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Replacing a Discontinued Part
Drives · Allen-Bradley Alternatives
Replacing a Discontinued
Allen-Bradley PowerFlex Drive
When a PowerFlex drive fails and the model is no longer available, the machine still has to run. Here's how to identify exactly what you have, size and cross-reference a substitute, and plan the parameters and wiring so the swap goes smoothly.
01 / Overview Why This Comes Up
A good drive, a dead end
PowerFlex drives have been installed in plants for years, and many are still running. But every drive family eventually reaches the end of its life cycle, and when one fails on an older machine, the choice of what replaces it is not always obvious. A like-for-like part may be hard to find, and a newer model may not be a simple drop-in.
This guide walks through a practical process for PowerFlex replacement, including when an AB drive alternative from another manufacturer makes sense, and what has to be matched to make the swap work.
02 / Identification Identify the Failed Drive
Start with the nameplate, not the model family
"PowerFlex" covers a wide range of drives with different power ratings, features, and communication options. Before any sourcing starts, record exactly what is installed. Take photos of the nameplate and the wiring as well.
01
Catalog Number
The full number on the nameplate, not just the series name. It encodes voltage, rating, and enclosure.
02
Voltage & Power
Input voltage and phase, plus the drive's HP or kW and output current rating.
03
Motor Data
Motor nameplate HP, voltage, full-load amps, and speed, since the replacement is sized to the motor.
04
Control Method
Whether it runs open-loop, with encoder feedback, or in another mode, and how it is commanded.
05
Options Installed
Communication adapters, I/O boards, braking resistors, or filters fitted to the drive.
06
Failure Mode
What the fault display showed and how it failed, which helps judge whether the drive itself is the cause.
It's also worth confirming the drive itself is the problem. A tripped fault can come from the motor, cabling, or power quality, and replacing a drive without checking those can repeat the failure.
03 / Options Replacement Paths
Four ways to get the machine back up
| Path | When It Fits | Tradeoff |
|---|---|---|
| Same drive | A tested unit of the exact drive is available | Quickest swap with the least rework, but the model is still near or past end of life |
| Manufacturer successor | A current model is designated to replace the old one | Closest in function, though mounting, terminals, and parameters can still differ |
| Another brand's drive | No suitable successor, or lead time or support is the concern. Siemens, ABB, and Yaskawa are common choices | Wider availability, but wiring, parameters, and network integration all need to be redone |
| Broader upgrade | Several drives on the machine are aging at once | Higher upfront cost, but resets the support horizon |
04 / Selection Sizing & Cross-Reference
Match what the drive actually has to do
A substitute should be sized to the motor and the application, not just to the old drive's horsepower label. These are the main points to match.
| Item | What to Match |
|---|---|
| Voltage & phase | The supply the drive will be connected to |
| Current rating | Output current at or above the motor's full-load amps, with margin for duty cycle and overload demands |
| Control mode | The same control method the application depends on, such as open-loop, vector, or encoder feedback |
| I/O | Enough digital and analog inputs and outputs of the right type to cover what is wired today |
| Communication | Support for the network the PLC uses, with the adapter or built-in port to match |
| Physical fit | Frame size, mounting, and cooling clearance in the existing panel |
IAC's cross-reference tool can compare the drive you have against stocked alternatives, but the final sizing and compatibility should be confirmed by an engineer against current manufacturer documentation before anything is ordered or installed.
05 / Integration Parameters & Wiring
The part that takes the time
Getting the right drive is half the job. The other half is making it behave like the one it replaces.
Parameters do not transfer across brands
Each manufacturer organizes drive settings differently, so a parameter file from the old drive cannot be loaded into a drive from another brand. The practical approach is to record the old drive's settings first, such as motor data, accel and decel times, speed limits, and control source, and then enter the equivalent values in the new one and tune.
Control wiring needs to be re-mapped
Terminal layouts differ between drives, and so do input and output functions. Walk through every wire on the old drive, note what it does, and map it to the new drive's terminals before powering up.
Network integration may change the PLC side
If the drive communicates with a PLC over a network, a different brand typically means a different communication profile, and the PLC program that reads and commands the drive may need to be updated.
Drive swap checklist
- Nameplate photos and full catalog numbers saved for the drive and motor
- Parameter list exported or written down before the old drive is removed
- Every control wire labeled and mapped to the new drive's terminals
- Network adapter and PLC program changes identified in advance
- Motor and cabling checked so the cause of the failure is not repeated
- Commissioning and tuning time scheduled with the machine's operators
06 / Sourcing Getting a Replacement, Fast
IAC can help find the match or the alternative
IAC stocks drives from Siemens, ABB, and Yaskawa, and its cross-reference tool can help compare a PowerFlex against stocked alternatives. If you're not sure which route fits, send the nameplate details and we'll help narrow it down.
Browse Siemens, ABB & Yaskawa drives
Shop the CatalogNote: Industrial Automation Co. is not an authorized Rockwell Automation distributor. Allen-Bradley and PowerFlex are trademarks of Rockwell Automation, Inc. and are referenced here only to identify the equipment being replaced.
Warranty and verification
Every component IAC ships carries a 2-year in-service warranty — twice the industry standard for refurbished industrial parts. Components are functionally tested before they leave the warehouse.
Same-day shipping
In-stock parts ordered before 4:00 PM Eastern ship same day. For urgent needs, call (877) 727-8757 during business hours — quote turnaround is typically under five minutes. You can also submit a part number via the quote form ↗ or email sales@iac.us.com.
Discontinued drive. Machine still running.
Send IAC the nameplate and we'll check stock and cross-reference alternatives. Quotes in 5 minutes during business hours. Same-day shipping on in-stock units.