Allen-Bradley PowerFlex 4 AC Drives

Technical Dossier

Product Details And Specifications

Allen-Bradley PowerFlex 4 Series: Comprehensive Module Range and Technical Overview

The Allen-Bradley PowerFlex 4 is a compact, general-purpose AC variable frequency drive (VFD) manufactured by Rockwell Automation. It is deployed across heavy industrial sectors including petrochemical plants, water treatment facilities, pulp and paper mills, mining operations, and food processing lines. With a global installed base spanning North America, Europe, and Asia-Pacific, the PowerFlex 4 series occupies a critical position in the mid-range drive market for applications requiring precise motor speed control in the 0.2 kW to 11 kW range. Its DIN rail-mountable form factor, integrated EMC filter options, and compatibility with DeviceNet and RS-485 (DSI) communication protocols made it a standard specification in distributed control system (DCS) architectures throughout the 2000s and 2010s.

The Evolution of PowerFlex 4 Architecture

The PowerFlex 4 (catalog prefix: 22A) was introduced by Rockwell Automation as a successor to the 1305 and 1336 PLUS drive families. It represented a shift toward a more compact, panel-mount form factor with integrated operator interface (OIM) and simplified parameter programming via a 4-digit LED display. The drive operates on a V/Hz control algorithm with optional sensorless vector control, supporting single-phase 120V, single-phase/three-phase 240V, and three-phase 480V input configurations.

The PowerFlex 4 was followed by the PowerFlex 40 (catalog prefix: 22B), which added enhanced PID control, expanded I/O, and full DeviceNet/EtherNet/IP adapter support. For applications requiring higher performance, Rockwell positioned the PowerFlex 400 (22C) for HVAC/pump duty and the PowerFlex 4M (22F) as a cost-reduced micro-drive variant. As of 2024, the PowerFlex 4 series has entered the End of Life (EOL) phase, with Rockwell Automation recommending migration to the PowerFlex 520 series (25A/25B/25C). Compatibility between generations requires adapter modules and parameter remapping, making long-term spare parts inventory a critical operational requirement for facilities that cannot execute a full drive replacement program.

PowerFlex 4 Full Catalog & Functionalities (SKU List)

The following SKUs represent the verified PowerFlex 4 (22A) product range, organized by voltage class and current rating. Each unit is a standalone AC drive with integrated keypad, RS-485 DSI port, and configurable analog/digital I/O.

120V Single-Phase Input (0.2–0.4 kW)

• 22A-A2P5N103: 120V 1-phase input, 2.5A output, 0.2 kW — entry-level conveyor and pump duty
• 22A-A5P0N103: 120V 1-phase input, 5.0A output, 0.4 kW — light-duty fan and agitator control

240V Single/Three-Phase Input (0.4–7.5 kW)

• 22A-B2P5N104: 240V, 2.5A, 0.4 kW — compact single-phase input, general purpose
• 22A-B5P0N104: 240V, 5.0A, 0.75 kW — pump and fan speed regulation
• 22A-B8P0N104: 240V, 8.0A, 1.5 kW — standard conveyor and mixer drive (this listing)
• 22A-B012N104: 240V, 12A, 2.2 kW — medium-duty material handling
• 22A-B017N104: 240V, 17A, 3.7 kW — three-phase 240V, compressor and pump duty
• 22A-B024N104: 240V, 24A, 5.5 kW — heavy conveyor and centrifugal pump
• 22A-B033N104: 240V, 33A, 7.5 kW — high-current 240V, industrial fan and blower

480V Three-Phase Input (0.4–11 kW)

• 22A-D2P3N104: 480V, 2.3A, 0.75 kW — three-phase 480V entry, HVAC auxiliary
• 22A-D4P0N104: 480V, 4.0A, 1.5 kW — standard 480V industrial drive
• 22A-D6P0N104: 480V, 6.0A, 2.2 kW — pump and compressor speed control
• 22A-D010N104: 480V, 10A, 4.0 kW — conveyor line and mixer duty
• 22A-D013N104: 480V, 13A, 5.5 kW — heavy industrial fan and blower
• 22A-D017N104: 480V, 17A, 7.5 kW — high-power 480V pump and conveyor
• 22A-D024N104: 480V, 24A, 11 kW — maximum rating in the 22A series, heavy-duty process lines

Communication & Peripheral Accessories

• 22-HIM-A3: Remote handheld OIM (operator interface module) for PowerFlex 4/40 — panel-mount remote programming
• 22-HIM-C2S: LCD remote OIM with copy/paste parameter function — commissioning and diagnostics tool
• 22-COMM-D: DeviceNet communication adapter — integrates PowerFlex 4 into DeviceNet network topology
• 22-COMM-E: EtherNet/IP communication adapter — enables Logix-based network control

Sourcing Hard-to-Find & Obsolete PowerFlex 4 Parts

With the PowerFlex 4 series at End of Life status, Rockwell Automation has ceased active production of the majority of 22A catalog numbers. Lead times through authorized distribution channels are extended, and new unit availability is increasingly constrained. DriveKNMS maintains a dedicated inventory of new-surplus, reconditioned, and tested PowerFlex 4 drives to support facilities operating legacy systems where a full migration to PowerFlex 520 is not operationally or financially viable in the short term.

DriveKNMS sources PowerFlex 4 units globally, including from decommissioned plant equipment, authorized surplus channels, and OEM overstock. All units are cataloged by exact part number, firmware revision where applicable, and physical condition grade. For facilities requiring long-term maintenance agreements or bulk spare parts packages for PowerFlex 4 fleets, DriveKNMS provides quotation-based procurement support with documented traceability.

Quality Control for the PowerFlex 4 Range

Each PowerFlex 4 unit processed by DriveKNMS undergoes a structured inspection and functional test protocol prior to dispatch. The procedure covers: visual inspection of the power board, gate driver board, and control board for capacitor degradation, burn marks, and corrosion; insulation resistance testing of the DC bus; functional power-up test under no-load conditions with parameter verification against factory defaults; output voltage balance measurement across all three phases at 25%, 50%, and 100% of rated frequency; and DSI communication port verification using a 22-HIM-A3 or equivalent interface. Units that fail any stage of the test protocol are quarantined and not listed for sale. Reconditioned units are clearly identified with condition grade documentation supplied with each shipment.

© 2026 DriveKNMS. All trademarks belong to their respective owners. Specifications are for reference only and subject to change without notice. Verify all parameters against official documentation before installation.