25B-D024N104 — 525 Series AC Drive, 480V Three-Phase, 1.1 kW, EtherNet/IP

The 25B-D024N104 is a 1.1 kW / 1.5 HP variable frequency drive from the 525 series, configured for 380–480V AC three-phase input with 2.4A output current. It carries the full 525 platform feature set: embedded dual-port EtherNet/IP, sensorless vector control, Safe Torque Off, and a peripheral option port for expansion modules. At this power level it's a compact unit — the frame A housing keeps panel space requirements low while delivering the connectivity and control capability of drives in significantly larger packages.

The 525 series is one of the more capable drive families at the sub-5 HP range. For machine builders who need drives that are fully visible on an EtherNet/IP network — readable, controllable, and diagnosable from the controller without add-on cards — the 25B-D024N104 covers that from the base configuration. Speed reference, fault status, output current, operating temperature: all available as controller tags with nothing extra required.

Specifications

Parameter	Value
Part Number	25B-D024N104
Series	525 Series
Power Rating	1.1 kW / 1.5 HP
Input Voltage	380–480V AC, Three-Phase
Output Current	2.4 A
Output Frequency Range	0–500 Hz
Control Modes	V/Hz, Sensorless Vector (SVC)
Embedded Communication	EtherNet/IP, dual-port (built-in)
DLR Support	Yes
Option Port	1 × peripheral expansion slot
Digital Inputs	6 × 24V DC (programmable)
Analog Inputs	2 × 0–10V / 0–20 mA (selectable)
Relay Output	1 × Form C
Safe Torque Off	Category 3 / PLd (hardwired, standard)
Enclosure	IP20 / Open Type
Operating Temperature	−10°C to 50°C (derate above 40°C)
Approvals	UL, CE, RCM

Running at 2.4A on 480V — Load Sizing in Practice

At 2.4A output on a 480V bus, the maximum motor size this drive can serve is approximately 1.1 kW / 1.5 HP on a standard 4-pole induction motor. This assumes normal duty operation — loads that don't regularly exceed 110% of the drive's rated current. For loads with higher overload requirements (conveyors starting under full load, compressors with high starting torque), size the drive for the peak current demand rather than the motor nameplate alone.

For centrifugal pump and fan loads, which are the most common applications at this power level, 2.4A is typically well above what the motor draws at running speed — centrifugal loads draw significantly less current at reduced speed, so the drive rarely operates near its current limit in normal variable-speed pump and fan service. The drive's electronic overload protection still monitors motor current relative to the motor's rated current entered in the parameters; accurate motor data entry at commissioning is what makes overload protection reliable.

A Typical Integration Scenario

A packaging machine with four conveyor sections, each driven by a 1.1 kW motor, uses four 25B-D024N104 drives in a DLR ring. One Ethernet cable enters the ring from the controller's EtherNet/IP module; the cable then daisy-chains through all four drives and loops back, completing the ring. Each drive receives a speed reference from the CompactLogix controller every 10 ms via cyclic I/O. The controller program monitors output frequency and current from each drive on every scan — if any drive faults, the alarm logic identifies the specific zone and stops the affected section while keeping the others running.

The STO inputs on each drive connect to the machine's safety relay. When the E-stop is pressed, all four drives receive STO simultaneously — they coast to stop regardless of any network command. The safety function is independent of the network and the controller program. Restart requires operator reset of the safety relay followed by a controlled restart sequence from the controller program.

FAQ

Q: Can the drive be controlled from hardwired inputs rather than EtherNet/IP?

Yes. The six digital inputs and two analog inputs support standalone hardwired control — start/stop from pushbuttons, speed reference from a potentiometer or PLC analog output. The drive's control source parameter selects between network, terminal block, and HIM as the command source.

Q: How is the IP address set on this drive?

Default method is BOOTP. For production installations, set a static IP via the HIM (front keypad/display) in the drive's network parameters, or use Connected Components Workbench over a temporary network connection. Static addresses prevent IP reassignment after a network restart.

Q: What does the Form C relay output provide over a standard Form A?

Form C provides both a normally open (NO) and normally closed (NC) contact from the same relay. This means a single output can simultaneously close one circuit and open another — useful for run confirmation with fail-safe logic, where both run-confirmed and stopped-confirmed signals are needed without two separate relay outputs.

Q: Is sensorless vector autotune necessary for pump and fan applications?

For standard centrifugal loads, V/Hz mode works well without autotune. SVC mode delivers better low-speed torque and speed regulation, but requires a static autotune with accurate motor nameplate data first. For pump and fan operation above 20 Hz, the performance difference between V/Hz and SVC is minor. SVC is worth the setup effort for loads that need speed regulation under variable load or tight speed holding at low frequencies.

25B-D024N104 New Ser A 525 AC Drive 11kW 15Hp 25BD024N104