-H6C3-C40 140M-F8E-C32 CLASS J or T / 60 – –
25B-D037N114 25.0 18.5 20.0 15.0 37.0 30.8 33.7 E 100-C43 45 70 140U-H6C3-C50 140M-F8E-C45 CLASS J or T / 70 – 140M-F8E-C45
25B-D043N114 30.0 22.0 25.0 18.5 43.0 35.6 38.9 E 100-C60 50 80 140U-H6C3-C60 140M-F8E-C45 CLASS J or T / 80 – 140M-F8E-C45

28
29
25B-E0P9N104 0.5 0.4 0.5 0.4 0.9 1.4 1.2 A 100-C09 3 6 140U-D6D3-B20 140M-C2E-B25 CLASS RK5, J or T / DLS-R-6 – 140M-C2E-B25
25B-E6P6N104 5.0 3.7 5.0 3.7 6.6 9.1 8.0 B 100-C09 10 20 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-20 – 140M-C2E-C10
25B-E9P9N104 7.5 5.5 7.5 5.5 9.9 12.8 11.2 C 100-C16 15 25 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-25 – 140M-C2E-C16
25B-E012N104 10.0 7.5 10.0 7.5 12.0 15.4 13.5 C 100-C23 20 30 140U-D6D3-C20 140M-C2E-C16 CLASS RK5, J or T / DLS-R-30 – 140M-C2E-C16

25B-E019N104 15.0 11.0 15.0 11.0 19.0 27.4 24.0 D 100-C30 30 50 140U-H6C3-C30 140M-F8E-C25 CLASS J or T / 50 – –
25B-E022N104 20.0 15.0 15.0 11.0 22.0 31.2 27.3 D 100-C30 35 60 140U-H6C3-C35 140M-F8E-C32 CLASS J or T / 60 – –
25B-E027N104 25.0 18.5 20.0 15.0 27.0 28.2 24.7 E 100-C30 35 50 140U-H6C3-C35 140M-F8E-C32 CLASS J or T / 50 – 140M-F8E-C32
25B-E032N104 30.0 22.0 25.0 18.5 32.0 33.4 29.2 E 100-C37 40 60 140U-H6C3-C50 140M-F8E-C32 CLASS J or T / 60 – 140M-F8E-C32

Accessories and Dimensions

Dynamic Brake Resistors
Drive Ratings Minimum Resistance Resistance
Input Voltage HP kW Ω ± 10% Ω ± 5% Catalog No.(1)(2)
100...120V 0.5 0.4 60 91 AK-R2-091P500
50/60 Hz 1.0 0.75 60 91 AK-R2-091P500
1-Phase
1.5 1.1 48 91 AK-R2-091P500
200...240V 0.5 0.4 60 91 AK-R2-091P500
50/60 Hz 1.0 0.75 60 91 AK-R2-091P500
1-Phase
2.0 1.5 48 91 AK-R2-091P500
3.0 2.2 32 47 AK-R2-047P500
200...240V 0.5 0.4 60 91 AK-R2-091P500
50/60 Hz 1.0 0.75 60 91 AK-R2-091P500
3-Phase
2.0 1.5 60 91 AK-R2-091P500
3.0 2.2 32 47 AK-R2-047P500
5.0 3.7 19 47 AK-R2-047P500
7.5 5.5 19 30 AK-R2-030P1K2
10.0 7.5 15 30 AK-R2-030P1K2
15.0 11.0 15 15 AK-R2-030P1K2(3)
20.0 15.0 11 15 AK-R2-030P1K2(3)
380...480V 0.5 0.4 97 360 AK-R2-360P500
50/60 Hz 1.0 0.75 97 360 AK-R2-360P500
3-Phase
2.0 1.5 97 360 AK-R2-360P500
3.0 2.2 97 120 AK-R2-120P1K2
5.0 4.0 77 120 AK-R2-120P1K2
7.5 5.5 55 120 AK-R2-120P1K2
10.0 7.5 55 120 AK-R2-120P1K2
15.0 11.0 50 60 AK-R2-120P1K2(3)
20.0 15.0 50 60 AK-R2-120P1K2(3)
25.0 18.5 30 40 AK-R2-120P1K2(4)
30.0 22.0 30 40 AK-R2-120P1K2(4)
525...600V 0.5 0.4 120 360 AK-R2-360P500
50/60 Hz 1.0 0.75 120 360 AK-R2-360P500
3-Phase
2.0 1.5 120 360 AK-R2-360P500
3.0 2.2 120 120 AK-R2-120P1K2
5.0 3.7 82 120 AK-R2-120P1K2
7.5 5.5 65 120 AK-R2-120P1K2
10.0 7.5 65 120 AK-R2-120P1K2
15.0 11.0 65 60 AK-R2-120P1K2(3)
20.0 15.0 65 60 AK-R2-120P1K2(3)
25.0 18.5 60 60 AK-R2-120P1K2(3)
30.0 22.0 38 40 AK-R2-120P1K2(4)
(1) The resistors listed in this tables are rated for 5% duty cycle.
(2) Use of Rockwell Automation resistors is always recommended. The resistors listed have been carefully selected for optimizing performance in a variety of applications. Alternative resistors may be used,
however, care must be taken when making a selection. See the PowerFlex Dynamic Braking Resistor Calculator, publication PFLEX-AT001.
(3) Requires two resistors wired in parallel.
(4) Requires three resistors wired in parallel.

EMC Line Filters

Drive Ratings
Input Voltage HP kW Current (A) Frame Size Catalog No.
100...120V 0.5 0.4 2.5 A 25-RF011-AL
50/60 Hz 1.0 0.75 4.8 B 25-RF023-BL
1-Phase
1.5 1.1 6.0 B 25-RF023-BL
200...240V 0.5 0.4 2.5 A 25-RF011-AL
50/60 Hz 1.0 0.75 4.8 A 25-RF011-AL
1-Phase
2.0 1.5 8.0 B 25-RF023-BL
3.0 2.2 11.0 B 25-RF023-BL
200...240V 0.5 0.4 2.5 A 25-RF014-AL
50/60 Hz 1.0 0.75 5.0 A 25-RF014-AL
3-Phase
2.0 1.5 8.0 A 25-RF014-AL
3.0 2.2 11.0 A 25-RF014-AL
5.0 3.7 17.5 B 25-RF021-BL
7.5 5.5 24.0 C 25-RF027-CL
10.0 7.5 32.2 D 25-RF035-DL
15.0 11.0 48.3 E 25-RF056-EL
20.0 15.0 62.1 E 25-RF056-EL
380...480V 0.5 0.4 1.4 A 25-RF7P5-AL
50/60 Hz 1.0 0.75 2.3 A 25-RF7P5-AL
3-Phase
2.0 1.5 4.0 A 25-RF7P5-AL
3.0 2.2 6.0 A 25-RF7P5-AL
5.0 4.0 10.5 B 25-RF014-BL
7.5 5.5 13.0 C 25-RF018-CL
10.0 7.5 17.0 C 25-RF018-CL
15.0 11.0 24.0 D 25-RF033-DL
20.0 15.0 30.0 D 25-RF033-DL
25.0 18.5 37.0 E 25-RF039-EL
30.0 22.0 43.0 E 25-RF039-EL(1)
525...600V 0.5 0.4 0.9 A 25-RF8P0-BL
50/60 Hz 1.0 0.75 1.7 A 25-RF8P0-BL
3-Phase
2.0 1.5 3.0 A 25-RF8P0-BL
3.0 2.2 4.2 A 25-RF8P0-BL
5.0 3.7 6.6 B 25-RF8P0-BL
7.5 5.5 9.9 C 25-RF014-CL
10.0 7.5 12.0 C 25-RF014-CL
15.0 11.0 19.0 D 25-RF027-DL
20.0 15.0 22.0 D 25-RF027-DL
25.0 18.5 27.0 E 25-RF029-EL
30.0 22.0 32.0 E 25-RF029-EL(1)
(1) EMC Line Filter size is based on the input current of the drive. See the tables on page 28 and page 29 for more information.
EMC Plates
Item Description Frame Size Catalog No.
EMC Plate Optional grounding plate for shielded cables. A 25-EMC1-FA
B 25-EMC1-FB
C 25-EMC1-FC
D 25-EMC1-FD
E 25-EMC1-FE

Human Interface Modules and Accessories

Item Description Catalog No.
LCD Display, Remote Panel Mount Digital speed control 22-HIM-C2S
CopyCat capable
IP 66 (NEMA Type 4X/12) indoor use only
Includes 2.9 meter cable
LCD Display, Remote Handheld Digital speed control 22-HIM-A3
Full numeric keyboard
CopyCat capable
IP 30 (NEMA Type 1)
Includes 1.0 m cable
Panel mount with optional Bezel Kit
Remote Handheld HIM Wireless Interface Module with Bluetooth® technology 22-WIM-N1
IP 30 (NEMA Type 1)
Panel Mount with optional bezel kit
Does not support the new dynamic parameter groups (AppView, CustomView).
Remote Panel Mount HIM Wireless Interface Module with Bluetooth® technology 22-WIM-N4S
IP 66 (NEMA Type 4X/12) indoor use only.
Does not support the new dynamic parameter groups (AppView, CustomView).
Bezel Kit Panel mount for LCD Display, Remote Handheld unit, IP 30 (NEMA Type 1) 22-HIM-B1
Includes 2.0 m DSI cable
DSI HIM Cable 1.0 m (3.3 ft) 22-HIM-H10
(DSI HIM to RJ45 cable) 2.9 m (9.51 ft) 22-HIM-H30
IP 30/NEMA 1/UL Type 1 Kit

IP 30/NEMA 1/UL Type 1 Kit Field installed kit. Converts drive to IP 30/NEMA 1/UL Type 1 enclosure. Includes conduit box A 25-JBAA
with mounting screws and plastic top panel. B 25-JBAB
C 25-JBAC
D 25-JBAD
E 25-JBAE
Control Module Fan Kit

Control Module Fan Kit For use with drive in environments with ambient temperatures up to 70 °C or horizontal A...D 25-FAN1-70C
mounting. E 25-FAN2-70C
Incremental Encoder Input Option

Incremental Encoder Incremental encoder input option board. 25-ENC-1
Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate

B160
Mounting Adapter Plate For use with drive when replacing Bulletin 160 drives in existing installations to a A 25-MAP-FA
PowerFlex 520-Series drive. Select the catalog number based on the frame size of your B 25-MAP-FB
Bulletin 160 drive.

Replacement Parts
PowerFlex 520-Series Power Module
Item Description
PowerFlex 525 Power Module Replacement power module for use with PowerFlex 520-Series drives. Includes:
• Power Module
• Power Module Front Cover
• Power Terminal Guard
• Heatsink Fan
Output Ratings
HP kW HP kW Output Current (A) Input Voltage Range Frame Size Catalog No.
0.5 0.4 0.5 0.4 2.5 85...132 A 25-PM1-V2P5
1.0 0.75 1.0 0.75 4.8 85...132 B 25-PM1-V4P8
1.5 1.1 1.5 1.1 6.0 85...132 B 25-PM1-V6P0
0.5 0.4 0.5 0.4 2.5 170...264 A 25-PM1-A2P5
1.0 0.75 1.0 0.75 4.8 170...264 A 25-PM1-A4P8
2.0 1.5 2.0 1.5 8.0 170...264 B 25-PM1-A8P0
3.0 2.2 3.0 2.2 11.0 170...264 B 25-PM1-A011
0.5 0.4 0.5 0.4 2.5 170...264 A 25-PM2-A2P5
1.0 0.75 1.0 0.75 4.8 170...264 A 25-PM2-A4P8
2.0 1.5 2.0 1.5 8.0 170...264 B 25-PM2-A8P0
3.0 2.2 3.0 2.2 11.0 170...264 B 25-PM2-A011
0.5 0.4 0.5 0.4 2.5 170...264 A 25-PM1-B2P5
1.0 0.75 1.0 0.75 5.0 170...264 A 25-PM1-B5P0
2.0 1.5 2.0 1.5 8.0 170...264 A 25-PM1-B8P0
3.0 2.2 3.0 2.2 11.0 170...264 A 25-PM1-B011
5.0 3.7 5.0 3.7 17.5 170...264 B 25-PM1-B017
7.5 5.5 7.5 5.5 24.0 170...264 C 25-PM1-B024
10.0 7.5 10.0 7.5 32.2 170...264 D 25-PM1-B032
15.0 11.0 15.0 11.0 48.3 170...264 E 25-PM1-B048
20.0 15.0 15.0 11.0 62.1 170...264 E 25-PM1-B062
0.5 0.4 0.5 0.4 1.4 323...528 A 25-PM1-D1P4
1.0 0.75 1.0 0.75 2.3 323...528 A 25-PM1-D2P3
2.0 1.5 2.0 1.5 4.0 323...528 A 25-PM1-D4P0
3.0 2.2 3.0 2.2 6.0 323...528 A 25-PM1-D6P0
5.0 4.0 5.0 4.0 10.5 323...528 B 25-PM1-D010
7.5 5.5 7.5 5.5 13.0 323...528 C 25-PM1-D013
10.0 7.5 10.0 7.5 17.0 323...528 C 25-PM1-D017
15.0 11.0 15.0 11.0 24.0 323...528 D 25-PM1-D024
20.0 15.0 15.0 11.0 30.0 323...528 D 25-PM1-D030
0.5 0.4 0.5 0.4 1.4 323...528 A 25-PM2-D1P4
1.0 0.75 1.0 0.75 2.3 323...528 A 25-PM2-D2P3
2.0 1.5 2.0 1.5 4.0 323...528 A 25-PM2-D4P0
3.0 2.2 3.0 2.2 6.0 323...528 A 25-PM2-D6P0

Output Ratings
HP kW HP kW Output Current (A) Input Voltage Range Frame Size Catalog No.
5.0 4.0 5.0 4.0 10.5 323...528 B 25-PM2-D010
7.5 5.5 7.5 5.5 13.0 323...528 C 25-PM2-D013
10.0 7.5 10.0 7.5 17.0 323...528 C 25-PM2-D017
15.0 11.0 15.0 11.0 24.0 323...528 D 25-PM2-D024
20.0 15.0 15.0 11.0 30.0 323...528 D 25-PM2-D030
25.0 18.5 20.0 15.0 37.0 323...528 E 25-PM2-D037
30.0 22.0 25.0 18.5 43.0 323...528 E 25-PM2-D043
0.5 0.4 0.5 0.4 0.9 446...660 A 25-PM1-E0P9
1.0 0.75 1.0 0.75 1.7 446...660 A 25-PM1-E1P7
2.0 1.5 2.0 1.5 3.0 446...660 A 25-PM1-E3P0
3.0 2.2 3.0 2.2 4.2 446...660 A 25-PM1-E4P2
5.0 3.7 5.0 3.7 6.6 446...660 B 25-PM1-E6P6
7.5 5.5 7.5 5.5 9.9 446...660 C 25-PM1-E9P9
10.0 7.5 10.0 7.5 12.0 446...660 C 25-PM1-E012
15.0 11.0 15.0 11.0 19.0 446...660 D 25-PM1-E019
20.0 15.0 15.0 11.0 22.0 446...660 D 25-PM1-E022
25.0 18.5 20.0 15.0 27.0 446...660 E 25-PM1-E027
30.0 22.0 25.0 18.5 32.0 446...660 E 25-PM1-E032
PowerFlex 520-Series Control Module

PowerFlex 525 Control Module Replacement control module for use with PowerFlex 520-Series drives. Includes: A...E 25B-CTM1
• Control Module
• Control Module Front Cover
Other Parts
PowerFlex 525 Control Module Front Replacement cover for the control module I/O terminals, EtherNet/IP and DSI ports. A...E 25B-CTMFC1
Cover
PowerFlex 520-Series Power Module Replacement cover for the PowerFlex 520-Series power module. B 25-PMFC-FB
Front Cover C 25-PMFC-FC
D 25-PMFC-FD
E 25-PMFC-FE
PowerFlex 520-Series Power Terminal Replacement finger guard for power terminals. A 25-PTG1-FA
Guard B 25-PTG1-FB
C 25-PTG1-FC
D 25-PTG1-FD
E 25-PTG1-FE
PowerFlex 520-Series Heatsink Fan Kit Replacement fan for drive power module. A 25-FAN1-FA
B 25-FAN1-FB
C 25-FAN1-FC
D 25-FAN1-FD
E 25-FAN1-FE

Communication Option Kits and Accessories

Communication Adapters Embedded communication options for use with the PowerFlex 520-Series drives:
• DeviceNet 25-COMM-D
• Dual Port EtherNet/IP 25-COMM-E2P
• PROFIBUS DP-V1 25-COMM-P
Compact I/O Module Three channel 1769-SM2
Universal Serial Bus™ (USB) Provides serial communication via DF1 protocol for use with Connected Components 1203-USB
Converter Module Workbench software. Includes:
• 2m USB cable (1)
• 20-HIM-H10 cable (1)
• 22-HIM-H10 cable (1)
Serial Converter Module Provides serial communication via DF1 protocol for use with Connected Components 22-SCM-232
(RS485 to RS232) Workbench software. Includes:
• DSI to RS232 serial converter (1)
• 1203-SFC serial cable (1)
• 22-RJ45CBL-C20 cable (1)
DSI Cable 2.0 m RJ45 to RJ45 cable, male to male connectors. 22-RJ45CBL-C20
Serial Cable 2.0 m serial cable with a locking low profile connector to connect to the serial converter and a 1203-SFC
9-pin sub-miniature D female connector to connect to a computer.
Splitter Cable RJ45 one to two port splitter cable (Modbus only) AK-U0-RJ45-SC1
Terminating Resistors RJ45 120 Ohm resistors (2 pieces) AK-U0-RJ45-TR1
Terminal Block RJ45 Two position terminal block (5 pieces) AK-U0-RJ45-TB2P
Connected Components Workbench Windows-based software packages for programming and configuring Allen-Bradley drives http://ab.rockwellautomation.com/
Software and other Rockwell Automation products. programmable-controllers/connected-
(Download or DVD-ROM) Compatibility: components-workbench-software
Windows XP, Windows Vista and Windows 7
Bulletin 1321-3R Series Line Reactors

Output Ratings(1) Input Line Reactor(2)(3) Output Line Reactor(2)(3)
Normal Duty Heavy Duty IP 00 (Open Style) IP 11 (NEMA/UL Type 1) IP 00 (Open Style) IP 11 (NEMA/UL Type 1)
HP kW HP kW Catalog No. Catalog No. Catalog No. Catalog No.
200...240V 50/60 Hz 3-Phase
0.5 0.4 0.5 0.4 1321-3R2-D 1321-3RA2-D 1321-3R2-D 1321-3RA2-D
1.0 0.75 1.0 0.75 1321-3R4-A 1321-3RA4-A 1321-3R4-A 1321-3RA4-A
2.0 1.5 2.0 1.5 1321-3R8-A 1321-3RA8-A 1321-3R8-A 1321-3RA8-A
3.0 2.2 3.0 2.2 1321-3R12-A 1321-3RA12-A 1321-3R12-A 1321-3RA12-A
5.0 3.7 5.0 3.7 1321-3R18-A 1321-3RA18-A 1321-3R18-A 1321-3RA18-A
7.5 5.5 7.5 5.5 1321-3R25-A 1321-3RA25-A 1321-3R25-A 1321-3RA25-A
10.0 7.5 10.0 7.5 1321-3R35-A 1321-3RA35-A 1321-3R35-A 1321-3RA35-A
15.0 11.0 15.0 11.0 1321-3R45-A 1321-3RA45-A 1321-3R45-A 1321-3RA45-A
20.0 15.0 15.0 11.0 1321-3R55-A (ND) 1321-3RA55-A (ND) 1321-3R55-A 1321-3RA55-A
1321-3R45-A (HD) 1321-3RA45-A (HD)
380...480V 50/60 Hz 3-Phase
0.5 0.4 0.5 0.4 1321-3R1-C 1321-3RA1-C 1321-3R2-B 1321-3RA2-B
1.0 0.75 1.0 0.75 1321-3R2-A 1321-3RA2-A 1321-3R2-A 1321-3RA2-A
2.0 1.5 2.0 1.5 1321-3R4-B 1321-3RA4-B 1321-3R4-B 1321-3RA4-B
3.0 2.2 3.0 2.2 1321-3R8-C 1321-3RA8-C 1321-3R8-C 1321-3RA8-C
5.0 4.0 5.0 4.0 1321-3R8-B 1321-3RA8-B 1321-3R8-B 1321-3RA8-B
7.5 5.5 7.5 5.5 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B
10.0 7.5 10.0 7.5 1321-3R18-B 1321-3RA18-B 1321-3R18-B 1321-3RA18-B

Bulletin 1321-3R Series Line Reactors

Output Ratings(1) Input Line Reactor(2)(3) Output Line Reactor(2)(3)
Normal Duty Heavy Duty IP 00 (Open Style) IP 11 (NEMA/UL Type 1) IP 00 (Open Style) IP 11 (NEMA/UL Type 1)
HP kW HP kW Catalog No. Catalog No. Catalog No. Catalog No.
15.0 11.0 15.0 11.0 1321-3R25-B 1321-3RA25-B 1321-3R25-B 1321-3RA25-B
20.0 15.0 15.0 11.0 1321-3R35-B (ND) 1321-3RA35-B (ND) 1321-3R25-B 1321-3RA25-B
1321-3R25-B (HD) 1321-3RA25-B (HD)
25.0 18.5 20.0 15.0 1321-3R35-B 1321-3RA35-B 1321-3R35-B 1321-3RA35-B
30.0 22.0 25.0 18.5 1321-3R45-B (ND) 1321-3RA45-B (ND) 1321-3R45-B 1321-3RA45-B
1321-3R35-B (HD) 1321-3RA35-B (HD)
460...600V 50/60 Hz 3-Phase
0.5 0.4 0.5 0.4 1321-3R2-B 1321-3RA2-B 1321-3R2-B 1321-3RA2-B
1.0 0.75 1.0 0.75 1321-3R2-B 1321-3RA2-B 1321-3R2-B 1321-3RA2-B
2.0 1.5 2.0 1.5 1321-3R4-D 1321-3RA4-D 1321-3R4-D 1321-3RA4-D
3.0 2.2 3.0 2.2 1321-3R4-C 1321-3RA4-C 1321-3R4-C 1321-3RA4-C
5.0 3.7 5.0 3.7 1321-3R8-C 1321-3RA8-C 1321-3R8-C 1321-3RA8-C
7.5 5.5 7.5 5.5 1321-3R12-C 1321-3RA12-C 1321-3R12-C 1321-3RA12-C
10.0 7.5 10.0 7.5 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B
15.0 11.0 15.0 11.0 1321-3R18-B 1321-3RA18-B 1321-3R18-B 1321-3RA18-B
20.0 15.0 15.0 11.0 1321-3R25-B (ND) 1321-3RA25-B (ND) 1321-3R25-B 1321-3RA25-B
1321-3R18-B (HD) 1321-3RA18-B (HD)
25.0 18.5 20.0 15.0 1321-3R35-C (ND) 1321-3RA35-C (ND) 1321-3R35-C 1321-3RA35-C
1321-3R25-B (HD) 1321-3RA25-B (HD)
30.0 22.0 25.0 18.5 1321-3R35-B (ND) 1321-3RA35-B (ND) 1321-3R35-B 1321-3RA35-B
1321-3R35-C (HD) 1321-3RA35-C (HD)
(1) Normal Duty and Heavy Duty ratings for 15 HP / 11 kW and below are identical.
(2) Catalog numbers listed are for 3% impedance. 5% impedance reactor types are also available. See publication 1321-TD001.
(3) Input line reactors were sized based on the NEC fundamental motor amps. Output line reactors were sized based on the VFD rated output currents.

Accessory Dimensions
IP 30/NEMA 1/UL Type 1 Kit – Dimensions are in mm and (in.).
Frame A
15.0 (0.59)
A 51.1 (2.01)
D 21.0 (0.82)
ø21.5 (ø0.85)
Frame D
135.4 (5.33)
96.0 (3.78)
B 70.0 (2.76)
44.0 (1.73)
111.9 (4.41)
Esc Sel
30.0 (1.18)
88.2 (3.47)
E
ø21.5 (ø0.85)
64.7 (2.55)
H ø33.5 (ø1.32)
153.3 (6.04)
Frame B
66.1 (2.60)
63.1 (2.48)
33.5 (1.32)
109.8 (4.32)
23.9 (0.94)
ø21.5 (ø0.85)
ø27.5 (ø1.08)
128.5 (5.06)
108.5 (4.27)
Frame E
127.5 (5.02)
88.3 (3.48)
C
82.5 (3.25) 62.5 (2.46)
67.3 (2.65)
42.5 (1.67)
ø21.5 (ø0.85)
ø43.7 (ø1.72)
Frame C
80.5 (3.17)
212.0 (8.35)
66.5 (2.62)
34.5 (1.36)
181.0 (7.13)
26.5 (1.04)
ø21.5 (ø0.85)
164.0 (6.46)
ø27.5 (ø1.08)
F
123.3 (4.85)
82.2 (3.24)
Frame Size A B C D E F G H
A 72.0 (2.83) 219.0 (8.62) 172.0 (6.77) 57.5 (2.26) 152.0 (5.98) 92.7 (3.65) 6.0 (0.24) 140.0 (5.51)
B 87.0 (3.43) 218.0 (8.58) 172.0 (6.77) 72.5 (2.85) 180.0 (7.09) 92.7 (3.65) 6.0 (0.24) 168.0 (6.61)
C 109.0 (4.29) 255.0 (10.04) 184.0 (7.24) 90.5 (3.56) 222.0 (8.66) 92.7 (3.65) 6.0 (0.24) 207.0 (8.15)
D 130.0 (5.12) 295.0 (11.61) 212.0 (8.35) 116.0 (4.57) 260.0 (10.24) – 6.0 (0.24) 247.0 (9.74)
E 185.0 (7.28) 350.0 (13.78) 279.0 (10.98) 160.0 (6.30) 300.0 (11.81) – 7.6 (0.30) 280.0 (11.02)

Control Module Fan Kit – Dimensions are in mm and (in.).

Frame A...D Frame E
A A A A
B
C B
C
Esc Sel
Esc Sel
Frame Size A B C
A...D 56.0 (2.20) 32.0 (1.26) 99.8 (3.93)
E 196.0 (7.72) 52.0 (2.05) 114.3 (4.50)
EMC Line Filter – Dimensions are in mm and (in.).

Frame A...D Frame E
A B ø5.5 A H B ø5.5
D F (ø0.22) D F (ø0.22)
E C E
E C E
G H I
F
G H I
F
Frame Size A B C D E F G H I
A 55.0 (2.17) 72.0 (2.83) 234.0 (9.21) 30.0 (1.18) 223.0 (8.78) 54.0 (2.13) 20.0 (0.79) 23.0 (0.91) 5.5 (0.22)
B 70.0 (2.76) 87.0 (3.43) 270.0 (10.63) 35.0 (1.38) 258.0 (10.16) 58.0 (2.28) 25.0 (0.98) 24.0 (0.94) 5.5 (0.22)
C 70.0 (2.76) 109.0 (4.29) 275.0 (10.83) 37.0 (1.46) 263.0 (10.35) 76.0 (2.99) 25.0 (0.98) 28.0 (1.10) 5.5 (0.22)
D 80.0 (3.15) 130.0 (5.12) 310.0 (12.20) 33.0 (1.30) 298.0 (11.73) 90.0 (3.54) 33.0 (1.30) 28.0 (1.10) 5.5 (0.22)
E 80.0 (3.15) 155.0 (6.10) 390.0 (15.35) 33.0 (1.30) 375.0 (14.76) 110.0 (4.33) 33.0 (1.30) 28.0 (1.10) 5.5 (0.22)

Safe-Torque-Off Function
The PowerFlex 525 Safe-Torque-Off function, when used with other safety components, helps provide protection
according to EN ISO 13849 and EN62061 for safe-off and protection against restart. The PowerFlex 525 Safe-Torque-Off
function is just one component in a safety control system. Components in the system must be chosen and applied
appropriately to achieve the desired level of operator safeguarding.
PowerFlex 525 Safe-Torque-Off Overview

The PowerFlex 525 Safe-Torque-Off function:
• Provides the Safe-Torque-Off (STO) function defined in EN IEC 61800-5-2.
• Blocks gate-firing signals from reaching the Insulated Gate Bipolar Transistor (IGBT) output devices of the drive.
This prevents the IGBTs from switching in the sequence necessary to generate torque in the motor.
• Can be used in combination with other safety devices to fulfill the requirements of a system “safe torque off ”
function which satisfies Category 3 / PL (d) according to EN ISO 13849-1 and SIL CL2 according to EN/IEC
62061, IEC 61508, and EN/IEC 61800-5-2.
EC Type Examination Certification
TÜV Rheinland has certified the PowerFlex 525 Safe-Torque-Off function compliant with the requirements for machines
defined in Annex I of the EC Directive 2006/42/EC, and that it complies with the requirements of the relevant standards
listed below:
• EN ISO 13849-1:2008 Safety of machinery – Safety related parts of control systems – Part 1: General principles for
design. (PowerFlex 525 STO achieves Category 3 / PL(d))
• EN 61800-5-2:2007 Adjustable speed electrical power drive systems – Part 5-2 Safety requirements – Functional.
(PowerFlex 525 STO achieves SIL CL 2)
• EN 62061:2005 Safety of machinery – Functional safety of safety-related electrical, electronic and programmable
electronic control systems.
• IEC 61508 Part 1-7:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems
– Parts 1-7.
TÜV also certifies that the PowerFlex 525 STO may be used in applications up to Category 3/ PL(d) according to EN ISO
13849-1 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508.
The TÜV Rheinland certificate may be found at http://www.rockwellautomation.com/products/certification/.
Safety Concept
The PowerFlex 525 Safe-Torque-Off function is suitable for use in safety applications up to and including Category 3 /
PL(d) according to EN ISO 13849-1 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508.
In addition, the PowerFlex 525 STO function may be used together with other components in a safety application to
achieve an overall Category 3 / PL(e) according to EN ISO 13849-1 and SIL 3 according to EN 62061 and IEC 61508.
This is illustrated in Example 3 on page 42.
Safety requirements are based on the standards current at the time of certification.

The PowerFlex 525 STO function is intended for use in safety-related applications where the de-energized state is
considered to be the safe state. All of the examples shown here are based on achieving de-energization as the safe state for
typical Machine Safety and Emergency Shutdown (ESD) systems.
PFD and PFH Data

PFD and PFH calculations are based on the equations from Part 6 of EN 61508.
This table provides data for a 20-year proof test interval and demonstrates the worst-case effect of various configuration
changes on the data.
PFD and PFH for 20-year Proof Test Interval
Attribute Value
PFD 6.62E-05 (MTTF = 3593 years)
PFHD 8.13E-10
SFF 83%
DC 62.5%
CAT 3
HFT 1 (1oo2)
PTI 20 YEARS
Hardware Type Type A
Safety Reaction Time
The safety reaction time from an input signal condition that triggers a safe stop, to the initiation of the configured Stop
Type, is 100 ms (maximum).

Connection Examples
Example 1 – Safe-Torque-Off Connection with Coast-to-Stop Action, SIL 2/PL d

Stop Category 0 – Coast
AC line
input power
+24V DC PF 525
+24V DC
GuardMaster
Gate Trojan Stop
Stop
Start
A1 S21 S11 S52 41 13 23 33 Start
E-Stop MSR Gate control

latching power supply
button
A2 S22 S14 S34 42 14 24 34
24V DC Gate control

common circuit
S1
S2
(1)
AC line
input power
PF 525
+24V DC
GuardMaster
Gate Trojan Stop
Stop
Start
Start
E-Stop Gate control

latching power supply
button
Gate control
circuit
S1
S2
(2)
(1) Safety relay and PowerFlex 525 must be installed in the same enclosure.
(2) In some situations, a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure.

Example 2 – Safe-Torque-Off Connection with Controlled Stop Action, SIL 2/PL d

Stop Category 1– Controlled
(1) AC line
input power
GuardMaster PF 525
Trojan
Gate +24V DC
Stop
Stop
+24V DC Start
Start
A1 S21 S11 S52 S12 S22 37 47 57 13 23 S33 S34
Gate control
Minotaur power supply
MSR138DP
A2 X1 X2 X3 X4 Y39 Y40 38 48 58 14 24 Y2 Y1
24V DC
Common Gate control
circuit
S1
S2
Example 3 – Safe-Torque-Off Connection with Coast-to-Stop Action Using External +24V supply, SIL 3/PL e
Stop Category 0 – Coast
AC line
input power
PF 525
External +24V DC
+24V DC
Stop
Reset Start
Open COM
A1 S11 S52 S12 13 23 33 41
Gate control
MSR127TP power supply
S21 S22 S34 A2 14 24 34 42

Closed
Gate control
circuit
S1
S2
(1)
X1 AUX
X2 13 23 33
A1 Coil 14 24 34
A2
24V DC COM External 100-C
contactor 100S-C

Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.
Title Publication
PowerFlex 525 Adjustable Frequency AC Drive User Manual 520-UM001
PowerFlex 4-Class Human Interface Module (HIM) DSI Quick Reference 22HIM-QR001
PowerFlex 525 Embedded EtherNet/IP Adapter User Manuals (Including dual port Ethernet) 520COM-UM001
PowerFlex 525 DeviceNet Adapter User Manual 520COM-UM002
PowerFlex 525 PROFIBUS DP Adapter User Manual 520COM-UM003
Dynamic Braking Resistor Calculator PFLEX-AT001
Wiring and Grounding Guidelines for PWM AC Drives DRIVES-IN001
Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1
You can view or download publications at http://www.rockwellautomation.com/literature/. To order paper copies of

technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Important Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this publication are included solely for illustrative purposes. Because of the many variables
and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this
document, complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.
Allen-Bradley, Rockwell Software, Rockwell Automation, PowerFlex, Connected Components Workbench, Studio 5000, DriveTools SP, AppView, CustomView, MainsFree Programming, and P ointStop are trademarks of
Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
www.rockwel lautomation.com
Power, Control and Information Solutions Headquarters

Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
Publication 520-TD001B-EN-E - June 2013

Supersedes Publication 520-TD001A-EN-E – February 2013 Copyright © 2013 Rockwell Automation, Inc. All rights reserved.

Powerflex 525 Ac Drive Specifications: Technical Data

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Technical Data

PowerFlex 525 AC Drive Specifications

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By combining a variety of motor control options, communications, energy

Maximize your system performance and productivity by taking advantage of

PowerFlex 525 Drive Features

Packaging and Mounting

2 Rockwell Automation Publication 520-TD001B-EN-E - June 2013

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PowerFlex 525 Advanced Features

Non-inductive Opto Common

0/4-20mA Pulse In SNK

0-10V Digital SRC

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Basic Position Control

Outer Position Control Loop

• 5V/12V DC supply, 10 mA min per channel Internal Drive Cm

• Duty Cycle of 50%, +10% 12V DC, 250 mA

• Pulse Train Input Encoder to Power Supply

• Frequency controlled PWM to SHLD

• Allowable Pulse Frequency DC to 250 kHz.

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Improved Ride Through

Operation Down to 1/2 Line Voltage

Optimized for Common DC Bus Installations

Enhanced Control of Internal Pre-charge

Safety Inside using Safe-Torque-Off Function

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Communications and Software

Connected Components Workbench™

Studio 5000™ Logix Designer

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PowerFlex 525 Drive Family

Frame A Frame B Frame C Frame D Frame E

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Catalog Number Explanation

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Relative Humidity: 0...95% noncondensing

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C-Tick Australian Communications and Media Authority

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Dimensions and Weights

PowerFlex 525 Drive Ratings

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Drive Dimensions and Weight

Frame Size A B C D E Weight