Allen-Bradley PowerFlex 4 22A-D4P0N104 1.5 kW AC Drive

A compact 1.5 kW drive for fans, pumps and conveyors

The Allen-Bradley 22A-D4P0N104 is a PowerFlex 4 AC drive rated 1.5 kW (2 HP) on 380 to 480 V three-phase supplies, with 4.0 A output current. The PowerFlex 4 and PowerFlex 40 are the smallest, lowest-cost drives in the PowerFlex family and are intended for speed control of fans, pumps, conveyors, material handling equipment and machine tools. The 22A-D4P0N104 is a Frame A, panel-mount IP20 drive with an integral keypad, a 4-digit display and a local speed potentiometer, so it can run straight out of the box.

The drive is easy to program because ten common parameters sit in a Basic Program Group, and its keys work like those of every other PowerFlex drive. Integral RS-485 communications allow programming from a PC and multi-drop networks, and communication cards extend it to DeviceNet, EtherNet/IP, PROFIBUS DP, LonWorks or ControlNet.

Technical specifications

Reading the catalog number

22A is the PowerFlex 4 (22B is the PowerFlex 40), D is the 480 V three-phase rating, 4P0 means 4.0 A output for 1.5 kW, N is the panel-mount IP20 enclosure, the first 1 is the fixed keypad, 0 means no integral filter, and the final 4 means the drive has a brake IGBT. Positions 13 and 14 are reserved for custom firmware. Check each position when matching a spare, since a 22A-D4P0N103 has no brake transistor and an N114 would add a filter.

Installation, protection and sizing

Rockwell lists a 10 A UL fuse, the 140M-C2E-B63 or 140MT-C3E-B63 manual motor controller, and the 100-C09 or 100-E09 contactor for this rating. If you use the manual motor controller, the drive must be in an enclosure of at least 1655 cubic inches, and the drive dissipates 60 W in total. Zero stacking is allowed up to 40 °C ambient, and 50 °C is permitted with minimal spacing; the ambient limit for the IP20 version is -10 to +50 °C.

The integral brake transistor allows dynamic braking with a simple external resistor. The drive provides 150 percent overload for 60 seconds and 200 percent for 3 seconds, and a removable MOV to ground allows use on ungrounded distribution systems.

Commissioning a PowerFlex 4 on site

Before applying power, check that the incoming supply matches the 380 to 480 V rating, that the motor nameplate current suits the 4.0 A output, and that motor and supply cables are connected to the correct terminals and tightened. Verify the insulation of the motor and its cable with the drive disconnected, never through the drive. Once energised, enter the motor nameplate data and the acceleration, deceleration and speed limits in the Basic Program Group, then run the motor uncoupled at low speed to confirm rotation direction before connecting the load.

If a braking resistor is fitted to the brake IGBT, confirm that the related parameters are set to match it, and check the resistor mounting for adequate cooling and guarding. Record the final parameter values, or save them with the PC tools over RS-485, so the drive can be restored quickly after a replacement.

Panel heat and dust in Gulf installations

The stated ambient limit for the IP20 drive is +50 °C, and the space around it inside the enclosure can reach that figure on summer days in Oman and other GCC countries, particularly in outdoor kiosks or unconditioned pump houses. Measure the real panel temperature during the hottest period, keep the drive’s cooling path clear, and add ventilation or air-conditioning where the margin is small. Because the drive is an open-type device, filtered ventilation or a sealed, cooled enclosure is needed to keep fine sand off the heat sink and the control board.

Humidity must remain non-condensing according to the specification table. Panels near the coast or in irrigation and water-pumping stations should be checked for condensation, especially where cool air-conditioned air meets warm humid air; an enclosure heater or controlled cooling can prevent moisture forming on the electronics.

Periodic maintenance

During routine shutdowns, isolate the drive, clean dust from the heat sink area, check terminal tightness, and review the fault history on the display. Simple, regular checks like these catch overheating and loose connections before they cause unplanned stops.

Documents and quotation

The Rockwell Automation PowerFlex 4 and 40 AC Drives technical data is attached. Compare with the Allen-Bradley PowerFlex 525 for networked and safety applications, and see the AC drives category. Confirm the exact catalog number, series letter and firmware or hardware revision on the product label, and the compatibility with your existing system, before ordering. Seven Star LLC supplies against the full catalog number; stock and lead time are confirmed at quotation.