Allen-Bradley 25A-E027N104
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The Allen-Bradley 25A-E027N104 is a PowerFlex 25A series AC variable frequency drive manufactured by Allen-Bradley, a brand of Rockwell Automation. This unit belongs to the PowerFlex 25A family, which is designed for general-purpose motor speed control applications requiring compact footprint and flexible installation. The SKU 25A-E027N104 identifies a specific configuration within this series, rated for 27A output current in a standard enclosure format.
The PowerFlex 25A drive supports multiple embedded communication options and is compatible with common industrial networks including EtherNet/IP, DeviceNet, and RS485 (DSI). It features an integrated EMC filter, adjustable carrier frequency, and built-in motor protection functions such as overload, overvoltage, undervoltage, and phase loss detection. The drive supports V/Hz and sensorless vector control modes, providing flexibility for a range of motor types and load profiles. Parameter storage and drive configuration can be managed via the integral keypad or through connected programming tools such as Connected Components Workbench.
The PowerFlex 25A series is widely deployed in manufacturing, material handling, HVAC, pump and fan control, and packaging machinery applications. Its compact design makes it suitable for panel-mounted installations where space is limited, and its broad input voltage tolerance allows use across varying supply conditions. The drive is commonly found in conveyor systems, mixers, compressors, and other variable-torque or constant-torque loads in light to medium industrial environments.
Technical Specifications
| Series/Product Family | PowerFlex 25A |
|---|---|
| Output Current (Continuous) | 27 A |
| Input/Operating Voltage | 480 V AC, 3-phase |
| Power Rating | 15 kW (20 HP) |
| Control Type | V/Hz, Sensorless Vector |
| Communication Interface | EtherNet/IP, DeviceNet, RS485 (DSI) |
| Operating Temperature | 0 to 50 degrees C |
| Storage Temperature | -40 to 85 degrees C |
| Relative Humidity | 5 to 95% non-condensing |
| IP/Protection Rating | IP20 |
| Mounting | Panel mount, DIN rail compatible |
| Certifications | UL, CE, RoHS |
| Safety Features | Overload protection, overvoltage, undervoltage, phase loss detection |
| Carrier Frequency | 2 to 16 kHz adjustable |
Common Fault Codes
- Fault Code F2
- Auxiliary input fault. The auxiliary input interlock has been opened.
Check the auxiliary input wiring and ensure any external interlock or safety circuit connected to the auxiliary input terminal is closed and functioning correctly. - Fault Code F3
- Power loss fault. Input power to the drive was lost or dropped below acceptable levels.
Check incoming AC supply voltage for loss of phase, low voltage, or intermittent supply. Verify fusing and upstream contactors. - Fault Code F4
- Undervoltage fault. DC bus voltage has dropped below the minimum threshold.
Measure incoming line voltage and verify it is within the drive's rated input range. Check for voltage sags or supply issues. - Fault Code F5
- Overvoltage fault. DC bus voltage has exceeded the maximum allowable level.
Check for regenerative loads causing bus voltage rise. Consider adding a dynamic braking resistor or reducing deceleration rate. - Fault Code F6
- Motor stall fault. The motor has stalled or is unable to accelerate to the commanded speed within the allowed time.
Check for mechanical overload on the motor shaft. Verify motor parameters are correctly programmed and that the load is within the drive's rated capacity. - Fault Code F7
- Motor overload fault. The drive's electronic overload protection has tripped due to sustained overcurrent condition.
Allow the drive and motor to cool. Check motor current draw against nameplate rating. Verify motor overload parameter settings in the drive. - Fault Code F12
- Hardware overcurrent fault. Output current has exceeded the drive's peak current hardware limit.
Check for short circuits in the motor cable or motor windings. Verify that the motor is correctly rated for the drive output. Inspect output wiring insulation. - Fault Code F33
- Auto-restart attempts exceeded. The drive attempted to automatically restart after a fault but exceeded the configured number of retries.
Identify and resolve the underlying fault that triggered the auto-restart attempts. Review fault history log and address the root cause before re-enabling the drive.
Frequently Asked Questions
What is the output current rating of the 25A-E027N104?
The 25A-E027N104 is rated for 27 A continuous output current, corresponding to approximately 15 kW (20 HP) at 480 V AC three-phase input.
What communication protocols does the PowerFlex 25A support?
The PowerFlex 25A supports EtherNet/IP, DeviceNet, and RS485 (DSI) communication interfaces, allowing integration with a wide range of Rockwell Automation and third-party control systems.
Can the 25A-E027N104 be used with sensorless vector control?
Yes, the PowerFlex 25A supports both V/Hz and sensorless vector control modes, making it suitable for applications requiring improved torque control without the need for an encoder feedback device.
What is the enclosure protection rating of this drive?
The 25A-E027N104 carries an IP20 protection rating, meaning it is intended for installation inside a control panel or enclosure to protect it from environmental contaminants.
Is the PowerFlex 25A compatible with Connected Components Workbench software?
Yes, the PowerFlex 25A can be configured and programmed using Rockwell Automation's Connected Components Workbench software, which provides parameter access, monitoring, and diagnostic capabilities.
Troubleshooting
Drive displays an overvoltage fault during deceleration
Monitor the DC bus voltage during deceleration using the drive's diagnostic parameters. If bus voltage rises above the overvoltage threshold, regenerative energy from the load is the likely cause.
Increase the deceleration time in the drive parameters to reduce regenerative energy. If fast deceleration is required, install a dynamic braking resistor and enable the braking chopper function.
Drive powers on but motor does not rotate when a run command is issued
Verify that the run command source is correctly configured (terminal block, keypad, or network). Check that the speed reference is non-zero and that no active faults or inhibits are present in the drive status.
Confirm parameter settings for command source and speed reference source. Check control wiring at the terminal block for correct signal levels. Clear any latched faults and retry.
Drive trips on motor overload fault repeatedly
Measure actual motor current using a clamp meter and compare to the motor nameplate full-load ampere rating. Check the motor overload parameter setting in the drive to ensure it matches the motor rating.
Correct the motor overload parameter to match the motor nameplate FLA. Investigate mechanical load for binding or excessive friction. Ensure adequate cooling for both motor and drive.
Communication loss between drive and PLC over EtherNet/IP
Verify network cable connections at the drive and switch. Check the drive's IP address configuration and confirm it matches the address expected by the PLC program. Use network diagnostic tools to ping the drive.
Re-seat Ethernet cables and check for damaged connectors. Reconfigure the drive IP address if necessary. Verify EtherNet/IP adapter parameters in the drive and update the PLC I/O configuration to match.
Drive output frequency fluctuates erratically during operation
Check the speed reference signal for noise or instability. If using an analog input, measure the signal voltage at the drive terminal with a multimeter while the drive is running to identify any fluctuation.
Shield and properly ground the analog reference cable. Increase the analog input filter parameter in the drive settings. If using a digital network reference, check for communication errors or packet loss on the network.
| Condition | Repair, Used, Refurbished, New in box (sealed) |
|---|
Common defects
Common defects on a Allen-Bradley 25A-E027N104 are:
Power Supply Related Issues
- No power / drive not turning on
- Blown fuses
- Defective rectifier bridge
- Damaged DC bus capacitors
- IGBT / MOSFET module failure
- Overvoltage / undervoltage errors
Control & Electronics Failures
- Faulty control board or PCB damage
- Firmware or memory corruption
- Fieldbus communication errors (Profibus, Modbus, EtherCAT, CANopen)
- Input / output circuit damage
- Gate driver module failure
Motor Control Problems
- Motor not starting or no output
- Unstable speed control
- No torque output
- Trip during acceleration or deceleration
- Encoder feedback errors
Thermal & Cooling Defects
- Overheating due to failed cooling fans
- Defective temperature sensors
- Poor heatsink performance
Mechanical & Environmental Damage
- Burnt or loose connectors
- PCB track damage
- Corrosion or moisture ingress
- Oil, dust or contamination damage
- Cracked solder joints
Error Codes & Drive Trips
- Overcurrent faults (OC)
- Ground fault / earth leakage error
- Short-circuit fault
- Motor or drive overload
- Overvoltage or undervoltage error
- Undervoltage trip when starting or stopping
- Phase loss / imbalance
- Synchronization issues with multiple drives
Other
- Display defect
- Control keys or keypad not working
- Parameters no longer readable or lost
- Brake resistor problems (brake chopper defect)
- Internal relays/contactors defective
- EMI/RFI interference due to defective filters
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