Allen-Bradley PowerFlex 40 Modules: 22B-D010C104

Technical Dossier

Product Details And Specifications

Allen-Bradley PowerFlex 40 Series Technical Notes

The Allen-Bradley PowerFlex 40 series (Bulletin 22B) is a compact, general-purpose AC variable frequency drive manufactured by Rockwell Automation. It is deployed across a broad spectrum of heavy industrial applications including petrochemical processing plants, offshore oil platforms, pulp and paper mills, water treatment facilities, and continuous mining operations. With a power range spanning 0.4 kW (0.5 HP) to 22 kW (30 HP) at 200–240V and 380–480V three-phase input, the PowerFlex 40 occupies the mid-tier segment of Rockwell's drive portfolio, positioned between the entry-level PowerFlex 4 and the full-featured PowerFlex 400. Its embedded EtherNet/IP and DeviceNet communication options, combined with a DPI (Drive Peripheral Interface) port, made it a standard selection for distributed motor control architectures throughout the 2000s and 2010s. Installed base counts in the hundreds of thousands of units globally, ensuring sustained demand for spare parts and replacement modules well into the 2030s.

The Evolution of PowerFlex 40 Architecture

The PowerFlex 40 was introduced by Rockwell Automation in the early 2000s as a successor to the 1305 and 1336 PLUS II drive families. Its architecture is built around a single-board control design with an integrated keypad (HIM — Human Interface Module) and a DPI serial communication port operating at 500 kbps. Early firmware revisions (v1.xx) supported only SCANport peripherals via an adapter; later revisions (v3.xx and above) introduced full DSI/DPI compatibility and expanded parameter sets.

The 22B bulletin designation encodes the drive's voltage class and frame size. Frame sizes A through D cover the full power range, with Frame A units (0.4–2.2 kW) being the most commonly replaced due to their prevalence in conveyor and pump applications. The drive's control architecture uses a 32-bit DSP for PWM generation, with carrier frequencies selectable from 2 to 16 kHz.

Compatibility considerations are critical for maintenance engineers: PowerFlex 40 drives are not pin-compatible with PowerFlex 4 (22A) units despite sharing a similar form factor. The DPI port on the 22B series accepts 22-COMM-x communication adapters (EtherNet/IP, DeviceNet, PROFIBUS, ControlNet), which are not interchangeable with the older 1203-GU6 SCANport gateway used on legacy 1336 drives. As of 2023, Rockwell Automation has designated the PowerFlex 40 as a mature product, with the PowerFlex 40P (22D) and PowerFlex 400 (22C) recommended as migration paths for new installations.

PowerFlex 40 Full Catalog & Functionalities (SKU List)

The following SKUs represent the verified, commonly stocked models within the Allen-Bradley PowerFlex 40 (22B) series. Models are organized by voltage class and power rating.

200–240V Single-Phase Input (22B-S_xx)

22B-S012N104: 1.5 kW (2 HP), 240V 1Ø input, IP20, no filter, Frame A
22B-S018N104: 2.2 kW (3 HP), 240V 1Ø input, IP20, no filter, Frame A
22B-S037N104: 5.5 kW (7.5 HP), 240V 1Ø input, IP20, no filter, Frame B

200–240V Three-Phase Input (22B-A_xx)

22B-A004N104: 0.4 kW (0.5 HP), 240V 3Ø, IP20, Frame A, no EMC filter
22B-A008N104: 1.1 kW (1.5 HP), 240V 3Ø, IP20, Frame A, no EMC filter
22B-A012N104: 1.5 kW (2 HP), 240V 3Ø, IP20, Frame A, no EMC filter
22B-A018N104: 2.2 kW (3 HP), 240V 3Ø, IP20, Frame A, no EMC filter
22B-A027N104: 4.0 kW (5 HP), 240V 3Ø, IP20, Frame B, no EMC filter

380–480V Three-Phase Input (22B-D_xx) — Core Industrial Range

22B-D004N104: 0.75 kW (1 HP), 480V 3Ø, IP20, Frame A, standard I/O
22B-D006N104: 1.1 kW (1.5 HP), 480V 3Ø, IP20, Frame A, standard I/O
22B-D010C104: 4.0 kW (5 HP), 480V 3Ø, IP20, Frame B, with EMC filter (Class C2)
22B-D012N104: 5.5 kW (7.5 HP), 480V 3Ø, IP20, Frame B, no EMC filter
22B-D017N104: 7.5 kW (10 HP), 480V 3Ø, IP20, Frame C, no EMC filter
22B-D024N104: 11 kW (15 HP), 480V 3Ø, IP20, Frame C, no EMC filter
22B-D030N104: 15 kW (20 HP), 480V 3Ø, IP20, Frame D, no EMC filter
22B-D045N104: 22 kW (30 HP), 480V 3Ø, IP20, Frame D, no EMC filter

Communication Adapters (22-COMM-x Series)

22-COMM-E: EtherNet/IP DPI adapter for PowerFlex 40/400/70
22-COMM-D: DeviceNet DPI adapter, supports explicit and I/O messaging
22-COMM-P: PROFIBUS DP DPI adapter, up to 12 Mbps
22-COMM-C: ControlNet DPI adapter, scheduled and unscheduled connections

Human Interface Modules (HIM)

22-HIM-A3: Full numeric keypad HIM with LCD display, panel-mount
22-HIM-C2S: Remote HIM with 1m cable, IP66 rated

Quality Control for the PowerFlex 40 Range

Each PowerFlex 40 unit processed by DriveKNMS undergoes a structured test protocol designed around the drive's specific power stage and control board architecture:

Power Stage Verification: DC bus capacitance measurement (target: >85% of rated capacitance), IGBT gate drive integrity check, and inrush current limiter (NTC thermistor) continuity test. Frame B and C units are load-tested at 50% and 100% rated output current using a calibrated motor load bank.

Control Board Diagnostics: DPI port communication test using a 22-HIM-A3 reference module. Parameter upload/download cycle via RSLogix 5000 or Connected Components Workbench to verify EEPROM integrity. Fault history cleared and firmware version documented.

EMC Filter Integrity (C-suffix models): For filtered variants such as the 22B-D010C104, the integrated Class C2 EMC filter is tested for capacitor leakage current and inductor continuity. Units failing filter tests are repaired or clearly marked as non-filtered equivalents.

Final Functional Test: Each unit is run through a full speed ramp (0–60 Hz) under load, with output voltage balance across all three phases verified to within ±2%. Thermal imaging is performed on the heatsink and power module after a 30-minute run cycle.