Overview
Allen-Bradley 22D-D4P0N104 is a PowerFlex 40P series adjustable frequency AC drive engineered by Rockwell Automation for precise control of three-phase induction motors in industrial automation, packaging machinery, material handling, and process control applications. Rated at 1.5 kW (2 HP) with 480V 3-phase input and 4.0A continuous output, this compact Frame B drive delivers reliable motor speed and torque control in a space-efficient panel-mount enclosure. Though currently end-of-life (discontinued June 2025), the 22D-D4P0N104 remains a critical spare part for facility maintenance and system continuity.
Key Features
- Sensorless vector control for superior low-speed torque and dynamic response
- V/Hz control mode for standard induction motor applications
- Integrated process PID loop capability for closed-loop speed regulation
- Dynamic braking via DC injection with integrated brake IGBT for smooth deceleration
- RS-485 communication port for networked control over long distances in noisy environments
- Category 3 safe torque-off (SIL 2) for integrated functional safety
- 2 partially programmable and 5 fully programmable digital inputs; 1 analog input/output; 1 programmable relay; 2 opto-isolated outputs
- Keypad with integral LED display and 4-digit readout plus status indicators
- Optional IP30 conversion kit available for enhanced environmental protection
- Class 10 electronic motor overload protection with i²t algorithm
Technical Specifications
- Rated Power Output: 1.5 kW (2 HP)
- Input Voltage: 480V AC, 3-phase
- Input Current: 5.2 KVA, 5.3A (typical)
- Output Current: 4.0A continuous
- Frequency Range: 48–63 Hz ±10%
- Power Factor: 0.98 (displacement)
- Enclosure: Frame Size B, Panel Mount, IP20 (NEMA Type Open)
- Control Modes: V/Hz, Sensorless Vector, PID Process Loop
- Communication: RS-485 serial port (no EtherNet/IP or PROFINET)
- Operating Temperature: 14–122°F (–10–50°C)
- Overload Protection: 150% for 60 seconds; 200% for 3 seconds
- DC Bus Limits: Overvoltage 1005V DC; Undervoltage 487V DC
- Current Fault Limit: 300% instantaneous
- Filter: None included; CE-compliant filter sold separately
- UPC: 820919654152
Typical Applications
The PowerFlex 40P 22D-D4P0N104 is suited for:
- Conveyor and diverter control in material handling systems
- Packaging machinery speed regulation
- Fiber spinning and textile machinery
- Small-motor closed-loop control with safe torque-off safety functions
- OEM retrofit and spare-parts replacement on legacy PowerFlex 40P installations
Compatibility & Replacements
Compatible With
- Rockwell Automation CompactLogix and ControlLogix systems (via serial interface)
- Third-party industrial controllers with RS-485 serial communication
- Allen-Bradley HIM (Human Interface Module) — panel-mounted, remote handheld, or wireless options
- PowerFlex standard safety integrations (SIL 2, Category 3)
Replaces / Drop-In Replacement For
- Older 22B-D4P0N104 PowerFlex 40 drives (earlier generation; verify firmware compatibility)
- Legacy Allen-Bradley small-motor AC drives rated 2 HP 480V with comparable I/O pinouts
- Note: This unit is End-of-Life; Rockwell’s current replacement is the 25B-D4P0N104 PowerFlex 755T series for new installations
Works With
- RS-485 serial communication protocol (Modbus RTU compatible on some configurations)
- Rockwell Automation DriveLogix and Studio 5000 software via serial gateway modules
- Allen-Bradley PowerMonitor and energy management systems
- Standard three-phase induction motors, 2 HP maximum
- Note: Does NOT support EtherNet/IP, PROFINET, Modbus TCP, or CANopen native interfaces
