Allen-Bradley 22-RF5P7-AL
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The Allen-Bradley 22-RF5P7-AL is an EMC (Electromagnetic Compatibility) line filter designed for use with the PowerFlex 4M series of AC variable frequency drives. This accessory filter, identified by SKU 22-RF5P7-AL, is manufactured by Allen-Bradley (a Rockwell Automation brand) and is intended to reduce conducted electromagnetic interference generated by the drive on the AC supply lines. It is a passive filter component that connects between the AC mains supply and the drive input terminals.
The 22-RF5P7-AL is rated for a continuous input current of 5.7 A and is designed for single-phase or compatible three-phase input configurations as specified for the PowerFlex 4M drive family. It provides attenuation of high-frequency conducted emissions to help the associated drive system comply with EN 55011 Class C2 (or equivalent) EMC standards. The filter includes internal common-mode and differential-mode filtering components, and its compact form factor is designed to mount in close proximity to or directly beneath the drive to minimize unfiltered cable runs.
This EMC filter is commonly used in light industrial and commercial applications where the PowerFlex 4M drive is deployed, including conveyor systems, pump and fan control, HVAC equipment, and general-purpose machine automation. It is particularly suited for installations in environments with strict electromagnetic compatibility requirements, such as facilities sharing power infrastructure with sensitive instrumentation or in regions where CE marking and EMC directive compliance is mandatory. The filter enables integrators to achieve regulatory compliance without requiring significant panel redesign.
Technical Specifications
| Series/Product Family | PowerFlex 4M Accessories |
|---|---|
| Compatible Drive Series | PowerFlex 4M (22F) |
| Continuous Current Rating | 5.7 A |
| Input Voltage | 120 V AC / 240 V AC, 50/60 Hz |
| Filter Type | EMC Line Filter (Common-mode and Differential-mode) |
| EMC Compliance | EN 55011 Class C2 / CE |
| Mounting | DIN Rail or Panel Mount, adjacent to drive |
| Operating Temperature | 0 to 50 degrees C |
| Storage Temperature | -40 to 85 degrees C |
| Relative Humidity | 5 to 95% non-condensing |
| Certifications | CE, UL |
| IP/Protection Rating | IP20 |
| Control Type | Passive (no active control) |
Common Fault Codes
- Fault Code F2
- Auxiliary input fault on the associated PowerFlex 4M drive. This can be triggered by an external fault signal or wiring issue upstream of the drive, sometimes related to filter or supply wiring.
Check wiring between the EMC filter output and drive input terminals. Verify auxiliary input wiring and ensure no loose connections at the filter terminals. - Fault Code F3
- Power loss fault on the PowerFlex 4M drive. Indicates that the drive detected a loss of input AC power, which may be caused by a poor connection through the line filter.
Inspect all terminal connections on the 22-RF5P7-AL filter. Check for loose screws, corroded terminals, or undersized wiring. Verify incoming supply voltage is within specification. - Fault Code F5
- Overvoltage fault on the DC bus of the drive. Can occur if the filter is not correctly matched to the supply or if transient overvoltages are present on the supply line.
Verify that the supply voltage is within the rated range for the drive and filter. Check for voltage spikes on the supply; consider adding surge protection upstream of the filter. - Fault Code F6
- Undervoltage fault on the DC bus. May indicate insufficient supply voltage reaching the drive due to excessive voltage drop across filter components or a failing filter.
Measure AC voltage at the filter input and output terminals under load. If a significant voltage drop is observed across the filter, inspect filter components for damage or overheating. - Fault Code F7
- Motor overload fault on the associated drive. Not directly related to the filter, but can be triggered if the filter is causing supply imbalance or harmonic distortion affecting drive operation.
Verify filter is correctly rated for the drive and load current. Check that the 5.7 A current rating of the filter is not being exceeded. Inspect motor and drive parameters. - Fault Code F12
- Hardware overcurrent fault on the drive. Can occur if the EMC filter is damaged internally and causing impedance issues on the supply lines, leading to abnormal current draw.
Disconnect the filter and test the drive directly on the supply to isolate the fault. If the fault clears, inspect or replace the 22-RF5P7-AL filter. Check for signs of overheating or physical damage on the filter. - Fault Code F33
- Auto-restart attempts exceeded on the PowerFlex 4M drive. Repeated faults related to supply quality may be caused by inadequate EMC filtering allowing noise to disrupt drive operation.
Review the fault history to identify the underlying recurring fault. Ensure the EMC filter is properly installed with short, direct wiring runs. Verify grounding of the filter chassis to panel earth.
Frequently Asked Questions
Which Allen-Bradley drive is the 22-RF5P7-AL filter designed for?
The 22-RF5P7-AL is designed specifically as an accessory EMC line filter for the Allen-Bradley PowerFlex 4M (22F series) AC drives. It should be matched to the appropriate drive rating based on current and voltage requirements.
What is the current rating of the 22-RF5P7-AL filter?
The 22-RF5P7-AL is rated for a continuous current of 5.7 A, making it suitable for use with lower-horsepower PowerFlex 4M drives operating on 120 V or 240 V AC single-phase supplies.
Is the 22-RF5P7-AL required for CE compliance?
Yes, installing the 22-RF5P7-AL EMC filter is typically required when the PowerFlex 4M drive system must comply with CE marking requirements under the EMC Directive. It attenuates conducted emissions to meet Class C2 limits as defined in EN 55011.
How should the 22-RF5P7-AL be mounted relative to the drive?
The filter should be mounted as close as possible to the drive input terminals, with short and direct wiring runs between the filter output and the drive. The filter chassis must be bonded to a common earth ground to ensure effective EMC performance.
Can the 22-RF5P7-AL be used with drives other than the PowerFlex 4M?
The 22-RF5P7-AL is specifically designed and rated for use with the PowerFlex 4M series. While it is electrically a passive filter, using it with other drive families is not recommended or supported by Allen-Bradley, as impedance characteristics and current ratings may not be compatible.
Troubleshooting
Drive trips on power-up with no load connected after filter installation
Check whether the fault clears when the filter is bypassed and the drive is connected directly to the supply. Measure supply voltage at the filter input and output terminals to detect any abnormal voltage drop or imbalance.
Verify that the filter current rating (5.7 A) is appropriate for the drive model. Ensure all terminal connections are tight and correctly wired. Confirm the filter ground terminal is securely bonded to the panel earth bar.
EMC filter runs hot or shows signs of overheating
Measure the actual load current through the filter using a clamp meter. Compare against the 5.7 A continuous rating. Check ambient temperature in the enclosure and verify adequate ventilation.
If current exceeds the filter rating, replace with a higher-rated filter appropriate for the load. Ensure the enclosure has adequate ventilation or forced cooling. Check for harmonic-rich loads that may cause elevated RMS current through filter components.
Persistent EMC interference or noise on supply lines despite filter installation
Inspect the physical installation for long wiring runs between the filter and drive input, which reduce filter effectiveness. Check that the filter chassis ground connection is secure and has low impedance to the panel earth.
Shorten wiring between the filter output and drive input terminals to the minimum practical length. Use shielded cable where required. Ensure a dedicated, low-impedance earth bond is made from the filter ground terminal to the panel earth busbar.
Drive displays undervoltage fault after filter is installed in the supply line
Measure AC voltage at the supply input to the filter and at the filter output terminals under operating conditions. A significant voltage drop across the filter under load indicates a wiring or component issue.
Check that all terminal screws are torqued to specification and that wire cross-sections are adequate for the load current. If the filter shows internal damage or abnormal resistance, replace the 22-RF5P7-AL unit.
Intermittent drive faults that clear on reset with no apparent cause
Review the drive fault history log to identify fault codes and timing. Inspect the filter for loose terminal connections that may cause momentary supply interruptions or voltage fluctuations under vibration.
Re-torque all terminal connections on the filter. Inspect for signs of arcing or discoloration at terminals. Ensure the filter is securely mounted to prevent vibration-induced loosening. If faults persist, replace the filter and retest.
| Condition | Repair, Used, Refurbished, New in box (sealed) |
|---|
Common defects
Common defects on a Allen-Bradley 22-RF5P7-AL are:
Power Supply Related Issues
- No power / drive not turning on
- Blown fuses
- Defective rectifier bridge
- Damaged DC bus capacitors
- IGBT / MOSFET module failure
- Overvoltage / undervoltage errors
Control & Electronics Failures
- Faulty control board or PCB damage
- Firmware or memory corruption
- Fieldbus communication errors (Profibus, Modbus, EtherCAT, CANopen)
- Input / output circuit damage
- Gate driver module failure
Motor Control Problems
- Motor not starting or no output
- Unstable speed control
- No torque output
- Trip during acceleration or deceleration
- Encoder feedback errors
Thermal & Cooling Defects
- Overheating due to failed cooling fans
- Defective temperature sensors
- Poor heatsink performance
Mechanical & Environmental Damage
- Burnt or loose connectors
- PCB track damage
- Corrosion or moisture ingress
- Oil, dust or contamination damage
- Cracked solder joints
Error Codes & Drive Trips
- Overcurrent faults (OC)
- Ground fault / earth leakage error
- Short-circuit fault
- Motor or drive overload
- Overvoltage or undervoltage error
- Undervoltage trip when starting or stopping
- Phase loss / imbalance
- Synchronization issues with multiple drives
Other
- Display defect
- Control keys or keypad not working
- Parameters no longer readable or lost
- Brake resistor problems (brake chopper defect)
- Internal relays/contactors defective
- EMI/RFI interference due to defective filters
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