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Allen-Bradley 20P21AE675RA0NNN PowerFlex DC Drive

1. Product Overview

The 20P21AE675RA0NNN is a high-power digital DC drive designed for demanding industrial motor-control applications. It belongs to the PowerFlex DC drive family and is intended for controlling large DC motors where accurate speed regulation, controlled acceleration, reliable torque control, and stable operation are required.

With a rated output current of approximately 675 A DC and a normal-duty rating of approximately 500 HP / 373 kW, this model is designed for large industrial machinery rather than small or general-purpose motor applications.

The drive is associated with the 500…600 V AC input class and uses a three-phase AC supply configuration. Its high-current architecture makes it suitable for heavy industrial equipment in which the motor requires substantial armature current.

The unit uses a two-quadrant, non-regenerative configuration, making it suitable for applications requiring controlled forward motoring and controlled braking within the operating limits of the complete drive and motor system.

The product is also available in an industrial cabinet-mounted format, making it suitable for integration into larger electrical control panels and automation systems.

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2. Basic Product Information

Item	Specification
Model	20P21AE675RA0NNN
Brand	Allen-Bradley
Product Series	PowerFlex DC
Product Family	PowerFlex Digital DC Drive
Product Type	DC Motor Drive
Drive Configuration	Non-Regenerative
Operating Configuration	Two-Quadrant
Input Voltage Class	500…600 V AC
Typical Input Voltage	575 V AC
Input Phase	Three-Phase
Input Configuration	6-Pulse
Rated DC Output Current	675 A
Normal-Duty Power	Approximately 373 kW
Normal-Duty Horsepower	Approximately 500 HP
Frame Size	Frame C
Enclosure Type	IP20 / Open Type
Field Supply	Regulated single-phase field supply
Conformal Coating	Yes
HIM Configuration	Blank plate / no standard HIM
Cooling	Forced-air cooling
Installation	Panel or cabinet mounting
Approx. Dimensions	521 × 511 × 416 mm
Approx. Weight	68 kg
Approx. Packaged Weight	Approximately 90 kg
Motor Type	DC motor
Main Application	Large industrial DC motor control

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3. Brand

Brand: Allen-Bradley

Allen-Bradley is the brand associated with this product family and is widely used in industrial automation, motor control, machine control, process equipment, and factory electrical systems.

The product is designed around an industrial automation architecture intended for integration with other control, protection, and monitoring equipment.

For replacement projects, it is important to match the complete catalog number rather than selecting a drive only according to horsepower.

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4. Product Series

Series: PowerFlex DC

The PowerFlex DC family is designed specifically for applications involving DC motors.

Compared with a conventional AC variable-frequency drive, a DC drive directly manages the electrical characteristics required by a DC motor, making this type of equipment particularly useful for existing production machinery equipped with large DC motors.

The family covers a relatively wide range of motor-current ratings, allowing users to select a drive according to the motor’s armature current, voltage, field requirements, power rating, and application characteristics.

The 20P21AE675RA0NNN represents a high-current version within this product family.

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5. Detailed Technical Specifications

Parameter	Specification
Catalog Number	20P21AE675RA0NNN
Brand	Allen-Bradley
Series	PowerFlex DC
Drive Type	Digital DC Drive
Application	DC motor speed and torque control
Input Voltage	500…600 V AC
Nominal System Voltage	575 V AC
Input Phase	3-phase
Input Frequency	50/60 Hz, system dependent
Input Rectification	6-pulse
Output Type	Controlled DC output
Rated DC Current	675 A
Normal-Duty Power	Approx. 373 kW
Normal-Duty Rating	Approx. 500 HP
Motor Control	DC armature control
Field Control	Regulated field supply
Operating Quadrants	Two-quadrant
Regenerative Operation	Non-regenerative configuration
Frame	C
Enclosure	IP20 / Open Type
Cooling	Forced air
Conformal Coating	Included
Operator Interface	Blank plate configuration
Communication Option	Configuration dependent
Mounting	Cabinet/panel mounting
Approx. Height	521 mm
Approx. Width	511 mm
Approx. Depth	416 mm
Dimensions	Approx. 521 × 511 × 416 mm
Net Weight	Approx. 68 kg
Shipping Weight	Approx. 90 kg
Motor Type	DC motor
Typical Duty	Industrial continuous-duty applications
Typical Environment	Industrial electrical cabinet
Typical Industry	Steel, paper, material handling, processing, manufacturing

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6. Product Dimensions and Weight

The 20P21AE675RA0NNN is a relatively large industrial drive because of its 675 A output-current rating.

Its approximate physical dimensions are:

Height: 521 mm

Width: 511 mm

Depth: 416 mm

The approximate drive weight is 68 kg.

The approximate packaged or shipping weight can reach approximately 90 kg, depending on packaging and shipping configuration.

Mechanical Parameter	Value
Height	521 mm
Width	511 mm
Depth	416 mm
Overall Dimensions	521 × 511 × 416 mm
Drive Weight	Approx. 68 kg
Approx. Shipping Weight	Approx. 90 kg
Mounting Type	Cabinet / panel
Frame	C

The dimensions above describe the drive itself and should not be treated as the complete cabinet dimensions.

When designing a control cabinet, additional space should be reserved for incoming power cables, motor cables, control wiring, ventilation, heat dissipation, service access, grounding, protective devices, and maintenance.

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7. Product Introduction

The 20P21AE675RA0NNN is designed for high-power DC motor applications where conventional low-power motor controllers are not suitable.

Its 675 A DC output rating gives it the capability required for large DC motors used in heavy industrial machinery.

A DC motor system can provide useful torque characteristics and speed-control behavior, especially in machinery designed around an existing DC motor and mechanical transmission.

For this reason, a high-power DC drive can be an effective component when modernizing an existing machine without completely redesigning its motor and mechanical system.

The product provides a digital control platform for applications requiring controlled motor acceleration, deceleration, speed regulation, current control, and torque management.

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8. Main Functions

8.1 Speed Control

The primary purpose of the drive is to control the operating speed of a DC motor.

The drive adjusts the motor operating conditions so that the machine can run at a controlled speed appropriate for the production process.

This is particularly useful for production lines where motor speed must change according to material flow, machine loading, product dimensions, or production requirements.

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8.2 Armature Current Control

The 675 A current rating allows the drive to handle a substantial DC motor armature current.

This makes the product suitable for large motors used in heavy industrial equipment.

Correct motor current selection is essential because the drive must be capable of handling both the motor’s continuous operating current and the required transient operating conditions.

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8.3 Acceleration and Deceleration Control

The drive can provide controlled acceleration and deceleration rather than allowing the motor to change speed abruptly.

Controlled acceleration can help reduce mechanical shock on:

• Gearboxes
• Couplings
• Shafts
• Rollers
• Belts
• Chains
• Winders
• Conveyors
• Production machinery

This is especially important for machines with large rotating masses.

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8.4 Torque Management

DC motor applications often require controlled torque behavior.

The drive can be configured to provide the motor-control characteristics required by the machine, helping the motor respond appropriately when the mechanical load changes.

This is useful in applications such as winding, rolling, material processing, and heavy conveying.

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8.5 Controlled Braking

The two-quadrant configuration allows controlled braking behavior within the capabilities of the complete motor and drive system.

This can be useful when the machine needs controlled deceleration rather than an uncontrolled stop.

The exact braking behavior depends on the complete system design, including motor characteristics, load inertia, mechanical transmission, control configuration, and braking requirements.

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9. Product Applications

The 20P21AE675RA0NNN is intended primarily for large industrial machinery using DC motors.

Typical application areas include:

Steel Processing

Large DC motors have historically been used in steel-processing machinery because of their controllability and torque characteristics.

The drive can be used for machinery requiring substantial motor current and controlled speed operation.

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Paper and Web Processing

Paper machines and web-processing equipment often require stable motor speed and controlled acceleration.

A DC drive can be suitable for legacy machinery where DC motors remain installed.

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Material Handling

Large conveyors, transport equipment, and other material-handling machinery may use high-power DC motors.

The drive can provide controlled starting, stopping, and speed regulation.

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Winding and Unwinding Machinery

Winding equipment requires careful control of motor speed and torque.

The drive can be used where the motor must respond to changing mechanical conditions while maintaining controlled operation.

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Rolling Machinery

Large rolling equipment can require high motor power and substantial current capacity.

The 675 A rating makes this type of drive suitable for applications requiring a large DC motor.

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Mining Equipment

Heavy industrial and mining machinery can require high-power motor-control equipment.

Where a DC motor is already installed, a high-current DC drive can provide a practical control solution.

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Extrusion Equipment

Industrial extrusion machinery can require stable motor speed and controlled torque.

The drive can be used where a high-power DC motor forms part of the extrusion system.

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Large Pumps and Fans

Some large industrial pumping and ventilation systems use DC motors.

The drive can provide controlled motor speed and can therefore help adjust machine output according to process requirements.

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10. Main Product Advantages

High Current Capacity

The 675 A DC output rating is one of the primary characteristics of this model.

It enables the drive to control large DC motors that require significantly more current than small industrial DC drives.

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High Power Rating

With an approximately 373 kW / 500 HP normal-duty rating, the drive is intended for high-power industrial equipment.

This makes it suitable for large production machines where both electrical capacity and reliable motor regulation are important.

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Suitable for Existing DC Motor Systems

One of the most practical advantages of a DC drive is the ability to continue using an existing DC motor.

For a production machine with a mechanically sound DC motor, replacing the drive may be considerably less disruptive than replacing the motor, gearbox, mechanical transmission, and associated electrical system at the same time.

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Controlled Speed

The drive provides a controlled method of operating the motor at different speeds.

This is particularly valuable for production machinery where process speed directly affects product quality and production efficiency.

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Controlled Acceleration

Large industrial motors can create considerable mechanical stress when started abruptly.

Controlled acceleration allows the motor to increase speed in a controlled manner and can help reduce mechanical stress on the machine.

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Industrial Construction

The Frame C construction and forced-air cooling are appropriate for high-power industrial equipment.

The physical construction reflects the relatively high current and power level of the drive.

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Conformal Coating

The specified configuration includes conformal coating.

This provides additional protection to electronic components in industrial environments where environmental contamination may be a concern.

The conformal coating should not, however, be interpreted as making the complete drive suitable for direct exposure to water, corrosive chemicals, or outdoor conditions.

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11. Five Related Models in the Same PowerFlex DC Family

The following models represent closely related high-power configurations within the same general DC drive family.

The main difference between them is the available DC current and corresponding motor-power range.

Model	Input Voltage Class	DC Output Current	Approx. Normal-Duty Power	Approx. HP	Frame	Approx. Dimensions	Approx. Weight
20P21AE405RA0NNN	500…600 V AC	405 A	224 kW	300 HP	B	Frame B size	Approx. 32 kg
20P21AE540RA0NNN	500…600 V AC	540 A	298 kW	400 HP	C	Approx. 521 × 511 × 416 mm	Approx. 68 kg
20P21AE675RA0NNN	500…600 V AC	675 A	373 kW	500 HP	C	Approx. 521 × 511 × 416 mm	Approx. 68 kg
20P21AE810RA0NNN	500…600 V AC	810 A	447 kW	600 HP	D	Frame D size	Higher than Frame C
20P21AE1K0RA0NNN	500…600 V AC	1080 A	597 kW	800 HP	D	Frame D size	Higher than Frame C

These models are useful when the required motor current is different from the 675 A rating.

The 405 A and 540 A versions represent lower-current alternatives, while the 810 A and 1,080 A versions provide higher-current capacity.

The exact physical dimensions and weight of Frame B and Frame D configurations vary with frame construction, so they should not be treated as identical to the Frame C dimensions.

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12. Comparison of the Five Related DC Models

Parameter	20P21AE405RA0NNN	20P21AE540RA0NNN	20P21AE675RA0NNN	20P21AE810RA0NNN	20P21AE1K0RA0NNN
DC Current	405 A	540 A	675 A	810 A	1080 A
Approx. Power	224 kW	298 kW	373 kW	447 kW	597 kW
Approx. HP	300 HP	400 HP	500 HP	600 HP	800 HP
Voltage Class	500…600 V	500…600 V	500…600 V	500…600 V	500…600 V
Input	3-phase AC	3-phase AC	3-phase AC	3-phase AC	3-phase AC
Configuration	Non-regenerative	Non-regenerative	Non-regenerative	Non-regenerative	Non-regenerative
Frame	B	C	C	D	D
Typical Use	Large DC motor	Large DC motor	Large DC motor	Very large DC motor	Very large DC motor
Dimensions	Frame B	Frame C	521 × 511 × 416 mm	Frame D	Frame D
Weight	Approx. 32 kg	Approx. 68 kg	Approx. 68 kg	Higher than Frame C	Higher than Frame C

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13. Five Popular Models from the Same Brand

The following models represent commonly used products from the same brand but belong to a different drive family and are generally intended for AC motor applications.

They should therefore be regarded as related products rather than direct replacements for the 20P21AE675RA0NNN.

Model	Series	Motor Type	Input Voltage	Output Current	Approx. Motor Power	Frame	Dimensions	Weight
25B-D2P3N104	PowerFlex 525	AC Motor	380…480 V AC	2.3 A	0.75 kW / 1 HP	A	Approx. 72 × 152 × 172 mm	Approx. 1.1 kg
25B-D6P0N104	PowerFlex 525	AC Motor	380…480 V AC	6.0 A	2.2 kW / 3 HP	A	Approx. 72 × 152 × 172 mm	Approx. 1.1 kg
25B-D010N104	PowerFlex 525	AC Motor	380…480 V AC	10.5 A	4 kW / 5 HP	B	Approx. 87 × 180 × 172 mm	Approx. 1.6 kg
25B-D017N104	PowerFlex 525	AC Motor	380…480 V AC	17 A	7.5 kW / 10 HP	C	Approx. 109 × 220 × 184 mm	Approx. 2.3 kg
25B-D024N114	PowerFlex 525	AC Motor	380…480 V AC	24 A	11 kW / 15 HP	D	Approx. 130 × 260 × 212 mm	Approx. 3.9 kg

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14. Popular Model Comparison

Parameter	25B-D2P3N104	25B-D6P0N104	25B-D010N104	25B-D017N104	25B-D024N114
Series	PowerFlex 525	PowerFlex 525	PowerFlex 525	PowerFlex 525	PowerFlex 525
Motor Type	AC	AC	AC	AC	AC
Voltage	380…480 V	380…480 V	380…480 V	380…480 V	380…480 V
Current	2.3 A	6.0 A	10.5 A	17 A	24 A
Power	1 HP	3 HP	5 HP	10 HP	15 HP
Approx. kW	0.75 kW	2.2 kW	4 kW	7.5 kW	11 kW
Frame	A	A	B	C	D
Dimensions	72 × 152 × 172 mm	72 × 152 × 172 mm	87 × 180 × 172 mm	109 × 220 × 184 mm	130 × 260 × 212 mm
Weight	Approx. 1.1 kg	Approx. 1.1 kg	Approx. 1.6 kg	Approx. 2.3 kg	Approx. 3.9 kg
Typical Application	Small machine	Small machine	Machine automation	Industrial machine	Industrial machine

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15. Difference Between the PowerFlex DC and PowerFlex 525 Families

Although both product groups are designed for motor control, they serve substantially different applications.

Feature	20P21AE675RA0NNN	PowerFlex 525
Drive Technology	DC drive	AC variable-frequency drive
Motor	DC motor	AC motor
Typical Power	Hundreds of kW	Small to medium power
Target Equipment	Large industrial machinery	General machine automation
Current	675 A DC	Typically several to tens of amps
Physical Size	Large	Compact
Installation	Large cabinet	Machine/control cabinet
Typical Motor	Large DC motor	Three-phase AC motor
Main Purpose	DC motor speed/torque control	AC motor speed/torque control
Direct Replacement	—	Not a direct replacement
Typical Environment	Heavy industrial	General industrial

The difference is fundamental.

A small AC drive cannot be selected as a direct substitute for a 675 A DC drive simply because both products are used for motor control.

The motor technology, motor voltage, current, control method, power rating, wiring, protection, braking method, and mechanical system all need to be considered.

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16. Typical Industries

The product family is suitable for many types of industrial machinery.

Steel Industry

Large DC motors can be found in rolling and processing equipment where high torque and controlled speed are required.

Paper Industry

Paper production equipment often requires stable and coordinated motor operation.

Printing Industry

Large printing systems may require precise motor-speed control, particularly on older production lines.

Mining Industry

Heavy-duty conveyors and processing equipment can require high-power motor control.

Material Handling

Large conveyors, lifting equipment, and transport systems can require controlled motor acceleration and deceleration.

Manufacturing

Production machinery using large DC motors can use this type of drive as part of the machine-control system.

Chemical Processing

Large pumps, mixers, processing machinery, and other industrial equipment can require controlled motor operation.

Cement and Construction Materials

Large rotating machinery may require high-power motor control and controlled starting.

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17. Advantages in Existing-Machine Modernization

A major practical use for this type of product is modernization of an existing DC motor system.

Many industrial machines have mechanical components designed around a particular DC motor.

Replacing the drive while retaining the existing motor can potentially reduce the scope of a modernization project.

This approach can preserve:

• Existing motor
• Existing gearbox
• Existing shafts
• Existing couplings
• Existing machine frame
• Existing mechanical transmission
• Existing production equipment

The electrical control system can then be modernized around the new drive.

This can be particularly useful when the mechanical equipment remains in good condition but the original drive has reached the end of its service life.

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18. Maintenance Considerations

Because the product is a high-power industrial electronic device, proper maintenance is important.

The cooling system should be kept clean and unobstructed.

Dust accumulation can reduce airflow and increase operating temperature.

High-power semiconductor equipment is sensitive to excessive heat, so cabinet ventilation and ambient temperature should be maintained within the specified operating range.

Electrical connections should also be checked periodically.

Loose high-current connections can produce heat and electrical stress.

The following areas should receive particular attention:

Maintenance Item	Recommended Attention
Cooling fan	Check operation and airflow
Air passages	Keep clean
Power terminals	Check for looseness or overheating
Grounding	Verify integrity
Cabinet ventilation	Maintain airflow
Control wiring	Check connection condition
Motor cables	Inspect insulation and terminals
Field wiring	Verify connections
Environment	Control dust, moisture and contamination
Parameters	Maintain backup configuration
Alarm history	Review recurring faults
Electrical protection	Verify correct operation

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19. Replacement Selection Checklist

When replacing an existing drive with the 20P21AE675RA0NNN, the following information should be collected first.

Item	Required Information
Existing Drive Model	Complete catalog number
Motor Manufacturer	Motor identification
Motor Voltage	Armature voltage
Motor Current	Armature current
Motor Power	kW / HP
Motor Speed	Rated RPM
Field Voltage	Field supply voltage
Field Current	Rated field current
Supply Voltage	AC input voltage
Supply Frequency	50 / 60 Hz
Regeneration	Required or not required
Quadrant Operation	Required operating mode
Control Method	Existing control architecture
Communication	Required network/interface
Cabinet Space	Available H × W × D
Ambient Temperature	Installation environment
Cooling	Cabinet cooling arrangement
Load Type	Conveyor, winder, roller, pump, fan, etc.
Braking	Required braking method
Safety System	Existing emergency-stop architecture

This information is much more useful for engineering selection than the horsepower rating alone.

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20. Important Selection Notes

The 20P21AE675RA0NNN should not be selected solely because the existing motor is approximately 500 HP.

The motor’s rated armature current must be compared with the drive’s 675 A rating.

The motor’s armature voltage must also be compatible with the drive.

The field voltage and field current are equally important.

The machine’s operating mode must also be considered.

If the application requires four-quadrant regenerative operation, a non-regenerative two-quadrant configuration may not provide the required functionality.

Likewise, if the machine requires a particular communication interface, operator terminal, feedback device, encoder interface, or other option, the complete configuration must be reviewed.

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21. Product Advantages at a Glance

Advantage	Description
High Current	675 A DC output capability
High Power	Approximately 373 kW / 500 HP
DC Motor Compatibility	Designed specifically for DC motor control
Speed Regulation	Suitable for variable-speed applications
Torque Control	Suitable for industrial torque-control requirements
Controlled Acceleration	Helps reduce mechanical shock
Controlled Deceleration	Supports controlled stopping behavior
Industrial Construction	Designed for cabinet-mounted industrial use
Conformal Coating	Additional protection for electronic circuitry
Large Motor Applications	Suitable for high-power machinery
Modernization	Useful for updating existing DC motor systems
Multiple Ratings	Same family provides different current levels

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22. Product Specification Summary

Category	20P21AE675RA0NNN
Brand	Allen-Bradley
Series	PowerFlex DC
Type	Digital DC Drive
Configuration	Non-regenerative
Input Voltage	500…600 V AC
Input Phase	3-phase
Input Type	6-pulse
Output Current	675 A DC
Normal-Duty Power	Approx. 373 kW
Horsepower	Approx. 500 HP
Quadrant	Two-quadrant
Frame	C
Enclosure	IP20 / Open Type
Field Supply	Regulated single-phase
Conformal Coating	Yes
Cooling	Forced air
Dimensions	Approx. 521 × 511 × 416 mm
Weight	Approx. 68 kg
Shipping Weight	Approx. 90 kg
Motor Type	DC
Primary Use	Large industrial DC motor control
Installation	Electrical cabinet / panel
Typical Industries	Steel, paper, mining, material handling, manufacturing, processing

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23. Related Model Selection Table

Model	Current	Power	HP	Frame	Dimensions	Weight	General Application
20P21AE405RA0NNN	405 A	224 kW	300 HP	B	Frame B	Approx. 32 kg	Large DC motors
20P21AE540RA0NNN	540 A	298 kW	400 HP	C	Approx. 521 × 511 × 416 mm	Approx. 68 kg	Large DC motors
20P21AE675RA0NNN	675 A	373 kW	500 HP	C	Approx. 521 × 511 × 416 mm	Approx. 68 kg	Large DC motors
20P21AE810RA0NNN	810 A	447 kW	600 HP	D	Frame D	Higher than 68 kg	Very large DC motors
20P21AE1K0RA0NNN	1080 A	597 kW	800 HP	D	Frame D	Higher than 68 kg	Very large DC motors

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24. Recommended Product Positioning

For industrial product listings, the 20P21AE675RA0NNN can be described as a high-current digital DC drive for large industrial motor systems.

Its main selling points are its 675 A output capability, approximately 500 HP power rating, DC motor compatibility, industrial cabinet installation, controlled speed operation, controlled acceleration and deceleration, and suitability for modernization of existing DC motor equipment.

The product is particularly relevant to customers who need to maintain an existing large DC motor while replacing or upgrading an older motor-control system.

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25. Conclusion

The 20P21AE675RA0NNN is a high-power PowerFlex DC drive designed for large industrial DC motor applications.

Its principal electrical characteristics include a 500…600 V AC input class, three-phase input, 675 A DC output rating, and approximately 373 kW / 500 HP normal-duty capacity.

Its Frame C construction provides an approximate physical envelope of 521 × 511 × 416 mm, while the drive weight is approximately 68 kg.

The combination of high current capability, DC motor compatibility, controlled speed operation, controlled acceleration and deceleration, industrial construction, and configurable control functions makes this type of drive suitable for large production machinery.

Typical applications include steel processing, paper machinery, material handling, winding equipment, rolling machinery, mining equipment, manufacturing equipment, pumps, fans, and other large industrial machines using DC motors.

For applications requiring different power levels, the closely related 20P21AE405RA0NNN, 20P21AE540RA0NNN, 20P21AE810RA0NNN, and 20P21AE1K0RA0NNN provide alternative current ratings within the same general PowerFlex DC product family.

For smaller AC motor applications, the 25B-D2P3N104, 25B-D6P0N104, 25B-D010N104, 25B-D017N104, and 25B-D024N114 represent compact products from the same brand family, although these are AC variable-frequency drives and therefore should not be considered direct replacements for the 20P21AE675RA0NNN.

For an actual replacement project, the most important information to verify is the motor armature voltage, armature current, field voltage, field current, required quadrant operation, input supply, braking requirements, communication requirements, cabinet dimensions, cooling conditions, and complete catalog configuration.