22-TD001I-EN-P PowerFlex 4 And 40 AC Drives Technical Data

Technical DataPowerFlex 4 and 40 AC DrivesOriginal InstructionsTopicProduct OverviewReference MaterialsPackaging and MountingStart Up, Programming and OperationOptimized PerformanceSensorless Vector PerformanceSensorless Vector ControlPerformanceI/OCommunicationsVersatile Programming and Network SolutionsPC Programming SoftwareCatalog Number ExplanationProduct SelectionUser Installed OptionsInstallation ConsiderationsControl WiringSpecificationsParameter DescriptionsProduct DimensionsPowerFlex 4 and 40 Configured DrivesPage2233444455668910141519222532

PowerFlex 4 and 40 AC DrivesProduct OverviewProviding users with powerful motor speed control in a compact, space saving design, the Allen-Bradley PowerFlex 4 and40 AC drives are the smallest and most cost-effective members of the PowerFlex family of drives. Available in power ratingsfrom 0.2 to 11 kW (0.25 to 15 HP) and in voltage classes of 120, 240, 480 and 600 volts, PowerFlex 4 and 40 are designedto meet global OEM and end-user demands for flexibility, space savings, ease of use and are cost-effective alternatives forspeed control of applications such as machine tools, fans, pumps and conveyors and material handling systemsReference MaterialsFor additional PowerFlex 4 and 40 data and general drive information, refer to the following publications:TitlePowerFlex 4 User ManualPowerFlex 40 User ManualWiring and Grounding Guidelines for PWM AC DrivesPreventive Maintenance of Industrial Control and Drive System EquipmentSafety Guidelines for the Application, Installation and Maintenance of Solid State literatureFor other information, contact Allen-Bradley Drives Technical Support:TitleAllen-Bradley Drives Technical SupportOnlinewww.ab.com/support/abdrivesShaded areas are applicable to PowerFlex 40 only.2Rockwell Automation Publication 22-TD001I-EN-P - June 2013

PowerFlex 4 and 40 AC DrivesPackaging and Mounting Installation can be a virtual snap using the DIN rail mounting feature onA and B frame drives. Panel mounting is also available, providing addedflexibility. Flange mount drives are available to reduce overall enclosure size. Zero Stacking is allowable for ambient temperatures up to 40 C, savingvaluable panel space. 50 C ambient temperatures are permitted withminimal spacing between drives. Integral filtering is available on all 230V single phase ratings, providing acost-effective means of meeting EN55011, Class A and B EMCrequirements. External filters provide compliance to Class A and Brequirements for all PowerFlex 4 and 40 ratings. An optional IP30, NEMA/UL Type 1 conduit box is easily adapted tothe standard IP20 (NEMA Type Open) product, providing increasedenvironmental ratings. IP66, NEMA/UL Type 4X/12 (Indoor) for mounting directly in theproduct environment. Listed by UL to resist dust, dirt, etc. and survivehigh pressure water spray. Also certified by NSF to ensure conformitywith international food equipment standards.Start Up, Programming and Operation An integral keypad provides out of the box operation using the localpotentiometer and control keys. The 10 most common application parameters are contained in the BasicProgram Group, making programming fast and easy. The programming keys have the same function as all other PowerFlexdrives, so if you can program one PowerFlex drive, you can program themall. 4 digit display with 10 additional LED indicators provides an intuitivedisplay of drive status and information. Integral RS-485 communications can be used for programming from aPC. It can also be used in a multi-drop network configuration. A serialconverter module provides connectivity to any controller with a DF1port. A NEMA/UL Type 4X remote and NEMA/UL Type 1 hand-heldLCD keypad provide additional programming and control flexibility,both featuring the popular CopyCat function.Rockwell Automation Publication 22-TD001I-EN-P - June 20133

PowerFlex 4 and 40 AC DrivesOptimized Performance Removable MOV to ground provides trouble-free operation when used on ungroundeddistribution systems. A relay pre-charge limits inrush current. Integral brake transistor, available on all ratings (except no brake version), providesdynamic braking capability with simple low cost brake resistors. DIP switch settable 24V DC sink or source control for control wiring flexibility. 150% overload for 60 seconds or 200% overload for 3 seconds provides robust overloadprotection. Adjustable PWM frequency up to 16 kHz ensures quiet operation.Sensorless Vector PerformancePowerFlex 4 Drive automatically provides auto boost (IRcompensation) and slip compensation. Provides excellent speed regulation and high levels oftorque across the entire speed range of the drive, andimproved speed regulation even as loading increases.Sensorless Vector ControlAB PowerFlex 40 3Hp - High SpeedPowerFlex 40 Sensorless Vector Control provides exceptional speedregulation and very high levels of torque across theentire speed range of the drive. The Autotune feature allows the PowerFlex 40 to adaptto individual motor characteristics.Torque ncy (HZ)Performance This graph depicts the ability of a PowerFlex 40 drive toaccelerate into at least 150% load. A PowerFlex 4 willperform similarly, but with a slightly higher accelerationtime. At 100% motor load, the drive will run the motor atsynchronous speed. Excellent current regulation. Linear acceleration. Best in class digital input response time andrepeatability.4Rockwell Automation Publication 22-TD001I-EN-P - June 2013CurrentSpeedTorque708090100

PowerFlex 4 and 40 AC DrivesPerformance Sensorless Vector Control develops high torque over a wide speed rangeand adapts to individual motor characteristics. Variable PWM allows the drive to output more current at lowfrequencies. Integral PID functionality enhances application flexibility. Timer, Counter, Basic Logic and StepLogic functions can reducehardware design costs and simplify control schemes.– Timer function: Relay or opto outputs controlled by driveperforming timer function. Timer is initiated by activating a digitalinput programmed as “Timer Start.”– Counter function: Relay or opto outputs controlled by driveperforming counter function. Counter function is activated by adigital input programmed as “Counter Input.”– Basic Logic: Relay or opto outputs controlled by status of digitalinputs programmed as “Logic Inputs.” Performs basic Boolean logic.– StepLogic: Logic-based steps using preset speed settings. Each stepcan be programmed for a specific speed, direction and accel/decelprofile. Drive outputs can be used to indicate which step is being performed.I/O Two (2) Analog Inputs (one unipolar and one bipolar) areindependently isolated from the rest of the drive I/O. These inputscan be toggled between via a digital input. Three (3) fixed and four (4) fully programmable Digital Inputsprovide application versatility. One (1) Analog Output is DIP switch selectable for either0 10V or 0 20mA. This scalable, 10-bit output is suitable formetering or as a speed reference for another drive. Two (2) Opto Outputs and one (1) form C relay output can beused to indicate various drive, motor or logic conditions.Analog Signal FollwerDrive 1Analog OutCommon14 16-/ 10VCommonDrive 2Analog In1314Communications Integral communication cards such as DeviceNet , EtherNet/IP ,PROFIBUS DP, LonWorks and, ControlNet can improve machineperformance. The DSI Wireless Interface Module (WIM) provides a wirelesscommunication interface between a Pocket PC, laptop computer ordesktop computer equipped with Bluetooth wireless technology, and anyAllen-Bradley product supporting the DSI protocol. Field installed option allows for future addition of stand-alone drives to anetwork. Online EDS file creation with RS NetWorx providing ease of set-up on anetwork.Rockwell Automation Publication 22-TD001I-EN-P - June 20135

PowerFlex 4 and 40 AC DrivesVersatile Programming and Network Solutions PowerFlex 4 and PowerFlex 40 are compatible withany device that acts as a RTU Master and supportsstandard 03 and 06 RTU commands. A network can be configured using PowerFlex 40drives with optional communication cards for highperformance and flexible configuration capabilities.– BACnet– ControlNet– DeviceNet– EtherNet/IP– LonWorks– PROFIBUS DP A multi-drive solution can be reached using a singlePowerFlex 40 DeviceNet option, with the ability forup to five drives to reside on one node. Integral RS485 communications enable the drives tobe used in a multi-drop network configuration. Aserial converter module (SCM) provides connectivityto any controller with a DF1 port. The SCM can beeliminated if the controller acts as a RTU Master.RTUup to 31 PowerFlex 4 or PowerFlex 40 drivesNetwork CommunicationNode 2Node 3Node 1PowerFlex 40with Comms cardDeviceNetRTUup to 4 PowerFlex 4 or PowerFlex 40 drivesDF1RTUSCMPC Programming SoftwarePowerFlex 40PowerFlex 40with Comms card with Comms cardup to 31 PowerFlex 4 or PowerFlex 40 drivesThrough the use of a Serial Converter Module andDriveExplorer or DriveTools SP software,programming can be greatly simplified.DriveExplorer Software View and modify drive and adapter parameters ina method similar to the file management capabilityof Microsoft Windows Explorer. Operate the drive via an on-screen Control Bar,which is a tool that allows you to start, stop, andchange the speed reference of the drive. Save, restore and print parameter information. Compare current parameters with factory defaultsor previously saved parameter values. Edit, upload and download parameters.DriveTools SP Software 6Online and offline programming capabilityIn-grid and dialog-based parameter editingImmediate visual indication of drive and communication status when viewing online driveIntegrated HTML Help architectureRockwell Automation Publication 22-TD001I-EN-P - June 2013

PowerFlex 4 and 40 AC DrivesUse the chart below to assist in determining which product is most appropriate for an application.FeatureCatalog Reference22A(1.1) 1.5 HP/115V, 1ø(2.2) 3 HP/230V, 1ø(3.7) 5 HP/230V, 3ø(3.7) 5 HP/460V, 3øMaximum (kW)HP Rating/Input Voltage150% for 60 seconds200% for 3 seconds Overload CapacityIP30, NEMA/UL Type 1 OptionIP66, NEMA/UL Type 4X/12 (Indoor)Internal - 1ø, 230VExternal - All 1ø, 115V and 3ø Ratings EMC FilteringDIN Rail Mounting StandardIntegral Keypad with Speed PotKeypad - Remote LCDKeypad CopyCat FunctionControl Type V/Hz Not available on no brake models.42 16 kHzInternal DB TransistorPreset SpeedsCarrier FrequencySkip FrequencyProcess Control LoopStepLogic FunctionalityTimer/Counter FunctionsControl Voltage24V sink/source3 fixed for START/STOP/REV2 fully programmable1(0 10V or 4 20 mA)Discrete InputsAnalog Input - UnipolarAnalog Input - BipolarAnalog ResponseRelay OutputDigital/Optocoupler Output2 Hz (500 ms)1 - N.O/N.C. dry contactAnalog OutputIntegral RS485RS232 (Requires use of Serial Converter sPROFIBUS DP (1) (1) (1) (1) (1) (1)22B(1.1) 1.5 HP/115V, 1ø(2.2) 3 HP/230V, 1ø(7.5) 10 HP/230V, 3ø(11.0) 15 HP/460V, 3ø(11.0) 15 HP/600V, 3ø150% for 60 seconds200% for 3 seconds (2)Internal - 1ø, 230VExternal - All 1ø, 115V and 3ø Ratings (Through 5 HP) Sensorless Vector & V/Hz 82 16 kHz (PID) 24V sink/source3 fixed for START/STOP/REV4 fully programmable2(0 10V and 4 20 mA)1( /- 10V) (3)100 Hz (10 ms)1 - N.O./N.C. dry contact2 (0 10V or 4 20 mA) (1) With 22-XCOMM-DC-BASE External mounting kit.(2) Frame B only.(3) When using bipolar input, the 0 10V unipolar input cannot be used.Rockwell Automation Publication 22-TD001I-EN-P - June 20137