Allen-Bradley 25B-D004N101 PowerFlex 525 Drive
Allen-Bradley 25B-D004N101 PowerFlex 525 Drive. NJT Automation sources the 25B-D004N101 on request; send the part number for a replacement or repair quote.
Quote required. Request a quote below for pricing and delivery.
| Part Number | 25B-D004N101 |
| Price | On Request Availability and condition determine final quote. |
| Description | Allen-Bradley 25B-D004N101 PowerFlex 525 Drive. |
| Shipping |
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| Warranty | 1-year full-function warranty provided by NJT Automation. Warranty details
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| Returns | 90-day free returns. View return policy |
| Exchange | Send us your defective 25B-D004N101 after your purchase for a 10% core credit. We also purchase old or damaged parts outright. |
| Availability | Sourced on request We do not have a 25B-D004N101 on the shelf right now. We can source one through our supplier network; request a quote and we confirm availability, price and lead time before you commit. |
| Sourcing | Sourced through our Level 1 network of vetted US suppliers. Each unit is checked before it ships and carries the same NJT warranty and return policy as our own stock. Quotes within one hour during business hours; typical delivery 3–5 business days, next-day air available. Sourced parts are not available for local pickup. |
| Repairs | 25B-D004N101 Mail-In Repair Service |
Intended Use | Intended for EtherNet/IP-connected general-purpose variable-speed control applications. PowerFlex 525 drives run conveyors, pumps, fans, mixers and small machines up to 30 Hp, with embedded EtherNet/IP, Safe Torque Off and a removable control module, under a Logix or Micro800 controller. |
| Category | PowerFlex 525 |
| Part Number | 25B-D004N101 |
| Manufacturer | Allen-Bradley |
Can the 25B-D004N101 be repaired?
Yes. NJT Automation repairs the 25B-D004N101 by mail-in: diagnostic evaluation, component-level repair and a functional test, backed by a 1-year full-function warranty.
Option 1
NJT managed repair
- Evaluation
- Free. No repair, no charge.
- Shipping
- Prepaid UPS label both ways.
- Pricing
- $650 minimum. Rush service available.
- Warranty
- 1-year full-function warranty included; 2- and 3-year options.
Option 2
Independent repair bids. Compare quotes from independent repair technicians. Post your repair on RepairMode to receive competitive bids from experienced technicians. Each technician sets their own pricing and warranty.
Common Failures
Failure patterns we regularly see on PowerFlex compact drive hardware like the 25B-D004N101:
- Parameter corruption or communication loss (F081) after a power event
- Heatsink overtemperature (F008) from a failed fan or blocked airflow
- DC bus undervoltage / overvoltage trips (F004 / F005) from weak incoming power or capacitor aging
- Keypad membrane or display failure on the integral keypad
- Power unit fault (F070): IGBT / gate driver failure
Fault code reference
25B-D004N101 Fault Codes
43 codes · 520-UM001
Fault codes a PowerFlex 525 AC drive reports on the drive's integral keypad display (F followed by the fault number), as documented in Rockwell Automation publication 520-UM001. Use them to narrow a problem down to the unit, its wiring or the application before sending it in for repair.
| Code | Fault | What it indicates |
|---|---|---|
| F002 | Auxiliary Input | The auxiliary input interlock is open. |
| F003 | Power Loss | Excessive DC bus voltage ripple: incoming phase loss, line imbalance or a blown input fuse. |
| F004 | UnderVoltage | DC bus voltage fell below the minimum value: low or interrupted incoming line. |
| F005 | OverVoltage | DC bus voltage exceeded the maximum value: high line, transients or regenerative load with too short a decel time. |
| F006 | Motor Stalled | The drive is unable to accelerate or decelerate the motor. |
| F007 | Motor Overload | Internal electronic motor overload trip. |
| F008 | Heatsink OvrTmp | Heatsink temperature exceeded the limit: blocked or dirty fins, high ambient or a failed fan. |
| F009 | CC OvrTmp | Control module temperature exceeded the limit. |
| F012 | HW OverCurrent | Output current exceeded the hardware current limit: shorted or grounded motor leads, or a failed power stage. |
| F013 | Ground Fault | A current path to earth ground was detected at one or more output terminals. |
Show 33 more codes
| F015 | Load Loss | Output torque current fell below the programmed load-loss level. |
| F021 | Output Ph Loss | Output phase loss detected (when enabled). |
| F029 | Analog In Loss | An analog input configured to fault on signal loss has lost its signal. |
| F033 | Auto Rstrt Tries | The drive used all programmed auto-restart attempts without clearing the fault. |
| F038 / F039 / F040 | Phase U / V / W to Gnd | A phase-to-ground fault was detected between the drive and motor in that phase. |
| F041 / F042 / F043 | Phase UV / UW / VW Short | Excessive current was detected between two output terminals. |
| F048 | Params Defaulted | The drive was commanded to write default values to EEPROM. |
| F059 | Safety Open | Both safety inputs (Safety 1, Safety 2) are not enabled. |
| F063 | SW OverCurrent | The programmed software current trip level was exceeded. |
| F064 | Drive Overload | The drive rating of 150% for 1 minute or 200% for 3 seconds was exceeded. |
| F070 | Power Unit | A failure was detected in the drive power section. |
| F071 | DSI Net Loss | The DSI communication network faulted. |
| F072 | Opt Net Loss | The option-card network faulted. |
| F073 | EN Net Loss | Control through the embedded EtherNet/IP adapter was interrupted. |
| F080 | Autotune Failure | The autotune function was cancelled or failed. |
| F081 | DSI Comm Loss | The RS-485 (DSI) port stopped communicating. |
| F082 | Opt Comm Loss | Communication with the option card was lost. |
| F083 | EN Comm Loss | Communication with the embedded EtherNet/IP adapter was lost. |
| F091 | Encoder Loss | Encoder feedback was lost (encoder option card). |
| F094 | Function Loss | The function-loss input is open. |
| F100 | Parameter Chksum | The parameter checksum does not match: reset to defaults and reprogram. |
| F101 | External Storage | External (keypad / USB) storage read or write failed. |
| F105 | C Connect Err | The control module was disconnected from the power module while powered. |
| F106 | Incompat C-P | The control module firmware is incompatible with the power module. |
| F107 | Replaced C-P | The control module was moved to a different power module; parameters were defaulted. |
| F109 | Mismatch C-P | The control module and power module ratings do not match. |
| F110 | Keypad Membrane | The keypad membrane failed or a key is stuck. |
| F111 | Safety Hardware | The safety input hardware failed. |
| F114 | uC Failure | Microcontroller failure. |
| F122 | I/O Board Fail | A failure was detected in the drive control and I/O section. |
| F125 | Flash Update Req | A firmware flash update is required. |
| F126 | NonRecoverablErr | A non-recoverable error occurred. |
| F127 | DSIFlashUpdatReq | A DSI firmware flash update is required. |
Where the manual's only remedy for a code is to replace the unit or module, the code is pointing at a hardware fault inside that part. Those are the faults NJT Automation repairs at component level, so a repair quote is usually the first thing to check before buying a replacement.
Source: Rockwell Automation publication 520-UM001, PowerFlex 520-Series Adjustable Frequency AC Drive User Manual. Codes are listed as documented; fault behaviour can vary by firmware revision, so confirm against the manual for your unit's series.
Photos by NJT Automation; test videos from NJT or network repair technicians.
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