Allen-Bradley PowerFlex 40 AC Drives – 22D-D010N104

Technical Dossier

Product Details And Specifications

Allen-Bradley PowerFlex 40 Series Technical Notes

The Allen-Bradley PowerFlex 40 is a compact, general-purpose AC variable frequency drive (VFD) manufactured by Rockwell Automation. It is deployed across a broad spectrum of heavy industrial applications including chemical processing plants, petroleum refineries, nuclear facility auxiliary systems, water treatment infrastructure, and discrete manufacturing lines. The PowerFlex 40 series occupies the mid-tier segment of Rockwell Automation's drive portfolio, positioned between the entry-level PowerFlex 4 and the advanced PowerFlex 70/700 platforms. Its combination of embedded EtherNet/IP and DeviceNet communication options, onboard PID control, and DPI (Drive Peripheral Interface) architecture has made it a standard specification in global OEM machine designs and plant-wide automation upgrades. Installed base estimates place the PowerFlex 40 among the most widely deployed drives in the 0.4–22 kW range across North America, Europe, and Asia-Pacific industrial facilities. Long-term plant maintenance programs at facilities running legacy Rockwell ControlLogix and SLC 500 architectures routinely include PowerFlex 40 units as direct replacement inventory.

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 introduced the Drive Peripheral Interface (DPI), a proprietary high-speed serial communication bus that standardized peripheral connectivity across the PowerFlex product line. This allowed a common set of Human Interface Modules (HIMs), communication adapters, and remote I/O devices to be shared across PowerFlex 4, 40, 70, and 700 platforms.

Early firmware revisions (series A) supported basic V/Hz control and simple I/O configurations. Series B and subsequent revisions added sensorless vector control (SVC), enhanced PID loop functionality, and expanded fault diagnostics. The 22-COMM-x adapter family enabled integration with DeviceNet (22-COMM-D), EtherNet/IP (22-COMM-E), PROFIBUS DP (22-COMM-P), and ControlNet (22-COMM-C) networks, making the PowerFlex 40 compatible with virtually all major industrial fieldbus architectures deployed between 2000 and 2020.

PowerFlex 40 Full Catalog & Functionalities (SKU List)

The PowerFlex 40 catalog number structure follows the format: 22B (240V) or 22D (480V) – [Current Rating] – [Enclosure] – [Control] – [Brake] – [EMC Filter] – [Communication]. Below is a representative cross-section of the series organized by voltage class and output current rating.

240V AC (22B) — Single & Three Phase Input

22B-D2P3N104: 240V, 2.3A output, IP20 open, no brake, no filter — 0.4 kW (0.5 HP) standard duty drive for light conveyor and pump applications.
22B-D4P0N104: 240V, 4.0A output, IP20 open — 0.75 kW (1 HP), single-phase input compatible, common in HVAC fan control retrofits.
22B-D6P0N104: 240V, 6.0A output — 1.1 kW (1.5 HP), three-phase, used in small mixer and agitator drives.
22B-D010N104: 240V, 10.0A output — 2.2 kW (3 HP), general-purpose three-phase, standard OEM machine drive.
22B-D017N104: 240V, 17.5A output — 4.0 kW (5 HP), three-phase, suitable for centrifugal pump and blower duty.
22B-D024N104: 240V, 24.0A output — 5.5 kW (7.5 HP), three-phase, used in compressor and conveyor applications.
22B-D033N104: 240V, 33.0A output — 7.5 kW (10 HP), three-phase, high-cycle duty packaging machinery.

480V AC (22D) — Three Phase Input

22D-D2P3N104: 480V, 2.3A output — 0.75 kW (1 HP), IP20, standard duty, common in water treatment pump skids.
22D-D4P0N104: 480V, 4.0A output — 1.5 kW (2 HP), three-phase, used in HVAC and light industrial fan drives.
22D-D6P0N104: 480V, 6.0A output — 2.2 kW (3 HP), three-phase, standard conveyor and mixer duty.
22D-D010N104: 480V, 10.0A output — 4.0 kW (5 HP), three-phase, IP20 open enclosure, sensorless vector control — the subject SKU of this listing, widely used in pump, fan, and compressor applications across process industries.
22D-D013N104: 480V, 13.0A output — 5.5 kW (7.5 HP), three-phase, used in centrifugal pump and blower duty cycles.
22D-D017N104: 480V, 17.5A output — 7.5 kW (10 HP), three-phase, standard in conveyor and material handling systems.
22D-D024N104: 480V, 24.0A output — 11 kW (15 HP), three-phase, used in large fan and pump applications.
22D-D030N104: 480V, 30.0A output — 15 kW (20 HP), three-phase, heavy-duty conveyor and compressor drive.
22D-D037N104: 480V, 37.0A output — 18.5 kW (25 HP), three-phase, used in high-inertia load applications including centrifuges and crushers.
22D-D043N104: 480V, 43.0A output — 22 kW (30 HP), three-phase, the largest frame in the standard PowerFlex 40 range, used in heavy process pump and fan duty.

Quality Control for the PowerFlex 40 Range

Each PowerFlex 40 unit processed by DriveKNMS undergoes a structured inspection and functional test protocol designed around the specific electrical and communication architecture of the series. The DPI bus interface is tested for signal integrity and correct enumeration with a reference HIM (22-HIM-A3 or equivalent). Power stage testing includes DC bus pre-charge verification, IGBT gate drive signal validation, and output phase balance measurement under resistive load. Control board firmware version is read and recorded; units with outdated firmware are flagged for customer notification prior to shipment.