PowerFlex 4, 40, 40P to PowerFlex 523/525: Catalog Numbers, Wiring, Parameters, Networks, Checklist

PowerFlex 4 (catalog 22A) and PowerFlex 40 (22B) were discontinued on 30 June 2025; the PowerFlex 40P (22D) product page shows the status "End of Life" with the same discontinued date. The replacement Rockwell lists on the product pages is PowerFlex 523 (25A) for PowerFlex 4, and PowerFlex 525 (25B) for PowerFlex 40 and 40P. PowerFlex 4M (22F) is different: the two product pages read (22F-B017N103, 22F-B025N104) still show "Active". All pages read 27 October 2026.

For PowerFlex 40/40P, Rockwell publishes a dedicated guide, PFLEX-AP011C-EN-P, PowerFlex 40 and 40P Drives to PowerFlex 525 Drives Migration Guide (09/2023). For PowerFlex 4, the documents read here only give the mounting adapter plate table in user manual 520-UM001O. This article summarises what changes when the drive is replaced and turns it into a checklist. The replacement for each old catalog number is in the end-of-life lookup.

Choosing the equivalent catalog number

The table covers 380–480 V three-phase drives (N104, IP20). The "Replace with" column follows the Rockwell product pages; output current and frame come from PFLEX-AP011C (p. 22), 520-UM001O (pp. 14, 180–182) and, for PowerFlex 4 output current, 22A-UM001L (p. 10).

PowerFlex 40P (22D-D…) drives pair exactly like PowerFlex 40 in Table 5 of PFLEX-AP011C (p. 22) and use the same adapter plates (p. 88). Points to check:

• Output current is not always equal or higher. At 120/240 V the guide pairs 22B-B012 and 22B-A012 (12 A) with 25B-B011 and 25B-A011 (11 A), 22B-B033 (33 A) with 25B-B032 (32.2 A) or 25B-B048, and 22B-A5P0/V5P0 (5 A) with a 4.8 A drive; the footnotes say the ratings do not match and the application must be checked (pp. 21–22).
• Different overload capability. PowerFlex 40/40P handle 150% for 60 s and 200% for 3 s; a Heavy Duty PowerFlex 525 handles 150% for 60 s and 180% for 3 s (200% programmable) (p. 14). Check high-inertia or hard-starting loads.
• Input voltage. PowerFlex 40/40P tolerance is ±10%; PowerFlex 525 is −15%/+10% (p. 21).
• Enclosure. When the guide was published, PowerFlex 525 was not available as a flange-mount (F104) or IP66 (C104) drive (p. 21). F or C type drives need a different mounting plan.
• Adapter plates. The 25-AP1-Fx plates are for old drives with an external EMC filter (520-UM001O pp. 180–182). For 11 kW, the standard column lists 25-AP0-FD while the external-filter column carries a note that no plate is needed because the mounting holes already match (p. 181); measure the holes in the panel.

Mounting and power wiring

• Dimensions. PowerFlex 40 frame B is 100 mm wide, 180 mm high and 136 mm deep (PFLEX-AP011C p. 23); PowerFlex 525 frame A is 72 mm wide and 152 mm high but 172 mm deep (p. 28). The new drive is narrower but deeper: check enclosure depth and door clearance.
• Input protection. Fuse and circuit breaker sizes can differ between the two families; select them again from the PowerFlex 525 tables (pp. 11, 36–44).
• DC bus inductor. PowerFlex 40/40P frame C drives have P1/P2 terminals for a DC bus inductor; PowerFlex 525 does not (pp. 45, 59).

Control wiring

Most terminal numbers stay the same (01–08, 11–16, 17–18), but a few points are easy to miss when rewiring (PFLEX-AP011C pp. 50–60):

Any circuit that used the R3 NC contact as a fault signal must move to relay 2, with its function set again in t081 (pp. 57–58). PowerFlex 525 has 16 preset speeds selected by four inputs instead of 8 selected by three (p. 12). When the inputs are switched to SNK, the 01–11 jumper moves to 01–04 (p. 95).

PowerFlex 4 to PowerFlex 523. PowerFlex 4 has an R1/R2/R3 changeover relay, terminals 01–06, a 0–10 V input on terminal 13 and a 4–20 mA input on terminal 15, and no analog output (22A-UM001L pp. 24–25). On a PowerFlex 523 Series B, R1/R2/R3 remain, but terminal 15 becomes an analog output; the single analog input is terminal 13, set to 0–10 V or 4–20 mA by a jumper (520-UM001O pp. 39–41). A 4–20 mA signal wired to terminal 15 has to move to terminal 13.

Safe Torque Off on PowerFlex 525

STO is on PowerFlex 525 only, not on PowerFlex 523 (520-UM001O p. 239). The drive ships with a protective jumper on S1, S2 and S+; the safety inputs only take effect once the jumper is removed (p. 243). STO on its own gives a coast stop; any other stop action needs additional external measures. If the two channels disagree for longer than the allowed time the drive faults F111; if both open within that time it shows F059 (p. 244). The guide suggests STO as an alternative to wiring terminal 01 as an enable input (PFLEX-AP011C p. 11). Where a 40P uses DriveGuard (22D-UM001F p. 32), the safety circuit has to be redesigned and revalidated for the PowerFlex 525 wiring.

SIL/PL levels and safety values must be determined by a competent engineer per ISO 13849-1 / IEC 62061 for each project.

Parameters and how to transfer them

Many parameter numbers change, and the selection values change too. The guide cross-references them (pp. 12–13, 98, 104–107); some examples:

PowerFlex 525 also needs motor data that PowerFlex 40 does not ask for: poles, rated speed, rated power, the P039 control mode and the P040 autotune (p. 98). The documents cited here describe parameter transfer through cross-reference tables; none offers a parameter file that loads directly from a PowerFlex 40 into a PowerFlex 525.

Once commissioned, save the PowerFlex 525 configuration for future replacements: the USB port uploads and downloads configurations (.pf5) and flashes firmware without powering the control module (MainsFree); C169 [MultiDrv Sel] in the target drive must match the file (520-UM001O pp. 67–68).

Communication: 22-COMM, DSI and EtherNet/IP

PowerFlex 40/40P drives take a 22-COMM adapter inside the drive under its own cover (22B-UM001J p. 109); PowerFlex 4 uses the external 22-XCOMM-DC-BASE kit (22A-UM001L p. 86). On PowerFlex 525 (PFLEX-AP011C pp. 17, 109–110):

• Embedded EtherNet/IP, one port on the control board. For two ports, use the 25-COMM-E2P. PowerFlex 523 has no embedded port and supports only the 25-COMM-E2P (520-UM001O p. 249).
• 25-COMM adapters: 25-COMM-D (DeviceNet), 25-COMM-E2P (dual-port EtherNet/IP), 25-COMM-P (PROFIBUS DP-V1).
• Existing 22-COMM-D/E/P adapters can still be used, but mounted externally on a 22-XCOMM-DC-BASE (with the optional 20-XCOMM-AC-PS1 supply).
• Not supported: 22-COMM-B (BACnet), 22-COMM-L (LonWorks) and, according to Chapter 3, 22-COMM-C (ControlNet). The comparison table on p. 17 lists ControlNet as optional through the 22-XCOMM-DC-BASE, so ControlNet systems need a check with Rockwell first.
• Modbus RTU over RS-485 remains: P036/P038 = 5 "Comm Port" become P046/P047 = 3 "Serial/DSI"; A103/A104/A107 become C123/C124/C127; the address takes effect only after a power cycle; b012 shows 33 instead of 52 (pp. 111–112).

The IP address comes from BootP by default; to set it by parameters, set C128 [EN Addr Sel] = 1 "Parameters" and then reset or power-cycle (p. 110). Speed reference and feedback remain 16-bit integers in 0.01 Hz. On DeviceNet, I/O size and mapping stay the same as long as no datalinks are added (pp. 113–115). The logic command word differs, though: bit 6 on PowerFlex 525 forces keypad control, and the three reference-select bits (12–14) mean different things; the status word also differs at bit 6 (pp. 115–117). If the PLC writes the command word, check every bit.

Software

The guide recommends Studio 5000 Logix Designer v21 or later (or RSLogix 5000 v17 or later) with the Add-On Profile (AOP), or Connected Components Workbench (CCW) v5.0 or later (PFLEX-AP011C p. 110). Legacy HIMs, the 1203-USB, the 22-SCM-232 or CCW online over DSI show only a linear parameter list, without the AppView/CustomView groups and without access to communication option settings (520-UM001O p. 71; PFLEX-AP011C p. 111). The Startup Wizard in CCW/Logix Designer needs firmware 5.001 or later and AOP 5.07 or later (p. 68). Firmware and AOP files are downloaded from the Product Compatibility and Download Center (p. 11). In the Logix program, a drive that sat on a 22-COMM-E has to be added again as a PowerFlex 525 with the AOP, and the I/O tag structure can change; see "Using the I/O" in the adapter's user manual (PFLEX-AP011C p. 112).

A TDL case

On the packing machines TDL migrated at P&G's Dong An plant (2024–2026), the networked drives in the new programs are PowerFlex 525 on EtherNet/IP. Details: P&G Dong An packing line project.

Checklist before replacing the drive

1. Upload and save the drive parameters with CCW or DriveExecutive; if the drive cannot be reached online, record them by hand (PFLEX-AP011C p. 6).
2. Record the motor nameplate; label all power, motor, digital and analog I/O wiring; save network files and the PLC program (p. 6).
3. Select by output current and overload rating, not by kW alone; review the 120/240 V pairs where current drops.
4. Measure enclosure depth and mounting holes, choose 25-AP0/25-AP1 plates; review fuses, breakers and any DC bus inductor.
5. Draw the rewiring list: relay R3 to R5/R6, opto common 09 to 19, shield 19 to C1; for PowerFlex 523, the 4–20 mA input from 15 to 13.
6. Decide on STO: keep the jumper or wire it into the safety circuit; revalidate if used.
7. Fix the communication path: embedded EtherNet/IP, 25-COMM, or an externally mounted 22-COMM; check ControlNet, BACnet and LonWorks with Rockwell first.
8. Install CCW/Studio 5000 and the right AOP; download the firmware.
9. Update the PLC/HMI program: drive module, command word, and any selection values written to the drive.
10. Commission: autotune, start/stop, speed reference, response to communication loss, STO; save the .pf5 file.

For faults after start-up, see PowerFlex 525 F004 and F005, F007, F013. TDL plans and carries out Rockwell Automation upgrades.

Need an engineer to survey the running system: send a request