Rockwell Automation Allen-Bradley PowerFlex 20P User manual

Technical Data
Original Instructions
PowerFlex DC Drive and Field Controller
Catalog Numbers 20P, 23P, 23PFC
Topic Page
Summary of Changes 2
The PowerFlex DC Drive 3
The PowerFlex DC Field Controller 4
The PowerFlex DC Standalone Regulator 5
Unsurpassed Capability in Network Communication 5
PowerFlex DC Drive Catalog Number Explanation 6
PowerFlex DC Field Controller Catalog Number Explanation 9
PowerFlex DC Field Controller Product Selection 9
Factory-installed Options 10
User-installed Options 10
Isolation Transformers 12
Installation Considerations 21
Typical Power Wiring Diagrams 24
PowerFlex DC Drives Terminal Block Locations 30
PowerFlex DC Drives and Field Controller Circuit Protection 48
Mounting 61
Approximate Dimensions – PowerFlex DC Drives 62
Approximate Dimensions and Weights – PowerFlex DC Field Controllers 68
PowerFlex DC Drive Specifications 70
PowerFlex DC Field Controller Specifications 73
IP20 NEMA/UL Type Open Watts Loss 74
Additional Resources 77

2Rockwell Automation Publication 20P-TD001K-EN-P - January 2021
PowerFlex DC Drive and Field Controller Technical Data
Summary of Changes
This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect
all changes.
Topic Page
Added Modbus communication adapter 5
Added Product Selection tables 7
Added Stand-alone Regulator Catalog Numbers 8
Updated Contactor Catalog Numbers from 100-D to 100E for 230V AC Input Drives 14
Updated Contactor Catalog Numbers from 100-D to 100E for 460V AC Input Drives 14
Updated Contactor Catalog Numbers from 100-D to 100E for 575V AC Input Drives 15
Updated Contactor Catalog Numbers from 100-D to 100E for 690V AC Input Drives 15
Updated Contactor Catalog Numbers from 100-D to 100E for 200V AC Field Controllers 16
Updated Contactor Catalog Numbers from 100-D to 100E for 500V AC Field Controllers 16
Changed graphics to show field leads coming off the primary side of isolation transformer and line reactor 25, 26, 27
Changed A+ and A- encoders from Single Channel to Single Ended 45
Updated Max. Airflow Noise Level for Frame B drives 75

Rockwell Automation Publication 20P-TD001K-EN-P - January 2021 3
PowerFlex DC Drive and Field Controller Technical Data
The PowerFlex DC Drive
The PowerFlex® DC drive (20P) provides digital control for precise speed and current regulation, easy programmability, extensive
diagnostics, and non-regenerative or regenerative operation. PowerFlex DC drives can run various applications, including extruder
operations, finishing, drawing, and coating. The PowerFlex DC drive can effectively control applications that exhibit shock loads, high inertia,
rapid acceleration and deceleration rates, or continuous regeneration. These features of the PowerFlex DC drive make it an excellent choice
for existing DC machinery upgrades. The compact design of this drive includes a fully contained power module and a common control
structure for the entire range of horsepower. And, to make connectivity even easier, the PowerFlex DC drive provides a standard DPI™
interface that is compatible with all PowerFlex DPI communication products.
The standard hardware consists of an open type enclosure, armature converter, regulated field converter for field weakening or economy
applications, and an advanced regulator with integrated DPI functionality. The standard I/O includes eight digital inputs, four digital outputs,
three analog inputs, two analog outputs, a DC tachometer, and encoder capability.
Optional I/O and feedback modules are available and are sold separately from the standard hardware offering. For more information, see I/O
Option Kits and Feedback Option Kit (only for PowerFlex DC drives) on page 10.
Drive Features
• Fast-acting Current Limit and Voltage Regulation result in maximum accelerate/decel without tripping.
•High-speed analog inputs improve drive response to torque or speed commands.
•Programming flexibility allows parameters to be linked within the drive.
•Field-flashable firmware through DPI interface.
•Flying Start delivers smooth and instantaneous connection into a rotating load, regardless of commanded direction, without the need
for any speed feedback.
•Single-phase Regulated Field supply (10 A, 14 A, 20 A, 40 A, and 70 A, depending on the drive size) standard on all frames.
•Integral Process PI Control replaces the need for a separate controller for a process loop.
•TorqProve™ helps assure control of the load when control is transferred between the drive and a mechanical brake.
•Speed Regulation - open-loop or closed-loop
- Armature Feedback provides a 2000:1 rpm speed range
- DC Tachometer Feedback provides up to 0.1% speed regulation
- Encoder Feedback provides up to 0.1% speed regulation for the tightest application requirements.
•Torque Regulation - open-loop or closed-loop
- Open-loop torque regulation provides ±5% regulation.
- Encoder Feedback provides ±1% regulation and the ability to hold full load at zero speed.
Packaging and Mounting
•IP20, NEMA/UL Type Open - For conventional mounting inside or outside a control cabinet.

4Rockwell Automation Publication 20P-TD001K-EN-P - January 2021
PowerFlex DC Drive and Field Controller Technical Data
Communication Tools
The PowerFlex DC drive and field controller provide common communication tools that are familiar and easy to use, including the LCD
Human Interface Module (HIM) and PC-based configuration tools.
• The LCD HIM provides:
- Large and easy to read 7 line x 21 character, backlit display
- Alternate function keys for shortcuts to common tasks
- ‘Calculator-like’ number pad for fast and easy data entry (full numeric version only)
- Control keys for local start, stop, speed, and direction
- Remote versions for panel mount applications
• PC-based configuration tools include:
- Connected Components Workbench™ (CCW) software v2.0. This software leverages proven Rockwell Automation and Microsoft®
Visual Studio® technologies for drive configuration and programming. CCW software can be downloaded for free from rok.auto/
ccw.
- DriveTools™ SP (v4.01 or higher is required with a PowerFlex DC drive specific software patch. The patch can be downloaded from
rok.auto/pcdc. A suite of software tools that provide an intuitive way to program, troubleshoot, and maintain Allen-Bradley drives,
including the PowerFlex DC Drive Startup Wizard.
• Internal communications allow you to integrate the drive and/or field controller into the manufacturing process. Status indicators for
all internal communication options are visible on the cover for easy setup and monitoring of drive communications. You can easily
manage information from ‘shop floor to top floor’ and seamlessly integrate a complete system as you control, configure, and collect
data.
The PowerFlex DC Field Controller
The PowerFlex DC Field Controller provides three-phase, four quadrant (reversing) DC motor or generator field control. The PowerFlex DC
Field Controller can be used for standalone DC motor field control applications, or with a PowerFlex DC Digital drive or PowerFlex DC
Standalone Regulator (SAR). A fiber-optic interface option module, or digital and analog I/O, provides transmission of the reference,
feedback, and status signals between the drive or regulator and the field controller.
In the standalone mode, the PowerFlex DC Field Controller provides power to a DC motor field with a fixed reference by using fixed I/O. The
PowerFlex DC Field Controller can also be used to supply various DC non-motor loads (highly inductive loads). These DC non-motor loads
include galvanic applications, electromagnets, synchronous motor excitation circuits, and others.
A PowerFlex DC field controller is a cost-effective way to modernize DC motor controls while using/re-purposing existing equipment.
Controller Features
•Programming flexibility allows parameters to be linked within the device.
•Field-flashable firmware through DPI interface.
•Reversing field supply standard on all frames.
•Control non-motor inductive loads, such as electromagnets

Rockwell Automation Publication 20P-TD001K-EN-P - January 2021 5
PowerFlex DC Drive and Field Controller Technical Data
The PowerFlex DC Standalone Regulator
The PowerFlex DC Standalone Regulator (SAR) and Gate Amplifier products provide an integrated solution to control external DC power
modules. The SAR is a DC drive regulator that provides armature regulation, armature SCR gate signals and a regulated field supply. The SAR
field supply consists of a single-phase, two quadrant (non-reversing) full wave rectified bridge, available as 40 amps or 70 amps. The SAR
supports an AC line input voltage range of 230…690V AC and a field input voltage range of 100…460V AC.
Unsurpassed Capability in Network Communication
PowerFlex DC products are fully compatible with the wide variety of Allen-Bradley DPI communication adapters, which offer the following
benefits:
BACnet ControlNet™ DeviceNet™ EtherNet/IP PROFIBUS RS-485 DF1 Modbus RTU
Description
 (Unconnected Messaging) permits other network devices (for example PanelView™) to communicate directly to a drive without
routing the communication through the network scanner.
  Adapter Routing - Plug personal computer into one drive and talk to all other Allen-Bradley drives on same network, without being
routed through network scanner.

Access to 100% of all parameters over the network.
  Autobaud capability makes initial connections less problematic.
Change of State significantly reduces network traffic by configuring control messages to be sent only upon customer defined states.
Flexible configuration for each node (Example: “reference must change by more than 5%”).
 Peer Control provides master-slave type control between drives. With this feature, one or more slave drives (consumers) can run based
on the status of a master drive (producer). This feature can significantly reduce network traffic.
ADR (Automatic Device Replacement) saves significant time and effort when replacing a drive. The scanner can be configured to
detect a new drive and download the required parameter settings.

Flexible Fault Configuration - Adapters can be programmed to take fault-based actions, such as Ramp to Stop, and send user-
configurable logic control and speed reference values. The drive can take different actions that are based on whether the network
experienced a serious problem (broken cable, for example) versus network idle condition (PLC set to “Program”).

6Rockwell Automation Publication 20P-TD001K-EN-P - January 2021
PowerFlex DC Drive and Field Controller Technical Data
PowerFlex DC Drive Catalog Number Explanation
20P41 A D4P1RA0NNN
abcdefghijkl
abcde
Drive Motor Operation Input Type Enclosure Input Voltage
Code Description Code Description Code Description Code Description Code Description
20P PowerFlex DC drive 2 Two quadrant operation(1)
(1) Not available for 230V AC input drives.
16pulse A IP20, NEMA/UL Type Open B230VAC
4 Four quadrant operation D460VAC
(2)
(2) Use this code for 400V AC input applications.
E600VAC
F690VAC
f1 f2 f3
230V, 60 Hz Input 460V, 60 Hz Input 575V, 60 Hz Input
Code Hp kW Armature (A) Frame Field Amps Code Hp kW Armature (A) Frame Field Amps Code Hp kW Armature (A) Frame Field Amps
7P0 1.5 1.2 7
A
10
4P1 2 1.5 4.1
A
10
067 50 37 67.5
B
20
9P0 2 1.5 9 6P0 3 2.2 6 101 75 56 101.3
012 3 2.2 12 010 5 3.7 10 135 100 75 135
020 5 3.7 20 014 7.5 505 14 270 200 149 270
029 7.5 5.5 29 019 10 7.5 19 405 300 224 405
038 10 7.5 38 027 15 11 27 540 400 298 540 C
055 15 11 55 035 20 15 35 675 500 373 675
073 20 15 73
14
045 25 18.5 45 810 600 447 810
D40
093 25 18.5 93 052 30 22 52 1K0 800 597 1080
110 30 22 110 073 40 30 73
14
1K2 900 671 1215
146 40 30 146
B
20
086 50 37 86 1K3 1000 746 1350
180 50 37 180 100 60 45 100 1K6 1250 932 1668
218 60 45 218 129 75 56 129
265 75 56 265 167 100 75 167
B
20
f4
360 100 75 360 207 125 93 207 690V, 60 Hz Input
434 125 93 434 250 150 112 250 Code Hp kW Armature (A) Frame Field Amps
521 150 112 521 C330 200 149 330 452 400 298 452 C20
700 200 149 700 412 250 187 412 565 500 373 565
875 250 186 875 D40 495 300 224 495 C678 600 447 678
D
40
1K0 300 224 1050 667 400 298 667 791 700 552 791
830 500 373 830
D
40 904 800 597 904
996 600 447 996 1K0 900 671 1017
1K1 700 552 1162
70
1K1 1000 746 1130
70
1K3 800 597 1328 1K2 1100 820 1243
1K4 900 671 1494 1K4 1250 932 1413
1K5 1400 1044 1582
ghijkl
Field Supply Packaging/Documentation HIM I/O Options(1)
(1) All I/O options are purchased separately and user installed. See I/O Option Kits on page 10.
Communication
Options Cabinet Options
Code Description Code Description Code Description Code Description Code Description Code Description
RSingle-phase
regulated AShipping carton and user manual 0BlankCover NNone(2)
(2) Eight 24V DC digital inputs, four digital outputs, three analog inputs, and two analog outputs are standard.
NNone(3)
(3) Standard; for user installed options, see Communication Option Kits on page 11.
NNone

Rockwell Automation Publication 20P-TD001K-EN-P - January 2021 7
PowerFlex DC Drive and Field Controller Technical Data
Product Selection
IP00/IP20, NEMA/UL Type Open
All drives are rated 150% overload for 60 seconds, 200% for 3 seconds.
200…240V AC, Three-Phase Drives
Drive Output Rating - 230V AC Input Regenerative Drives Cat. No. Frame Size
Normal Duty kW Normal Duty Hp Amps
1.2 1.5 7 20P41AB7P0RA0NNN
A
1.5 2 9 20P41AB9P0RA0NNN
2.2 3 12 20P41AB012RA0NNN
3.7 5 20 20P41AB020RA0NNN
5.5 7.5 29 20P41AB029RA0NNN
7.5 10 38 20P41AB038RA0NNN
11 15 55 20P41AB055RA0NNN
15 20 73 20P41AB073RA0NNN
18.5 25 93 20P41AB093RA0NNN
22 30 110 20P41AB110RA0NNN
30 40 146 20P41AB146RA0NNN
B
37 50 180 20P41AB180RA0NNN
45 60 218 20P41AB218RA0NNN
56 75 265 20P41AB265RA0NNN
75 100 360 20P41AB360RA0NNN
93 125 434 20P41AB434RA0NNN
112 150 521 20P41AB521RA0NNN C
149 200 700 20P41AB700RA0NNN
186 250 875 20P41AB875RA0NNN D
224 300 1050 20P41AB1K0RA0NNN
380…480V AC, Three-Phase Drives
Drive Output Rating - 460V AC Input Non-regenerative Drives Regenerative Drives Frame
Size
Normal Duty kW Normal Duty Hp Amps Cat. No. Cat. No.
1.5 2 4.1 20P21AD4P1RA0NNN 20P41AD4P1RA0NNN
A
2.2 3 6 20P21AD6P0RA0NNN 20P41AD6P0RA0NNN
3.7 5 10 20P21AD010RA0NNN 20P41AD010RA0NNN
5.5 7.5 14 20P21AD014RA0NNN 20P41AD014RA0NNN
7.5 10 19 20P21AD019RA0NNN 20P41AD019RA0NNN
11 15 27 20P21AD027RA0NNN 20P41AD027RA0NNN
15 20 35 20P21AD035RA0NNN 20P41AD035RA0NNN
18.5 25 45 20P21AD045RA0NNN 20P41AD045RA0NNN
22 30 52 20P21AD052RA0NNN 20P41AD052RA0NNN
30 40 73 20P21AD073RA0NNN 20P41AD073RA0NNN
37 50 86 20P21AD086RA0NNN 20P41AD086RA0NNN
45 60 100 20P21AD100RA0NNN 20P41AD100RA0NNN
56 75 129 20P21AD129RA0NNN 20P41AD129RA0NNN
75 100 167 20P21AD167RA0NNN 20P41AD167RA0NNN
B
93 125 207 20P21AD207RA0NNN 20P41AD207RA0NNN
112 150 250 20P21AD250RA0NNN 20P41AD250RA0NNN
149 200 330 20P21AD330RA0NNN 20P41AD330RA0NNN
187 250 412 20P21AD412RA0NNN 20P41AD412RA0NNN
224 300 495 20P21AD495RA0NNN 20P41AD495RA0NNN C
298 400 667 20P21AD667RA0NNN 20P41AD667RA0NNN

8Rockwell Automation Publication 20P-TD001K-EN-P - January 2021
PowerFlex DC Drive and Field Controller Technical Data
Stand-alone Regulator Catalog Numbers
Conformally coated circuit boards are provided with the following catalog numbers.
373 500 830 20P21AD830RA0NNN 20P41AD830RA0NNN
D
447 600 996 20P21AD996RA0NNN 20P41AD996RA0NNN
552 700 1162 20P21AD1K1RA0NNN 20P41AD1K1RA0NNN
597 800 1328 20P21AD1K3RA0NNN 20P41AD1K3RA0NNN
671 900 1494 20P21AD1K4RA0NNN 20P41AD1K4RA0NNN
500…600V AC, Three-Phase Drives
Drive Output Rating - 460V AC Input Non-regenerative Drives
Cat. No. Regenerative Drives Cat. No. Frame Size
Normal Duty kW Normal Duty Hp Amps
37 50 67.5 20P21AE067RA0NNN 20P41AE067RA0NNN
B
56 75 101.3 20P21AE101RA0NNN 20P41AE101RA0NNN
75 100 135 20P21AE135RA0NNN 20P41AE135RA0NNN
149 200 270 20P21AE270RA0NNN 20P41AE270RA0NNN
224 300 405 20P21AE405RA0NNN 20P41AE405RA0NNN
298 400 540 20P21AE540RA0NNN 20P41AE540RA0NNN C
373 500 675 20P21AE675RA0NNN 20P41AE675RA0NNN
447 600 810 20P21AE810RA0NNN 20P41AE810RA0NNN
D
597 800 1080 20P21AE1K0RA0NNN 20P41AE1K0RA0NNN
671 900 1215 20P21AE1K2RA0NNN 20P41AE1K2RA0NNN
746 1000 1350 20P21AE1K3RA0NNN 20P41AE1K3RA0NNN
932 1250 1688 20P21AE1K6RA0NNN 20P41AE1K6RA0NNN
690V AC, Three-Phase Drives
Drive Output Rating - 460V AC Input Non-regenerative Drives
Cat. No. Regenerative Drives Cat. No. Frame Size
Normal Duty kW Normal Duty Hp Amps
298 400 452 20P21AF452RA0NNN 20P41AF452RA0NNN C
373 500 565 20P21AF565RA0NNN 20P41AF565RA0NNN
447 600 678 20P21AF678RA0NNN 20P41AF678RA0NNN
D
552 700 791 20P21AF791RA0NNN 20P41AF791RA0NNN
597 800 904 20P21AF904RA0NNN 20P41AF904RA0NNN
671 900 1017 20P21AF1K0RA0NNN 20P41AF1K0RA0NNN
746 1000 1130 20P21AF1K1RA0NNN 20P41AF1K1RA0NNN
820 1100 1243 20P21AF1K2RA0NNN 20P41AF1K2RA0NNN
932 1250 1413 20P21AF1K4RA0NNN 20P41AF1K4RA0NNN
1044 1400 1582 20P21AF1K5RA0NNN 20P41AF1K5RA0NNN
230V/460V AVC Input Regulators 575V/690V AVC Input Regulators Field Amps
Cat. No. Cat. No.
23PMD4 23PMF4 40
23PMD7 23PMF7 70
23PAMP(1)
(1) Gate Amplifier - used with all voltage classes of the Stand-Alone Regulator. The Stand-Alone Regulator and Gate Amplifier are currently
sold through Rockwell Automation Drive Systems only. Consult the factory for availability.
23PAMP(1) (1)
380…480V AC, Three-Phase Drives (Continued)
Drive Output Rating - 460V AC Input Non-regenerative Drives Regenerative Drives Frame
Size
Normal Duty kW Normal Duty Hp Amps Cat. No. Cat. No.

Rockwell Automation Publication 20P-TD001K-EN-P - January 2021 9
PowerFlex DC Drive and Field Controller Technical Data
PowerFlex DC Field Controller Catalog Number Explanation
PowerFlex DC Field Controller Product Selection
All PowerFlex DC field controllers are conformal coated.
23PFC B 245
abc
abc
Drive Voltage Range/Phase DC Output (A)
Code Description Code Description Code Description
23PFC PowerFlex DC field controller B 60…200V AC (±10%) / 3 017 17
D 230…500V AC (±10%) / 3 060 60
120 120
245 245
365 365
570 570
IP20, NEMA/UL Type Open – 60…200V AC, Three-Phase, 50/60 Hz
Input, V AC DC Output, amps Cat. No. Frame Size
60…200
17 23PFCB017
A60 23PFCB060
120 23PFCB120
245 23PFCB245
B365 23PFCB365
570 23PFCB570
IP20, NEMA/UL Type Open – 230…500V AC, Three-Phase, 50/60 Hz
Input, V AC DC Output, amps Cat. No. Frame Size
230…500
17 23PFCD017
A60 23PFCD060
120 23PFCD120
245 23PFCD245
B365 23PFCD365
570 23PFCD570

10 Rockwell Automation Publication 20P-TD001K-EN-P - January 2021
PowerFlex DC Drive and Field Controller Technical Data
Factory-installed Options
Each PowerFlex DC drive includes one encoder and DC analog tachometer input. No other factory-installed options are currently available for
PowerFlex DC drives and field controllers.
User-installed Options
Unless otherwise specified, these user installed options are available for PowerFlex DC drives and field controllers.
Human Interface Modules
Description
Handheld/
Local Drive
Mount
Remote
(Panel Mount)
IP66, NEMA/UL
Type 4x/12(1)
(1) Only for indoor use.
Cat. No. Cat. No.
No HIM (blank plate) 20-HIM-A0 —
LCD display, full numeric keypad 20-HIM-A3 20-HIM-C3S(2)
(2) Includes a 1202-C30 interface cable (3 m) for connection to drive.
LCD display, programmer only 20-HIM-A5 20-HIM-C5S(2)
Enhanced LCD, full numeric keypad 20-HIM-A6 20-HIM-C6S(2)
Human Interface Module Accessories
Description Cat. No.
Bezel kit for LCD HIMs, NEMA/UL Type 1(1)
(1) Includes a 1202-C30 interface cable (3 m) for connection to drive.
20-HIM-B1
PowerFlex HIM interface cable, 1 m (39 in.)(2)
(2) Required only when HIM is used as a handheld or remote.
20-HIM-H10
Cable kit (male-female)(3)
• 0.33 m (1.1 ft)
• 1 m (3.3 ft)
• 3 m (9.8 ft)
•9m(29.5ft)
(3) Required in addition to 20-HIM-H10 for distances up to a total maximum of 10 m
(32.8 ft).
1202-H03
1202-H10
1202-H30
1202-H90
DPI/SCANport™ 1-to-2 port splitter cable 1203-S03
I/O Option Kits
Description Cat. No.
I/O expansion board(1)
(1) Has four 24V DC digital inputs, four digital outputs, and two analog outputs.
20P-S5V62
115V AC to 24V DC eight-channel I/O converter board(2)
(2) Converts eight digital inputs.
20P-S520L
Feedback Option Kit (only for PowerFlex DC drives)
Description Cat. No.
Resolver feedback option module(1)
(1) The PowerFlex DC drive is not CE Certified when the resolver feedback module is
installed in the drive.
20P-RES-A0
20-HIM-A0 20-HIM-A3 20-HIM-A5 20-HIM-A6
20-HIM-CS3 20-HIM-CS5 20-HIM-CS6