Allen-Bradley Products Explained: Drives, PLCs, Safety, and More

Allen-Bradley is a renowned brand of industrial automation technologies owned by Rockwell Automation, a company that offers a wide variety of digital transformation and factory automation solutions. The Allen-Bradley product line features a broad portfolio of industrial automation and control products like Human-Machine Interfaces (HMIs), Programmable Logic Controllers (PLCs), sensors, DC drives, Variable Frequency Drives (VFDs), and safety devices. All these products are designed for optimal performance, robust, and reliable operation in harsh industrial settings. They enable real-time system monitoring, precise control over machinery, and improved safety within manufacturing and other industrial environments.

PowerFlex DC Drive Products

The PowerFlex DC drive family is a complete collection of high-performance DC motor control technologies. It includes Allen-Bradley PowerFlex DC field controllers, PowerFlex DC drives, and PowerFlex DC stand-alone regulators (SARs).

PowerFlex DC Drives

PowerFlex DC drives provide cost-effective, high-performance control for DC motor applications and are designed for straightforward configuration across a wide range of systems. They support flexible I/O, built-in noise suppression for sensitive environments, flash-upgradeable firmware, global voltage ratings, and multiple feedback and communication options for easy system integration. These drives also offer Premier Integration with PowerFlex AC drives on the Allen-Bradley Logix platform.

PowerFlex DC drives are available from 1.5 to 1400 Hp (1.2 to 1044 kW) at 200 to 690V AC input in both regenerative and non-regenerative configurations, with engineered solutions available up to 6000 Hp (4000 kW). Standard hardware includes an armature converter, an advanced regulator with integrated DPI, encoder support, a regulated field DC converter for economy or field-weakening control, a DC tachometer input, and open-type enclosures.

We also have an article here explaining the differences between PowerFlex DC and AC drives in depth here!

PowerFlex DC Field Controllers

PowerFlex DC field controllers provide four-quadrant, three-phase reversing field control for DC motors and generators. They can operate alongside PowerFlex DC drives, standalone regulators, or independently for field-only control. Key features include integrated DPI communication, flash-upgradeable firmware, flexible I/O options, fiber-optic communication for feedback and reference signals, and an open-type enclosure.

These controllers are commonly used in retrofit and modernization projects, allowing existing DC motors to be reused with external power bridges while adding modern control and reversing capability. In standalone applications, they can also supply field power for electromagnets and non-motor loads. PowerFlex DC field controllers are available from 17 to 570 A output with 60 to 200V AC and 230 to 500V AC input.

PowerFlex AC Drives

Allen-Bradley PowerFlex Variable Frequency Drives (VFDs) come in a broad range of power ratings and input voltages, from low-voltage to medium-voltage AC drives. They are designed to provide advanced self-monitoring capabilities, high-performance motor control, and real-time operational data, increasing machine uptime, throughput, and energy savings. They include:

PowerFlex 525

These are low-voltage VFDs that provide power ratings of 0.5 to 30 HP (0.4 to 22 kW) with global voltages ranging from 100 to 600V. Key features include integrated EtherNet/IP communications, a PROFINET communication option card, standard safety features, USB programming, and a modular design that simplifies drive installation and configuration. They are suitable for use in pumps, conveyors, mixers, and fans.

PowerFlex 40P

They deliver closed-loop motor control in a cost-effective, space-saving design. They are ideal for basic position or speed control applications, such as fiber-spinning machines, packaging machines, diverters, and smart conveyors. They are available in power ratings of 0.4 to 11 kW (0.5 to 15 HP) and voltage classes of 200 to 600V, and with the option of a DriveGuard STO add-on option for further safety.

Safety Products

Allen-Bradley offers a complete line of innovative safety products designed to enhance the operational performance of industrial machinery while increasing efficiency, productivity, and personnel safety in discrete and process manufacturing applications.

440R Guardmaster Safety Relays

Allen-Bradley single-function Guardmaster safety relays provide a broad range of safety functions based on simple logic, reset, and timing configurations. They also provide an optional Ethernet/IP Network interface for configuration and communication. Built-in Guardmaster Dual GuardLink safety relays provide system status visibility on the device itself and enable easier diagnosis of issues.

440F MatGuard Safety Mats

These are pressure-sensitive, robust, and durable safety mats from Allen-Bradley. They support automated warnings, durable edge-trim options, and even trip detection. An IP67 rating means they can withstand dust and water, making them suitable for work environments.

440L Area Access Control Single Beam Sensors

These sensors can detect whole-body access to keep people out of hazardous areas and operate in two modes: long and short. Short mode can work within 0.5 to 20 meters (1.64 – 65.5 feet), and long mode can work within 15 to 70 meters (49.2 – 300 feet). They’re equipped with heated front-lenses suitable for outdoor use.

442L SafeZone Safety Laser Scanners

These Allen-Bradley scanners detect objects or personnel at 190 degrees or 270 degrees. With options for multiple samples (2-16), a built-in 7-segment diagnostic display, and availability with CIP Safety over EtherNet/IP, these scanners offer a wide range of configurations and functionalities.

Programmable Logic Controllers

Allen-Bradley offers a broad lineup of PLCs designed to meet different levels of automation complexity. PLCs are rugged industrial computers built to control machinery, robotic systems, and manufacturing processes in real time. They use programmable memory to execute control logic, monitor input signals, and drive outputs to motors, valves, and actuators. Designed for continuous operation in demanding environments, PLCs are widely used to improve production efficiency, increase system reliability, and reduce operator error across industries such as manufacturing, food processing, utilities, and energy.

Popular Allen-Bradley PLCs include:

ControlLogix 5570 Controllers

These are high-performance Allen-Bradley PLC controllers that support Analog motion, Integrated Sercos motion, and Integrated Motion on EtherNet/IP. They communicate through SynchLink, EtherNet/IP, Data Highway Plus, ControlNet, Remote I/O, DeviceNet, and third-party device and process networks. They are available in On-Machine, standard, extreme-temperature, and safety models, suitable for high-availability, discrete, process, and motion control applications.

ControlLogix 5590 Controllers

They are the latest innovation in the Allen-Bradley Logix control family. They offer integrated functional safety, faster scan times, expanded memory, and advanced communication options (e.g., dual EtherNet/IP ports and modern communication protocols such as OPC UA).  Available Allen‑Bradley ControlLogix 5590 PLC controllers are primarily engineered to optimize and simplify the complexities of modern industrial applications, as industrial automation operations become more performance-intensive, connected, and data-driven. Typical applications include discrete and motion control, process and batch control, and safety-critical and hybrid systems.

CompactLogix 5380 Process Controllers

These are Programmable Automation Controllers that focus on plant-wide process control. They include CompactLogix 5069-L320ERP and CompactLogix 5069-L340ERP controller models.  They allow faster system performance and motion control, and are conformally coated for additional protection in harsh, corrosive industrial environments.

Micro810 PLC Controllers

They feature a nano-sized footprint, a USB port for downloading programs, a 1.5-inch LCD for monitoring and modifying application data, and 12 I/O points with four high-current (8 A) relay outputs, ideal for smart relay applications. Typical applications include elevator control, heating and cooling, lighting control, and compressor control.

Power Supplies

Allen-Bradley provides reliable, industry-standard uninterruptible power supplies, transformers, and more, with a range of capabilities to fit your exact use cases.

1606-XLS Performance

This is Allen-Bradeley’s top-of-the-line switched-mode power supply lineup, with a small form factor and top-tier performance. These come in various voltages (5-, 12-, 15-, 24-, and 48-volts DC) and wattage (80 to 960W) configurations and significantly reduce the footprint while still providing up to 150% more power than previous models.

ArmorPower On-Machine Power Supplies

Allen-Bradley Bulletin 1607 power supplies provide a reliable output even under unstable voltage conditions, mitigating voltage drops due to line loss, while remaining compact and highly efficient. Their IP67 rating ensures that they can operate in extreme industrial environments and even have smooth surfaces suitable for washdown applications.

1497 Global Control Transformers

These are a versatile range of transformers from Allen-Bradley, available in dual, single, and multi-tap primary winding voltages. They allow users to safely step down power levels to meet a wide range of application needs. They offer single-phase voltage ratings of 63 to 2000 VA at input AC frequencies of 60, 50, and 60/50 Hz.

Human Machine Interfaces

Allen-Bradley’s PanelView lineup is designed to give operators a visual reference for the operation, as well as the ability to control and stop it as needed. The most common of the lineup are:

PanelView 5000 Graphic Terminals

These terminals allow screen refresh rates up to 100ms for smoother animations. They support connections to up to 4 Logix controllers, up to 500 screens, and up to 4,000 tag-based alarms per Logix controller. The stainless-steel Allen-Bradley PanelView 5000 models are available with an IP69K environmental rating, suitable for use in hygienic environments such as food and beverage or marine applications.

PanelView Plus 7 Graphic Terminals

The Bulletin 2711P product line offers a variety of graphic terminals. They are available in screen sizes ranging from 4 to 19 inches, with up to 4GB of RAM, and 20GB of non-volatile storage. They also include VNC support for remote monitoring, and the stainless steel models are rated up to IP69K.

MobileView Tethered

The Allen-Bradley Bulletin 2711T mobile devices enable increased productivity in a safe, flexible manner. They include an LED indicator for when the E-stop is active and support location awareness to track the device’s location.

Final Thoughts

As you can see, Allen-Bradley’s offerings are pretty extensive and reach every corner of automation, and what we discussed today is only scratching the surface. Each product line is tailored to different automation needs, and users are highly likely to find something they need from Allen-Bradley’s catalog. In the case that you do find what you’re looking for, stop by because we have you covered with not only exceptional customer service, but free same-day shipping and a two-year warranty to top it off. If you haven’t quite found what you needed, not a problem! Give us a call today, and we can help you track just what would fit for your situation. As always, thank you for reading!