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Allen-Bradley 20P21AD100RA0NNN PowerFlex DC Drive

Product Parameters, Product Introduction, Applications, Advantages, Series Information and Related Model Recommendations

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1. Product Overview

The 20P21AD100RA0NNN is a high-power industrial DC drive designed for controlling medium-to-large DC motors in demanding industrial applications.

It belongs to the PowerFlex DC product family and is configured as a 100 A, 60 HP / 45 kW, 480 VAC-class, three-phase DC drive.

The drive uses a two-quadrant, non-regenerative operating configuration, making it suitable for conventional DC motor applications where the motor primarily operates in the motoring direction and continuous regenerative operation is not required.

The unit is designed for cabinet installation and uses an IP20, NEMA/UL Type Open enclosure. The standard configuration includes a blank front plate rather than a local HIM, and it does not include a communication module in the base configuration.

The product is particularly suitable for industrial machinery where precise DC motor speed and torque control is required, including conveyors, rollers, feeders, paper-processing equipment, printing machinery, material-handling systems, textile equipment and other production machinery.

With a 100 A output-current rating, this model provides a higher capacity than the 73 A and 86 A versions in the same general series and is appropriate for applications around the 60 HP / 45 kW motor class.

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2. Brand and Product Series

Item	Specification
Model	20P21AD100RA0NNN
Brand	Allen-Bradley
Product Family	PowerFlex
Product Series	PowerFlex DC
Product Type	Industrial DC Drive
Drive Type	Digital DC Drive
Current Rating	100 A
Motor Rating	60 HP
Metric Motor Rating	45 kW
Input Voltage Class	480 VAC
Input Phase	Three-phase
Operating Configuration	Two-quadrant
Regenerative Operation	Non-regenerative
Enclosure	IP20
Enclosure Type	NEMA/UL Type Open
Frame	Frame A
Cooling	Air cooled
Front Interface	Blank plate
HIM	Not included
Communication Module	Not included
Field Supply	Single-phase regulated
Feedback Capability	DC tachometer / encoder capable
Conformal Coating	Included

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3. Main Technical Parameters

Parameter	Specification
Model	20P21AD100RA0NNN
Series	PowerFlex DC
Product Type	Digital DC Drive
Input Voltage	480 VAC class
Nominal Input	460/480 VAC class
Input Frequency	50/60 Hz
Input Phase	Three-phase
Input Topology	Six-pulse
Output Current	100 A
Normal-Duty Motor Rating	60 HP
Metric Motor Rating	45 kW
Motor Operation	Two-quadrant
Regenerative Operation	No
Field Supply	Single-phase regulated
Enclosure	IP20
Enclosure Type	NEMA/UL Type Open
Frame Size	Frame A
Cooling Method	Air cooled
Front Display	Blank plate
HIM	Not included
Communication Module	Not included
Feedback	Tachometer / encoder capable
Conformal Coating	Yes
Installation	Panel / cabinet mounted
Height	279 mm / 11.0 in
Width	381 mm / 15.0 in
Depth	279 mm / 11.0 in
Dimensions	279 × 381 × 279 mm
Weight (kg)	Approx. 14.5 kg

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4. Product Introduction

The 20P21AD100RA0NNN is designed for industrial DC motor control applications requiring a relatively high armature-current capacity.

Its 100 A output rating places it in the higher-capacity range of the PowerFlex DC family.

The drive is associated with a 60 HP / 45 kW motor rating, making it suitable for heavier machinery than smaller 30 HP, 40 HP and 50 HP DC drive configurations.

The main function of the drive is to convert incoming three-phase AC electrical power into controlled DC power for the motor armature while also managing the motor field and control functions.

Instead of connecting a DC motor directly to a fixed electrical source, the drive allows the motor to operate according to controlled commands.

This provides a much more useful operating system for industrial machinery.

The drive can be used to control:

• Motor starting
• Acceleration
• Deceleration
• Speed
• Armature current
• Torque-producing current
• Field operation
• Speed feedback
• Motor protection
• Machine interlocking
• Fault conditions
• Process control

This makes the drive suitable for applications where stable motor operation is more important than simply providing power to the motor.

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5. 100 A Output Current

The most important specification of the 20P21AD100RA0NNN is its 100 A current rating.

The 100 A capacity allows the drive to support substantially larger DC motors than lower-current configurations.

Current is particularly important for DC motor applications because armature current is closely related to motor torque.

When a machine experiences an increased mechanical load, the motor may require additional armature current to maintain the required torque.

For this reason, drive selection should always consider the actual motor nameplate rather than relying only on horsepower.

Important motor data includes:

• Armature voltage
• Armature current
• Field voltage
• Field current
• Base speed
• Maximum speed
• Motor duty
• Motor cooling
• Feedback type
• Load characteristics
• Acceleration requirements
• Braking requirements

The 100 A rating provides a useful capacity level for machines that exceed the requirements of smaller 73 A and 86 A configurations.

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6. 60 HP / 45 kW Motor Class

The 20P21AD100RA0NNN is intended for the approximately 60 HP / 45 kW motor class.

This makes it appropriate for larger industrial machinery.

Typical equipment in this power range may include:

• Heavy conveyors
• Large rollers
• Material feeders
• Paper-processing machinery
• Printing machinery
• Textile machinery
• Industrial production lines
• Material-handling systems
• Large process machines
• Heavy-duty machine tools
• Industrial winding equipment

The exact motor suitability depends on the motor nameplate and operating conditions.

A 60 HP rating should not be treated as a substitute for checking actual motor current and voltage.

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7. Input Voltage

The product is designed for the 480 VAC industrial voltage class.

The three-phase input configuration makes it suitable for industrial electrical systems designed for this voltage range.

Before installation, the electrical supply should be checked for:

• Nominal voltage
• Frequency
• Phase configuration
• Phase balance
• Grounding
• Short-circuit conditions
• Branch protection
• Disconnect requirements
• Cable sizing
• Cabinet temperature
• Cooling requirements

Correct power-system selection is essential for safe operation.

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8. Three-Phase Input

The drive uses a three-phase industrial power input.

Three-phase power is particularly suitable for high-power motor-control systems because it provides a practical method of transferring substantial electrical power.

The drive converts the incoming electrical energy into controlled DC power for the motor.

This arrangement is common in industrial DC drive systems and is particularly useful when an existing DC motor remains in service.

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9. Six-Pulse Architecture

The drive uses a six-pulse input configuration.

This is a conventional architecture for industrial DC drives.

The incoming three-phase AC voltage is converted through the drive’s power-conversion section into controlled DC output for the motor armature.

This architecture is well suited to retrofit projects because many older industrial DC motor systems use similar basic power-conversion concepts.

When replacing an older drive, engineers should compare:

• Input voltage
• Input phase
• Motor armature voltage
• Motor armature current
• Field voltage
• Field current
• Feedback device
• Control wiring
• Braking arrangement
• Motor speed
• Machine inertia

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10. Two-Quadrant Operation

The 20P21AD100RA0NNN is configured for two-quadrant operation.

This configuration is suitable for applications where the motor primarily operates in one direction and continuous regenerative operation is not necessary.

Typical applications include:

• Conveyors
• Feeders
• Rollers
• Fans
• Pumps
• Material-handling systems
• Processing machinery
• Production equipment

The two-quadrant configuration can provide a straightforward solution for conventional DC motor applications.

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11. Non-Regenerative Operation

The drive is a non-regenerative DC drive.

This means that it is not intended to continuously return regenerative energy from the motor back into the AC power supply.

This characteristic is important when selecting a drive for machines with substantial inertia.

During deceleration, a motor can temporarily behave as a generator.

The application should therefore be evaluated for:

• Motor speed
• Load inertia
• Deceleration time
• Number of stops
• Reversing frequency
• Mechanical load
• Braking requirements
• Regenerative energy

Applications with frequent or substantial regeneration may require a regenerative configuration instead.

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12. Regulated Field Supply

The drive includes a single-phase regulated field supply.

The field circuit is an important part of a conventional DC motor.

The motor field establishes magnetic flux that is required for normal motor operation.

The field supply must therefore be matched to the motor.

Important field parameters include:

Field Parameter	Requirement
Field Voltage	Must match the motor field rating
Field Current	Must remain within the motor rating
Field Polarity	Must be verified
Field Wiring	Must be correctly connected
Field Loss Protection	Should be configured appropriately
Field Weakening	Must be compatible with motor design
Maximum Speed	Must remain within motor limits
Motor Cooling	Must be adequate

Incorrect field settings can result in poor motor performance or potentially unsafe operating conditions.

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13. Speed Feedback

The PowerFlex DC family supports speed-feedback applications.

Depending on the motor and machine configuration, speed feedback can be provided through:

• DC tachometer
• Encoder

Feedback becomes particularly valuable when the machine requires consistent motor speed under changing loads.

For example, if the machine load increases and the motor begins to slow, the control system can detect the change and adjust motor operation to maintain the commanded speed.

This can be useful in:

• Printing machines
• Paper machinery
• Textile machinery
• Roller systems
• Precision feeders
• Production lines
• Material-processing equipment

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14. Blank Front Plate Configuration

The standard configuration uses a blank front plate rather than a local HIM.

This arrangement can be useful when the drive is installed inside a control cabinet and the operator interacts with the machine through another interface.

The operator interface may be:

• HMI
• PLC
• Pushbuttons
• Selector switches
• Remote control panel
• Machine control station
• External speed reference

This configuration keeps the drive focused on motor-control functions while allowing the machine’s main control architecture to manage the user interface.

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15. Communication Configuration

The standard 20P21AD100RA0NNN does not include a communication module.

The drive can therefore be used in applications where control is primarily performed through hardwired I/O.

Typical hardwired control functions may include:

• Start
• Stop
• Enable
• Reset
• Direction
• Speed reference
• Drive ready
• Running status
• Fault status
• Alarm signals

For larger automation systems, communication options can be evaluated separately according to the control-system architecture.

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16. IP20 Enclosure

The drive uses an IP20, NEMA/UL Type Open enclosure.

This configuration is intended for installation inside a suitable electrical cabinet or protected control enclosure.

The drive should not be treated as a weatherproof or washdown-rated device.

The cabinet should protect the drive against:

• Water
• Condensation
• Heavy dust
• Conductive contamination
• Corrosive substances
• Direct spray
• Outdoor weather
• Excessive mechanical contamination

The cabinet should also provide adequate ventilation and heat dissipation.

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17. Conformal Coating

The product includes conformal coating.

Conformal coating provides additional protection for electronic circuitry against certain industrial environmental conditions.

This can be beneficial in environments where electronics may encounter:

• Humidity
• Dust
• Industrial airborne particles
• Mild contamination
• Production-related debris

However, conformal coating does not make an IP20 drive waterproof.

A suitable enclosure remains necessary.

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18. Frame A Construction

The 20P21AD100RA0NNN uses Frame A construction.

Its approximate dimensions are:

279 mm high

381 mm wide

279 mm deep

The approximate unit weight is:

14.5 kg

This is a relatively compact physical package considering the 60 HP / 45 kW power class.

The cabinet designer should nevertheless allow additional room for:

• Power cables
• Control cables
• Feedback wiring
• Grounding
• Cooling
• Maintenance
• Cable bending radius
• Terminal access
• Service clearance

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19. Dimensions and Weight

Mechanical Parameter	Specification
Model	20P21AD100RA0NNN
Frame	Frame A
Height	279 mm
Width	381 mm
Depth	279 mm
Dimensions	279 × 381 × 279 mm
Inch Dimensions	11.0 × 15.0 × 11.0 in
Weight (kg)	Approx. 14.5 kg
Enclosure	IP20
Enclosure Type	NEMA/UL Type Open
Cooling	Air cooled
Installation	Panel / cabinet
Mounting Environment	Protected industrial enclosure

The dimensions above represent the approximate drive body dimensions. Final cabinet layout should provide additional clearance for wiring, ventilation and maintenance access.

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20. Main Product Applications

20.1 Heavy Conveyor Systems

The 100 A output rating makes the drive suitable for heavy-duty conveyor applications using compatible DC motors.

Potential applications include:

• Heavy belt conveyors
• Material conveyors
• Transfer conveyors
• Roller conveyors
• Production conveyors
• Bulk material handling
• Assembly lines
• Industrial transport systems

Controlled acceleration can reduce mechanical shock to belts, gearboxes, couplings and shafts.

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21. Industrial Roller Systems

Industrial roller systems often require stable motor speed and predictable torque.

The drive can be considered for:

• Process rollers
• Feed rollers
• Paper rollers
• Printing rollers
• Textile rollers
• Material transport rollers
• Production rollers

Speed feedback can provide additional control performance when the process requires consistent roller speed.

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22. Paper Processing Equipment

Paper-processing machinery is a classic application area for DC motor control.

Potential applications include:

• Feed rollers
• Process rollers
• Paper transport
• Material feeding
• Production machinery
• Auxiliary drives
• Processing systems

A controlled DC drive can help maintain consistent speed during changes in machine load.

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23. Printing Machinery

Printing machines often require stable motor speed and controlled acceleration.

Potential uses include:

• Printing rollers
• Paper-feed mechanisms
• Material transport
• Process rollers
• Auxiliary drives
• Production equipment

Feedback control can be particularly useful when speed variation affects material positioning or process quality.

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24. Textile Machinery

Compatible DC motors in textile machinery can also be controlled by this type of drive.

Potential applications include:

• Textile rollers
• Feed mechanisms
• Material transport
• Processing systems
• Production lines
• Auxiliary machinery

Winding and unwinding applications require additional evaluation because the mechanical load can produce substantial regenerative energy during deceleration.

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25. Material-Handling Equipment

The 100 A current rating makes the drive appropriate for substantial material-handling systems.

Potential applications include:

• Heavy feeders
• Transfer systems
• Conveyors
• Rollers
• Production transport
• Sorting systems
• Industrial handling equipment
• Material-processing machinery

The drive can provide controlled acceleration and speed operation for compatible DC motors.

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26. Industrial Production Lines

The drive can be integrated into larger production systems where the DC motor is only one part of the overall machine.

Possible control architecture:

PLC → Drive Command → DC Drive → DC Motor → Mechanical Load

Feedback can also be incorporated:

Motor → Tachometer / Encoder → Drive → Speed Correction

This type of arrangement can provide stable motor operation while allowing the PLC to manage the broader production process.

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27. Machine Tools

The drive can be considered for compatible industrial machine-tool applications.

Possible applications include:

• Grinding equipment
• Feed systems
• Processing equipment
• Specialized machine tools
• Production machinery
• Material-processing equipment

Actual suitability depends on the motor voltage, current, speed and machine-control requirements.

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28. Product Advantages

28.1 100 A Current Capacity

The 100 A rating is one of the most important advantages of this model.

It provides significantly more current capacity than smaller 52 A, 73 A and 86 A configurations.

This makes it suitable for larger DC motors.

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28.2 60 HP / 45 kW Motor Class

The approximately 60 HP / 45 kW rating provides enough capacity for substantial industrial machinery.

This is a practical range for many heavy-duty production systems.

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28.3 480 VAC-Class Input

The 480 VAC-class input makes the drive suitable for many industrial three-phase power systems.

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28.4 Two-Quadrant Operation

Two-quadrant operation provides a practical solution for conventional motoring applications that do not require continuous regeneration.

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28.5 Regulated Field Supply

The regulated field supply supports controlled operation of compatible DC motor field circuits.

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28.6 Speed Feedback Capability

Tachometer and encoder capability can improve speed regulation.

This is especially valuable in applications where motor speed must remain stable as the load changes.

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28.7 Compact Frame A Design

The Frame A construction provides a relatively compact drive package for its power rating.

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28.8 Conformal Coating

Conformal coating provides additional protection for electronic components in suitable industrial environments.

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28.9 Retrofit Potential

The drive can be useful for modernization projects where the existing DC motor remains mechanically sound.

Instead of replacing the complete machine, the control electronics can potentially be modernized while retaining:

• Existing DC motor
• Gearbox
• Couplings
• Rollers
• Conveyor
• Shafts
• Bearings
• Mechanical transmission
• Existing PLC
• Existing HMI

This can reduce the mechanical scope of a modernization project.

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29. Product Advantages Summary

Feature	Practical Benefit
100 A output	Suitable for higher-current DC motors
60 HP / 45 kW	Suitable for heavy industrial machinery
480 VAC-class input	Suitable for industrial three-phase systems
Three-phase input	Appropriate for higher-power industrial installations
Six-pulse topology	Established DC drive architecture
Two-quadrant operation	Suitable for conventional motoring loads
Non-regenerative design	Suitable where continuous regeneration is unnecessary
Regulated field supply	Supports controlled DC motor field operation
Tachometer / encoder capability	Supports accurate speed regulation
Flexible I/O	Allows machine-control integration
Frame A	Compact mechanical construction
IP20	Suitable for cabinet installation
Conformal coating	Additional electronics protection
Blank front plate	Suitable for remote operator control

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30. Five Same-Series or Closely Related Models

The following models are useful for comparison when selecting a drive around the capacity of the 20P21AD100RA0NNN.

No.	Model	Series	Current	Motor Rating	Power	Input	Operation	Regenerative
1	20P21AD052RA0NNN	PowerFlex DC	52 A	30 HP	22 kW	460/480 VAC	Two-quadrant	No
2	20P21AD073RA0NNN	PowerFlex DC	73 A	40 HP	30 kW	460/480 VAC	Two-quadrant	No
3	20P21AD086RA0NNN	PowerFlex DC	86 A	50 HP	37 kW	460/480 VAC	Two-quadrant	No
4	20P21AD100RA0NNN	PowerFlex DC	100 A	60 HP	45 kW	460/480 VAC	Two-quadrant	No
5	20P41AD100RA0NNN	PowerFlex DC	100 A	60 HP class	45 kW class	460/480 VAC	Regenerative	Yes

The first four models form a useful capacity progression.

The fifth model is particularly relevant when the same approximate motor capacity is required but regenerative operation is necessary.

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31. Related Model 1 — 20P21AD052RA0NNN

The 20P21AD052RA0NNN is a lower-capacity DC drive.

Its approximate rating is:

52 A

with approximately:

30 HP / 22 kW

It is appropriate for smaller DC motors.

Compared with the 100 A model, it provides less current capacity and is better suited to machines with lower power requirements.

Typical applications include:

• Medium conveyors
• Feeders
• Rollers
• Production machinery
• Material transport
• Smaller processing systems

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32. Related Model 2 — 20P21AD073RA0NNN

The 20P21AD073RA0NNN provides approximately:

73 A

and:

40 HP / 30 kW

It sits between the 52 A and 86 A configurations.

It can be a good choice when the motor does not require the full capacity of the 100 A model.

Potential applications include:

• Industrial rollers
• Conveyors
• Feeders
• Material handling
• Paper machinery
• Production equipment

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33. Related Model 3 — 20P21AD086RA0NNN

The 20P21AD086RA0NNN is rated at approximately:

86 A

and:

50 HP / 37 kW

It is directly below the 100 A model in current capacity.

This makes it one of the most natural alternatives when the actual motor current is below 100 A.

For a motor operating around the 50 HP class, this configuration may provide a better match than selecting the larger 100 A unit.

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34. Related Model 4 — 20P41AD100RA0NNN

The 20P41AD100RA0NNN is a regenerative configuration in the approximately 100 A class.

It becomes more relevant when the machine produces substantial regenerative energy.

Potential applications include:

• Winders
• Unwinders
• Hoists
• Cranes
• High-inertia rollers
• Rapid stopping systems
• Frequent reversing machinery
• Machines with substantial braking energy

The main distinction is the regenerative operating capability.

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35. Related Model 5 — 20P21AD129RA0NNN

The 20P21AD129RA0NNN represents a higher-capacity configuration.

It is suitable for larger DC motors where 100 A is not sufficient.

Potential applications include:

• Large conveyors
• Heavy processing machines
• Large rollers
• Heavy feeders
• High-power production lines
• Large material-handling systems

The higher current capacity provides additional motor-control capability for demanding loads.

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36. Five Same-Brand Models for Broader Comparison

The following models can be considered as related products when evaluating different motor-control requirements.

No.	Model	Product Family	Product Type	Voltage Class	Current / Power	Typical Application	Dimensions	Weight (kg)
1	20P21AD073RA0NNN	PowerFlex DC	DC Drive	460/480 VAC	73 A / 40 HP	Industrial DC machinery	Approx. 279 × 381 × 279 mm class	Approx. 14.5
2	20P21AD086RA0NNN	PowerFlex DC	DC Drive	460/480 VAC	86 A / 50 HP	Heavy DC machinery	Approx. 279 × 381 × 279 mm class	Approx. 14.5
3	20P21AD100RA0NNN	PowerFlex DC	DC Drive	460/480 VAC	100 A / 60 HP	Heavy DC machinery	Approx. 279 × 381 × 279 mm	Approx. 14.5
4	20P21AD129RA0NNN	PowerFlex DC	DC Drive	460/480 VAC	129 A / 75 HP	High-power DC machinery	Larger frame	Higher
5	25B-D017N104	PowerFlex 525	AC Drive	380–480 VAC	17 A class	General AC motor control	Compact frame	Approx. 2–3

The first four are direct DC-drive comparisons.

The fifth model belongs to a different drive technology and is better considered when the project involves converting an existing DC motor application to an AC motor system.

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37. Capacity Comparison

Model	Current	Approx. HP	Approx. kW	Input	Operation	General Application
20P21AD019RA0NNN	19 A	10 HP	7.5 kW	460/480 VAC	Two-quadrant	Smaller DC machinery
20P21AD027RA0NNN	27 A	15 HP	11 kW	460/480 VAC	Two-quadrant	Medium machinery
20P21AD035RA0NNN	35 A	20 HP	15 kW	460/480 VAC	Two-quadrant	Medium industrial machinery
20P21AD045RA0NNN	45 A	25 HP	18.5 kW	460/480 VAC	Two-quadrant	Medium-heavy machinery
20P21AD052RA0NNN	52 A	30 HP	22 kW	460/480 VAC	Two-quadrant	Larger industrial machinery
20P21AD073RA0NNN	73 A	40 HP	30 kW	460/480 VAC	Two-quadrant	Heavy industrial machinery
20P21AD086RA0NNN	86 A	50 HP	37 kW	460/480 VAC	Two-quadrant	Heavy industrial machinery
20P21AD100RA0NNN	100 A	60 HP	45 kW	460/480 VAC	Two-quadrant	Large DC machinery
20P21AD129RA0NNN	129 A	75 HP	56 kW	460/480 VAC	Two-quadrant	Larger DC machinery

The 20P21AD100RA0NNN therefore occupies an important position in this range.

It provides a substantial increase over the 86 A model while remaining below the higher-current 129 A configuration.

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38. Detailed Product Parameter Table

Category	Parameter	Specification
Product	Model	20P21AD100RA0NNN
Product	Brand	Allen-Bradley
Product	Series	PowerFlex DC
Product	Product Type	Digital DC Drive
Electrical	Input Voltage	480 VAC class
Electrical	Nominal Voltage	460/480 VAC class
Electrical	Input Frequency	50/60 Hz
Electrical	Input Phase	Three-phase
Electrical	Input Topology	Six-pulse
Electrical	Output Current	100 A
Electrical	Normal-Duty Power	45 kW
Electrical	Normal-Duty Horsepower	60 HP
Electrical	Motor Operation	Two-quadrant
Electrical	Regenerative Operation	No
Field	Field Supply	Single-phase regulated
Enclosure	IP Rating	IP20
Enclosure	Enclosure Type	NEMA/UL Type Open
Mechanical	Frame	Frame A
Mechanical	Cooling	Air cooled
Mechanical	Height	279 mm
Mechanical	Width	381 mm
Mechanical	Depth	279 mm
Mechanical	Dimensions	279 × 381 × 279 mm
Mechanical	Weight (kg)	Approx. 14.5 kg
Interface	Front Interface	Blank plate
Interface	HIM	Not included
Communication	Communication Module	Not included
Feedback	Tachometer	Supported
Feedback	Encoder	Supported
Protection	Conformal Coating	Yes
Installation	Mounting	Panel / cabinet
Application	Motor Type	DC motor
Application	Typical Loads	Conveyors, rollers, feeders and process machinery

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39. Application Suitability

Application	Suitability	Main Reason
Heavy Conveyor	Excellent	High current and controlled acceleration
Industrial Roller	Excellent	Stable speed and torque control
Material Feeder	Excellent	100 A capacity
Paper Processing	Very Suitable	Controlled speed operation
Printing Equipment	Very Suitable	Feedback-based speed regulation
Textile Machinery	Suitable	Controlled DC motor operation
Material Handling	Very Suitable	60 HP-class capacity
Production Lines	Suitable	Flexible control integration
Machine Tools	Suitable	Speed and current control
Winder	Application Dependent	Regenerative energy must be evaluated
Unwinder	Application Dependent	Regeneration may be significant
Hoist	Application Dependent	Braking and regeneration require evaluation
Crane	Application Dependent	Four-quadrant operation may be required
Rapid Reversing Machine	Application Dependent	Regenerative energy must be considered

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40. Speed Regulation

Speed regulation is one of the major advantages of a digital DC drive.

The machine can provide a speed command to the drive.

The drive then controls motor operation to achieve the required speed.

When a feedback device is installed, the system can compare commanded speed with actual motor speed.

For example:

Commanded Speed → Drive → DC Motor → Mechanical Load

with feedback:

Motor → Encoder/Tachometer → Drive → Speed Correction

This arrangement can improve speed stability when machine load changes.

Applications benefiting from this approach include:

• Paper processing
• Printing
• Textile machinery
• Rollers
• Feeders
• Material handling
• Production lines

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41. Acceleration Control

Large DC motors can produce substantial starting torque.

If a large motor is started too aggressively, mechanical components can experience unnecessary stress.

Controlled acceleration can reduce stress on:

• Gearboxes
• Couplings
• Shafts
• Belts
• Bearings
• Rollers
• Conveyor components

The drive can therefore help create a smoother transition from standstill to operating speed.

This is particularly valuable for heavy machinery.

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42. Deceleration Control

Deceleration should be evaluated carefully because this is a non-regenerative configuration.

When the motor decelerates, stored mechanical energy may be transferred back toward the drive.

The application engineer should consider:

• Motor speed
• Load inertia
• Deceleration time
• Stopping frequency
• Reversing frequency
• Mechanical load
• Braking method
• Regenerative energy

If the machine produces substantial regeneration during normal operation, a regenerative model should be considered.

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43. Torque Control

DC motor torque is strongly related to armature current.

The 100 A output rating therefore gives the drive substantial torque-control capability when paired with a suitable DC motor.

This can be useful for:

• Heavy conveyors
• Feeders
• Rollers
• Material handling
• Production machinery
• Processing systems

The current limits must always be configured according to the actual motor specifications.

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44. Retrofit Applications

The 20P21AD100RA0NNN can be especially valuable in DC drive modernization projects.

An older machine may still have:

• A mechanically sound DC motor
• Good gearbox
• Good coupling
• Good conveyor
• Good rollers
• Good bearings
• Existing PLC
• Existing HMI

Replacing the drive electronics rather than the complete mechanical system may reduce the amount of modification required.

Potential benefits include:

• Reduced mechanical work
• Shorter modification time
• Less machine redesign
• Easier integration with existing controls
• Preservation of existing motor equipment
• Improved control capability

This is one of the most practical reasons to consider a modern DC drive for an existing industrial machine.

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45. Cabinet Design Considerations

The approximate drive dimensions are:

279 mm × 381 mm × 279 mm

The approximate weight is:

14.5 kg

However, these values should not be interpreted as the complete cabinet requirement.

The enclosure designer should provide additional space for:

• Power cables
• Control cables
• Feedback cables
• Ground connections
• Airflow
• Cooling
• Maintenance
• Cable bending radius
• Terminal access
• Service clearance

Other equipment inside the same cabinet should also be considered because it can contribute additional heat.

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46. Thermal Management

The drive generates heat during normal operation.

A suitable cabinet design should consider:

• Ambient temperature
• Internal cabinet temperature
• Airflow
• Cooling fan condition
• Heat from adjacent devices
• Ventilation
• Heat exchanger requirements
• Dust accumulation
• Cabinet loading

Maintaining appropriate temperature is important for long-term drive reliability.

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47. DC Motor Inspection Before Replacement

Before installing a new DC drive, the motor should be checked.

Important inspection areas include:

Motor Area	Recommended Check
Armature	Voltage and current rating
Field	Voltage and current rating
Brushes	Wear and seating
Commutator	Surface condition
Bearings	Wear and noise
Insulation	Insulation condition
Cooling	Fan and ventilation
Speed	Base and maximum speed
Feedback	Tachometer / encoder condition
Coupling	Alignment
Vibration	Excessive vibration
Temperature	Operating temperature

This is particularly important for older DC motors.

A drive replacement cannot correct mechanical wear, poor insulation, damaged brushes or a deteriorated commutator.

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48. Maintenance Recommendations

Routine maintenance should include inspection of:

• Cooling fan
• Air passages
• Power terminals
• Control terminals
• Field wiring
• Armature wiring
• Feedback wiring
• Grounding
• Cabinet cleanliness
• Motor brushes
• Motor commutator
• Motor bearings
• Fault history

A preventive maintenance program can help identify problems before they result in unplanned downtime.

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49. When to Choose the 100 A Model

The 20P21AD100RA0NNN is a strong candidate when:

• The motor is around 60 HP.
• The motor is around 45 kW.
• Armature current approaches the 100 A range.
• The plant has a compatible 460/480 VAC three-phase supply.
• The machine primarily operates in the motoring direction.
• Continuous regeneration is not required.
• The existing DC motor is in good condition.
• Speed regulation is required.
• Controlled acceleration is required.
• A protected cabinet is available.

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50. When to Select a Smaller Model

A smaller model may be more appropriate when the actual motor current is substantially below 100 A.

Examples include:

Motor Requirement	Possible Model
Around 30 HP / 22 kW	20P21AD052RA0NNN
Around 40 HP / 30 kW	20P21AD073RA0NNN
Around 50 HP / 37 kW	20P21AD086RA0NNN
Around 60 HP / 45 kW	20P21AD100RA0NNN

Selecting a drive that is appropriately matched to the motor can simplify system design and avoid unnecessary oversizing.

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51. When to Select a Larger Model

A larger model should be considered when:

• Motor current exceeds 100 A.
• The motor is larger than the 60 HP class.
• The machine has heavy continuous loading.
• The application requires additional current capacity.
• The motor’s actual operating point approaches the drive limit.

The 20P21AD129RA0NNN is a useful comparison for higher-capacity applications.

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52. When to Select a Regenerative Model

The 20P21AD100RA0NNN should not automatically be selected for machines with high regenerative energy.

A regenerative configuration should be evaluated for applications such as:

• Hoists
• Cranes
• Winders
• Unwinders
• High-inertia rollers
• Rapid stopping machines
• Frequent reversing machinery
• Downhill material conveyors
• Applications with continuous braking

For these machines, the regenerative energy characteristics should be analyzed before final drive selection.

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53. Five Recommended Same-Series or Related Models

No.	Model	Current	Approx. Motor Rating	Power	Input	Operation	Regenerative	Typical Use
1	20P21AD052RA0NNN	52 A	30 HP	22 kW	460/480 VAC	Two-quadrant	No	Medium DC machinery
2	20P21AD073RA0NNN	73 A	40 HP	30 kW	460/480 VAC	Two-quadrant	No	Conveyors and rollers
3	20P21AD086RA0NNN	86 A	50 HP	37 kW	460/480 VAC	Two-quadrant	No	Heavy DC machinery
4	20P41AD100RA0NNN	100 A	60 HP class	45 kW class	460/480 VAC	Regenerative	Yes	High-inertia applications
5	20P21AD129RA0NNN	129 A	75 HP class	56 kW class	460/480 VAC	Two-quadrant	No	Larger DC machinery

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54. Five Broader Same-Brand Recommendations

No.	Model	Series	Type	Voltage	Current / Power	Typical Application	Approx. Dimensions	Weight (kg)
1	20P21AD073RA0NNN	PowerFlex DC	DC Drive	460/480 VAC	73 A / 40 HP	Medium-heavy DC machinery	Approx. 279 × 381 × 279 mm class	Approx. 14.5
2	20P21AD086RA0NNN	PowerFlex DC	DC Drive	460/480 VAC	86 A / 50 HP	Heavy DC machinery	Approx. 279 × 381 × 279 mm class	Approx. 14.5
3	20P21AD100RA0NNN	PowerFlex DC	DC Drive	460/480 VAC	100 A / 60 HP	Heavy industrial machinery	Approx. 279 × 381 × 279 mm	Approx. 14.5
4	20P21AD129RA0NNN	PowerFlex DC	DC Drive	460/480 VAC	129 A / 75 HP	High-power DC machinery	Larger frame	Higher
5	25B-D017N104	PowerFlex 525	AC Drive	380–480 VAC	17 A class	General AC motor control	Compact frame	Approx. 2–3

The first four models are direct DC-drive comparisons.

The fifth model represents a different motor-control approach and is more suitable for applications where the existing DC system is being converted to AC motor technology.

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55. Model Selection Comparison

Model	Current	HP	kW	Typical Capacity	Regeneration	Recommended Application
20P21AD052RA0NNN	52 A	30 HP	22 kW	Medium	No	Medium industrial DC machinery
20P21AD073RA0NNN	73 A	40 HP	30 kW	Medium-heavy	No	Conveyors, rollers, feeders
20P21AD086RA0NNN	86 A	50 HP	37 kW	Heavy	No	Heavy industrial machinery
20P21AD100RA0NNN	100 A	60 HP	45 kW	Heavy	No	Larger industrial machinery
20P21AD129RA0NNN	129 A	75 HP	56 kW	Very heavy	No	High-power DC systems
20P41AD100RA0NNN	100 A	60 HP class	45 kW class	Heavy	Yes	Regenerative applications

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56. Product Configuration

The catalog number 20P21AD100RA0NNN identifies a particular configuration within the PowerFlex DC product family.

The important characteristics represented by this product configuration include:

• PowerFlex DC family
• 100 A current class
• 480 VAC-class input
• Three-phase input
• Two-quadrant operation
• Non-regenerative configuration
• IP20 enclosure
• NEMA/UL Type Open construction
• Conformal coating
• Blank front plate
• No standard HIM
• No communication module
• Frame A construction

The complete catalog number should always be used when identifying the exact replacement unit.

Two drives with similar current ratings should not automatically be assumed to be interchangeable.

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57. Industrial Environment

The drive should be installed in an appropriate industrial environment.

The installation should protect the unit against:

• Water
• Direct spray
• Condensation
• Excessive dust
• Conductive particles
• Corrosive gases
• Excessive vibration
• Mechanical impact

The cabinet should also maintain adequate ventilation.

Power wiring and control wiring should be arranged carefully to reduce unwanted electrical interference.

Feedback wiring should receive particular attention because speed feedback signals can be sensitive to electrical noise.

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58. Electrical Integration

A typical control system can be organized as follows:

Three-Phase AC Supply

↓

DC Drive

↓

DC Motor

↓

Mechanical Load

The control system can provide:

PLC / Controller → Drive Command

and feedback can provide:

Motor → Tachometer / Encoder → Drive

This creates a closed-loop motor-control arrangement when speed feedback is used.

The approach can provide:

• Stable speed
• Controlled acceleration
• Controlled deceleration
• Current limiting
• Torque control
• Fault monitoring
• Machine interlocking

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59. Advantages for Existing Machinery

For older production equipment, the most significant benefit may not simply be the drive’s current rating.

The larger benefit can be the ability to modernize motor control while keeping much of the original mechanical system.

A retrofit may allow continued use of:

• Existing motor
• Existing gearbox
• Existing mechanical transmission
• Existing conveyor
• Existing rollers
• Existing machine frame
• Existing PLC
• Existing HMI

This can make the modernization project less disruptive.

It may also reduce the amount of mechanical engineering required.

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60. Recommended Application Areas

Application	Main Benefit
Heavy Conveyors	Controlled acceleration and high-current motor control
Industrial Rollers	Stable speed and torque control
Paper Machinery	Consistent motor speed
Printing Equipment	Speed regulation and feedback capability
Textile Machinery	Controlled DC motor operation
Material Feeders	High torque capability
Production Lines	Integration with machine controls
Material Handling	60 HP-class motor support
Machine Tools	Speed and current regulation
Process Machinery	Controlled motor operation

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61. Detailed Mechanical Parameters

Mechanical Item	Specification
Model	20P21AD100RA0NNN
Frame	Frame A
Enclosure	IP20
Enclosure Style	NEMA/UL Type Open
Cooling	Air cooled
Height	279 mm
Width	381 mm
Depth	279 mm
Overall Dimensions	279 × 381 × 279 mm
Inch Dimensions	11.0 × 15.0 × 11.0 in
Weight (kg)	Approx. 14.5 kg
Mounting	Cabinet / panel
Front Interface	Blank plate
HIM	Not included
Communication Module	Not included

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62. Detailed Electrical Parameters

Electrical Item	Specification
Model	20P21AD100RA0NNN
Input Voltage	480 VAC class
Nominal Voltage	460/480 VAC class
Input Phase	Three-phase
Input Frequency	50/60 Hz
Input Configuration	Six-pulse
Output Current	100 A
Motor Rating	60 HP
Motor Rating	45 kW
Motor Type	DC motor
Operation	Two-quadrant
Regeneration	Non-regenerative
Field Supply	Single-phase regulated
Feedback	Tachometer / encoder capable
Enclosure	IP20
Cooling	Air cooled
Conformal Coating	Yes

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63. Technical Strengths at a Glance

Technical Feature	Benefit
100 A current rating	Supports larger DC motors
60 HP rating	Suitable for heavy machinery
45 kW capacity	Useful for substantial industrial loads
480 VAC input	Suitable for industrial power systems
Three-phase supply	Appropriate for higher-power installations
Two-quadrant control	Suitable for conventional motoring applications
Regulated field supply	Supports DC motor field control
Feedback capability	Supports accurate speed regulation
IP20 enclosure	Suitable for protected cabinets
Conformal coating	Additional protection for electronics
Frame A	Compact package for its power class
Blank front plate	Useful for remote control architectures

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64. Final Product Assessment

The 20P21AD100RA0NNN is a high-capacity industrial DC drive positioned around the 60 HP / 45 kW motor class.

Its 100 A current rating makes it suitable for heavier DC motor applications than the 52 A, 73 A and 86 A versions.

The combination of:

480 VAC-class input

Three-phase power

100 A output

60 HP / 45 kW motor capacity

Two-quadrant operation

Regulated field supply

Tachometer / encoder capability

and:

IP20 cabinet installation

makes it a practical solution for a wide range of industrial DC motor systems.

It is particularly attractive for machinery where an existing DC motor is still mechanically useful but the original drive-control system needs modernization.

For conveyors, rollers, feeders, paper-processing equipment, printing machinery, textile equipment and material-handling systems, the drive provides a substantial amount of motor-control capacity in a relatively compact Frame A package.

The approximate physical dimensions of 279 × 381 × 279 mm and approximate weight of 14.5 kg make it suitable for industrial panel installation, although additional cabinet space must be reserved for wiring, cooling and maintenance.

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65. Final Specification Summary

Parameter	Final Specification
Model	20P21AD100RA0NNN
Brand	Allen-Bradley
Product Family	PowerFlex
Series	PowerFlex DC
Product Type	Industrial Digital DC Drive
Input Voltage	480 VAC class
Nominal Input	460/480 VAC class
Input Phase	Three-phase
Input Frequency	50/60 Hz
Input Topology	Six-pulse
Output Current	100 A
Motor Rating	60 HP
Metric Motor Rating	45 kW
Motor Operation	Two-quadrant
Regenerative Operation	No
Field Supply	Single-phase regulated
Enclosure	IP20
Enclosure Type	NEMA/UL Type Open
Frame	Frame A
Cooling	Air cooled
Front Interface	Blank plate
HIM	Not included
Communication Module	Not included
Feedback	DC tachometer / encoder capable
Conformal Coating	Yes
Height	279 mm
Width	381 mm
Depth	279 mm
Dimensions	279 × 381 × 279 mm
Weight (kg)	Approx. 14.5 kg
Main Application	Industrial DC motor control
Typical Loads	Conveyors, rollers, feeders, paper and process machinery
Lower-Capacity Alternative	20P21AD086RA0NNN
Higher-Capacity Alternative	20P21AD129RA0NNN
Regenerative Alternative	20P41AD100RA0NNN

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66. Conclusion

The 20P21AD100RA0NNN is a powerful 100 A, 60 HP / 45 kW PowerFlex DC drive intended for demanding industrial DC motor applications.

Its position within the product family makes it a useful selection for applications that require more capacity than an 86 A drive but do not necessarily require a larger 129 A configuration.

The drive is particularly suitable for heavy conveyors, industrial rollers, feeders, paper-processing machinery, printing equipment, textile machinery, material-handling equipment and other production systems using compatible DC motors.

The two-quadrant, non-regenerative configuration is appropriate for conventional motoring applications where regenerative energy is limited.

For machines with frequent braking, rapid reversing, high inertia or continuous energy return, a regenerative configuration should be considered instead.

The regulated field supply provides an important control function for compatible DC motors, while tachometer and encoder capability can improve speed regulation in demanding processes.

The IP20 enclosure and Frame A construction make the drive appropriate for protected electrical cabinets.

The approximate 279 × 381 × 279 mm dimensions and 14.5 kg weight also make it practical for panel-mounted industrial installations.

From a system-design perspective, the most important point is to select the drive according to the complete motor and machine requirements rather than horsepower alone.

The motor’s armature voltage, armature current, field voltage, field current, base speed, maximum speed, feedback arrangement, duty cycle, load inertia and braking requirements should all be evaluated.

When these factors match the application, the 20P21AD100RA0NNN provides a strong combination of high-current capability, controlled speed operation, field regulation, feedback support and retrofit flexibility for industrial DC motor systems.