Product Description

Allen-Bradley 22C-D038A103 — PowerFlex 400 AC Drive, 18.5 kW / 25 HP, 480V

Fan and pump loads have a well-known characteristic: their power demand scales with the cube of speed. Drop a pump from 60 Hz to 48 Hz — just an 80% speed — and the motor draws only about half the power it would at full speed. Capture that relationship with variable-frequency control, and the energy savings on large HVAC and process pumping systems are substantial enough to pay for the drive many times over during a normal equipment life.

The 22C-D038A103 is Allen-Bradley's PowerFlex 400 drive at the 18.5 kW / 25 HP, 480V rating point — a Frame D unit built specifically for commercial and industrial fan and pump applications, with a suite of built-in features that go well beyond basic speed control.

New. In stock. Ready for immediate worldwide dispatch.

Technical Specifications

Parameter	Value
Catalog Number	22C-D038A103
Series	Allen-Bradley PowerFlex 400
Power Rating	18.5 kW / 25 HP
Frame Size	D
Enclosure	IP30 / NEMA Type 1 / UL Type 1 (panel component mount)
Input Voltage	380–480V AC (range: 342–528V AC)
Input Phases	3-phase
Input Frequency	48–63 Hz
Input Current	40A
Output Voltage	0–460V AC, 3-phase
Output Current (continuous)	38A
Output Frequency Range	0–400 Hz
Motor Control Mode	Volts/Hz (V/Hz)
HIM (Keypad)	Fixed integral LCD, 2-line × 16-character, 5 LED indicators
Communication (standard)	RS-485 (internal), DSI port
Standard Protocols	Modbus RTU, FLN (Apogee P1), Metasys N2, CIP (Common Industrial Protocol)
Optional Protocols	EtherNet/IP, ControlNet, DeviceNet, LonWorks, BACnet
Analog Inputs	2× (0–10V DC / 0–20 mA)
Analog Outputs	2× (0–10V DC / 0–20 mA)
Discrete Inputs	7× sink/source
Discrete Outputs	1× open collector + 2× Form C relay
Power Dissipation (open)	~606W
Max Power Wire Size	33.6 mm² (2 AWG)
Min Power Wire Size	8.4 mm² (8 AWG)
Power Terminal Torque	5.1 N·m (45 lb·in)
Recommended MCP	140M-F8E-C45
Recommended Contactor	100-C60
Dimensions (H × W × D)	Approx. 430 × 200 × 250 mm (16.93 × 7.87 × 9.84 in)
Weight	Approx. 12.95 kg (28.57 lb)
Operating Temperature	0–50°C (derating applies 45–50°C)

PowerFlex 400: Designed from the Ground Up for Fan and Pump

Most general-purpose AC drives can run a pump or fan — but the PowerFlex 400 was engineered specifically to do it well. The distinction shows up in the features that come standard, rather than requiring optional cards or special firmware.

Built-in PID control loop. The drive includes a fully functional Proportional-Integral-Differential (PID) process controller, allowing it to regulate a process variable — pressure, flow, temperature, or any 0–10V / 0–20mA signal — directly against a setpoint without a separate PLC loop. In a pressure-regulated pumping system, for example, the drive reads the pressure transducer, computes the required speed change, and adjusts motor output accordingly, all internally.

Hand/Off/Auto keypad mode. The integral keypad includes configurable Hand, Off, and Auto mode buttons — the standard operator interface convention for HVAC equipment. Hand runs the motor at a manually set speed for commissioning and testing. Off stops the drive. Auto hands control back to the building automation system or process controller. No additional programming is needed; the behavior is built in and selectable by configuration.

Purge and damper input. When a drive is installed on a supply fan serving a ventilation system, standard ASHRAE commissioning practice requires the ability to run the fan at a fixed purge speed to clear the ductwork before normal operation begins. The PowerFlex 400 accepts a dedicated purge input that triggers this sequence automatically — and the purge command takes priority over all other control sources including network stop commands, ensuring it cannot be overridden during a fire safety pre-purge sequence.

Sleep/wake function. For pump systems with variable demand where the motor idles for extended periods, the sleep/wake feature automatically stops the drive when output frequency falls below a configurable sleep threshold, and restarts it when demand recovers past a wake threshold. This eliminates the need for a separate speed switch or PLC logic to manage low-demand shutdown.

Auxiliary Motor Control: One Drive, Four Motors

One feature that distinguishes the PowerFlex 400 in multi-pump applications is Auxiliary Motor Control — the ability to start and stop up to three additional line-started motors in response to demand, alongside the primary variable-speed motor controlled directly by the drive.

The operating logic is straightforward: the VFD-controlled motor runs at variable speed tracking the process demand. When demand grows beyond the capacity of that single motor at full speed, the drive activates a relay output that line-starts the first auxiliary motor. If demand continues to grow, subsequent auxiliaries are staged on. When demand drops, motors are staged off in reverse order. The result is a complete multi-pump or multi-fan control system with staging logic built into the drive — no auxiliary sequencing controller required.

In a typical four-pump booster system, this architecture can deliver up to 4× the flow capacity of a single motor while maintaining pressure control across the full range, with the VFD-controlled motor handling the continuous modulation at each demand level.

Communication: RS-485 Built In, Fieldbus Expandable

Every 22C-D038A103 ships with an internal RS-485 port supporting DSI (Drive Serial Interface), Modbus RTU, FLN (Apogee P1 plant floor network), and Metasys N2 — the four serial protocols most widely used in building automation systems. Integration with Johnson Controls Metasys, Siemens Apogee, and any Modbus-capable BAS is possible without any additional hardware.

For systems requiring Ethernet or high-speed fieldbus connectivity, a DSI communication adapter slot accepts optional modules for EtherNet/IP, ControlNet, DeviceNet, LonWorks, and BACnet — expanding the drive's network capability without changing the base hardware. The Frame D enclosure on the 22C-D038A103 accommodates these modules directly without the communication cover adapter required for smaller Frame C units.

Ground Fault and Motor Protection Built In

The drive includes ground fault protection active during both starting and running, electronic motor overload protection (eliminating the need for a separate overload relay in many applications), and 6kV transient protection on the 380–480V input. These protections are active from the moment the drive powers up — they don't require separate configuration to function at their baseline level.

The integral LCD keypad provides two lines of alphanumeric display for fault codes, operating status, and parameter values, backed by five LED indicators for quick visual status assessment at the panel door. Fault history is stored in drive memory and is accessible via the keypad or over the communication link.

Connectivity to Fire and Life Safety Systems

A dedicated Function Loss input on the control terminal block allows the PowerFlex 400 to be wired directly to a fire alarm panel or other life safety system. If the Function Loss input opens — indicating an alarm condition — the drive immediately coasts the motor to a stop and issues a fault. The drive cannot restart until the alarm state has cleared and the fault has been manually reset. This hardwired interlock ensures that the drive cannot override a fire or safety shutdown through any software path.

Frequently Asked Questions

Q: What is the input voltage range for the 22C-D038A103?

A: The nominal input voltage is 480V AC, 3-phase. The operating range is 342–528V AC (−10% to +10% of the 380–480V nominal band), with an input frequency tolerance of 48–63 Hz. This range covers both 380V and 480V three-phase supplies, making the drive usable in North American 480V systems and European 400V systems.

Q: Does this drive support Modbus RTU out of the box?

A: Yes. Modbus RTU is supported as a standard protocol over the internal RS-485 port — no additional communication module is required. The drive also supports DSI, Apogee FLN P1, and Metasys N2 via the same RS-485 port. For Ethernet or other fieldbus protocols, an optional DSI adapter card is required.

Q: What is the difference between the 22C-D038A103 and catalog numbers with different suffixes (like N103)?

A: The catalog number suffix encodes specific factory-installed options. The "A" in position "d" indicates the IP30/NEMA Type 1 top cover and conduit box are fitted (converting the base IP20 frame to IP30). The "1" in position "e" indicates the fixed integral keypad is installed. The "03" suffix typically indicates the standard North American configuration. Always verify the full catalog number when ordering for exact specification matching.

Q: Can this drive be used for general-purpose applications beyond fans and pumps?

A: The PowerFlex 400 is optimized and marketed for fan and pump (variable torque) loads — the Volts/Hz control mode, PID loop, and HVAC-specific features reflect this design intent. It can run other variable-torque loads on the same control architecture. For constant-torque conveyor, hoist, or general machinery applications requiring sensorless vector control or dynamic torque response, the PowerFlex 40 or PowerFlex 70/700 series are more appropriate choices.

Q: How many additional motors can the drive stage with Auxiliary Motor Control?

A: Up to three additional line-started motors can be staged on and off via relay outputs, in addition to the primary motor directly controlled by the drive. With all four motors running, the system delivers up to 4× the single-motor capacity — suitable for multi-pump pressure boosting, cooling tower staging, and parallel fan applications.

Q: What wire size is required for the power terminals?

A: The Frame D power terminal block accepts wire from a minimum of 8.4 mm² (8 AWG) to a maximum of 33.6 mm² (2 AWG), using 90°C rated conductors. Terminal torque is 5.1 N·m (45 lb·in). For installations where local code requires conductor sizes outside this range, terminal lugs may be used. Always verify compliance with local wiring regulations.

Q: What is the recommended motor circuit protector for this drive?

A: Allen-Bradley recommends the 140M-F8E-C45 Motor Circuit Protector with a 100-C60 IEC contactor for the 22C-D038A103 installation. These selections are documented in the PowerFlex 400 product data sheet (publication 22C-TD001) and are sized for the 38A output current of this drive.

Q: What does "New" mean for this listing?

A: The unit is factory-new, genuine Allen-Bradley / Rockwell Automation manufacture, in original packaging, unused and uninstalled. It has not been previously powered, configured, or repaired. This is not refurbished, reconditioned, or repackaged surplus.

22C-D038A103 New 22CD038A103 AB A PowerFlex 400 18.5 kW 25 HP AC Drive