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Industrial Automation & Network Hardware
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Hardware Comparison: Allen Bradley VFD Selection Guide

May 06, 2025

As factories and warehouses increasingly rely on precise and efficient automation systems, motor speed control has become a critical component. Allen-Bradley, a Rockwell Automation brand, offers a comprehensive range of Variable Frequency Drives (VFDs) through its PowerFlex family to meet diverse industrial requirements. This guide compares the major VFD product lines, from low to medium voltage, helping users choose the best solution for their application.

 
Allen-Bradley Low Voltage VFDs

Compact Class VFDs

Compact drives are best suited for standalone and less complex systems requiring basic control functions.

PowerFlex 4M

  • Voltage/HP:

    • 110-115V: 0.25–1.5 HP

    • 200-240V: 0.25–10 HP

    • 400-480V: 0.5–15 HP

  • Output Frequency: Up to 400 Hz

  • Communication: RS485 (optional: EtherNet/IP, Profibus, etc.)

  • I/O: 5 digital inputs, 1 analog input, 1 relay output

PowerFlex 4

  • Voltage/HP:

    • 110-115V: 0.25–1.5 HP

    • 200-240V: 0.25–5 HP

    • 400-480V: 0.5–5 HP

  • Output Frequency: Up to 240 Hz

  • Slightly reduced capability vs. 4M in voltage range

PowerFlex 40

  • Voltage/HP:

    • 110-115V: 0.25–1.5 HP

    • 200-240V: 0.25–10 HP

    • 400-480V: 0.5–15 HP

    • 500-600V: 1.0–15 HP

  • Offers sensorless vector control

  • Enhanced I/O: 2 analog inputs, 7 digital outputs

PowerFlex 40P

  • Same power ratings as 40

  • Output Frequency: Up to 500 Hz

  • Integrated safety: SIL2, PLd, Cat3

  • 4-digit LED display (no local keypad)

PowerFlex 400

  • Optimized for HVAC

  • Voltage/HP:

    • 200-240V: 3–50 HP

    • 400-480V: 3–350 HP

  • Ideal for fans, pumps, and mechanical HVAC systems

PowerFlex 520 Series

PowerFlex 523

  • Voltage/HP:

    • 100-120V: 0.25–1.5 HP

    • 200-240V: 0.25–20 HP

    • 380-480V: 0.5–30 HP

    • 535-600V: 0.5–30 HP

  • Open-loop control, PID, flying start

  • Communication: RS485, EtherNet/IP, DeviceNet

  • I/O: 5 digital inputs, 1 analog input, 1 relay output

PowerFlex 525

  • Additional I/O: 7 digital, 2 analog in, 2 digital, 1 analog out

  • Integrated safety: Safe Torque-Off

  • Feedback options: Encoder, PWM, Pulse Train

  • Positioning and StepLogic capabilities

PowerFlex 527

  • Fully integrated with Studio 5000 only

  • Motor HP same as 525

  • Only EtherNet/IP communication

  • Designed for Logix-based systems

 
Architecture Class Low Voltage VFDs

Designed for high-performance systems with complex integration needs.

PowerFlex 70

  • Voltage/HP:

    • 200-240V: 0.5–25 HP

    • 400-480V: 0.5–50 HP

    • 500-600V: 0.5–50 HP

  • Control: Vector, sensorless vector, torque regulation

  • Communication: EtherNet/IP, ControlNet, Profibus, etc.

  • I/O: 2 analog in, 1 analog out, 6 digital in, 2 relay out

  • Safety: Safe Torque-Off (SIL2, PLd, Cat3)

PowerFlex 700

  • Voltage/HP:

    • 200-240V: 2.2–260 HP

    • 400-480V: 1.1–875 HP

    • 500-600V: 1.7–144 HP

    • 690V: 52–142 HP

  • Advanced vector control, encoder options

  • Same I/O as 70 plus one more analog out and relay out

PowerFlex 700H

  • Voltage/HP:

    • 400-480V: 200–900 HP

    • 500-600V: 0.5–50 HP

    • 690V: 160–800 HP

  • General-purpose speed variation

  • Sensorless vector only

  • Similar I/O to 70, with 2 analog outs and 2 relay outs

PowerFlex 700S

  • High-performance and heavy-duty applications

  • Adds permanent magnet control

  • Advanced feature set: position loop, SynchLink, DriveLogix

PowerFlex 753

  • Voltage/HP:

    • 200-240V: 2.2–477 HP

    • 400-480V: 1.0–350 HP

    • 500-600V: 1.7–289 HP

    • 690V: 12–263 HP

  • 7 analog in/out, 21 digital in, 7 relay out

  • Safe Torque-Off, Safe Speed Monitor

PowerFlex 755

  • Voltage/HP:

    • 200-240V: 0.5–200 HP

    • 400-480V: 1.0–2000 HP

    • 500-600V: 1.7–1530 HP

    • 690V: 12–1485 HP

  • Closed-loop control, Kinetix motion compatible

  • Multi-axis support, adjustable voltage, precise speed/torque control

 
Allen-Bradley Medium Voltage VFDs

PowerFlex 6000

  • Voltage/HP:

    • 2.4kV: 183–941 HP

    • 3.3kV: 235–2432 HP

    • 4.16kV: 294–3150 HP

    • 6.6kV: 294–4939 HP

    • 10kV: 268–7506 HP

  • Control: Volts per Hertz only

  • No regenerative braking

  • Communication: EtherNet/IP, Modbus, Profibus

  • Safety: Keyed interlock only

PowerFlex 7000

  • Voltage/HP:

    • 3.3kV: 250–4750 HP

    • 4.16kV: 350–5750 HP

    • 6.6kV: 500–8000 HP

  • Control: Vector, encoder feedback, PM motor support

  • Features: Regenerative braking, flying start, flux braking

  • I/O: 13 analog in, 1 analog out, 8 digital out

  • Communication: EtherNet/IP, ControlNet, Modbus, USB, Profibus, etc.

  • Safety: Safe Torque-Off, ArcShield arc-flash protection (select models)

 
Conclusion

Allen-Bradley offers an extensive line of VFDs for applications ranging from simple, standalone motors to complex, multi-axis control networks. Choosing the right VFD depends on your system voltage, control complexity, horsepower requirements, and communication protocols. Whether you need compact control with a PowerFlex 4M or a fully integrated solution like the PowerFlex 755 or 7000, Allen-Bradley has a VFD that can meet your needs efficiently and reliably.

For help choosing the right Allen-Bradley VFD or support with control integration, contact PLG Automation at sales@plgautomation.com or 800-906-9271.