User manual | Powerflex 4_40 Product Profile

PowerFlex® 4 and PowerFlex® 40 AC Drives
Provide Optimized Simplicity
Providing users with powerful motor speed
control, the Allen-Bradley® PowerFlex 4 and
PowerFlex 40 AC drives are ideal for machine
level speed control, and provide the application
versatility to meet the demands of global OEMs
and end users who require flexibility, space
savings and ease of use. The PowerFlex 4 and
PowerFlex 40 AC drives have commonality in
three key areas:
1
3
Flexible Packaging and
Mounting Options
• Installation can be a virtual snap using the
DIN rail mounting feature on selected drives.
• Flange mount drives are available to
reduce overall enclosure size.
• Zero Stacking™ is allowable for ambient
temperatures up to 40°C, saving valuable
panel space. 50°C ambient temperatures
are permitted with minimal spacing
between drives.
Easy to Start up and Operate
• Integral keypad features a 4 digit display
and 10 additional LED indicators providing
intuitive control.
• The keypad, control keys, and local
potentiometer are active out of the box,
simplifying start up.
• The most commonly programmed
parameters are grouped together for fast
and easy start up.
Versatile Programming and
Network Solutions
• Integral RS485 communications enable the
drives to be used in a multi-drop network
configuration. A serial converter module
provides connectivity to any controller that
has the ability to initiate DF1 messaging.
• DriveExplorer™ and DriveTools™ SP
software can be used to program, monitor
and control the drives.
• A NEMA/UL Type 4X remote and NEMA 1
handheld LCD keypad provide additional
programming and control flexibility, both
featuring the popular CopyCat function.
Premier Integration with
PowerFlex Drives
For simplified AC drive start-up and reduced
development time using the Allen-Bradley®
Logix control platform, we’ve integrated
PowerFlex® AC drive configuration with
RSLogix™ 5000 software. This single-software
approach simplifies parameter and tag
programming while still allowing stand-alone
drive software tool use on the factory floor.
2
4
1
2
3
PowerFlex 4 AC Drive
0.2 to 3.7 kW; 0.25 to 5
Hp @ 120, 240, 480 V
PowerFlex 40 AC Drive, 0.4 to
11 kW; 0.5 to 15 Hp @ 120, 240,
480, 600 V (Product shown with
DeviceNet option)
PowerFlex 4 and 40
Flange Mount Drives
PowerFlex 4 AC Drive
4
PowerFlex 40
NEMA / UL Type 4X/12
(IP66/54) 0.4 to 3.7 kW
(No additional
accessory required for
communication options)
Designed with simplicity and space savings in mind, the PowerFlex 4 is:
• Ideal for applications with limited panel space
• An economical replacement for electromechanical devices or DC solutions
PowerFlex 40 AC Drive
The PowerFlex 40 AC drive shares all the same features and functionality of the
PowerFlex 4 AC drive. In addition the PowerFlex 40 AC drive features sensorless vector
control and has additional I/O capability. Designed with application versatility and
robust performance in mind, the PowerFlex 40 AC drives also features:
• 0-10V or 4-20mA (10-bit) analog output for feedback or as reference for other drives
• Timer, counter and StepLogic® functions can reduce hardware design cost,
simplifying control schemes
• Two analog input channels, including PID capability, offer enhanced
application flexibility
• Integral communications options including DeviceNet™, ControlNet™, EtherNet/IP™
and a variety of 3rd party networks.
• IP66, NEMA/UL Type 4X/12 (indoor) – for mounting directly in the product
environment. Listed by UL to resist dust, dirt, etc. and survive high pressure
water spray. Also certified by NSF to ensure conformity with international food
equipment standards.
PowerFlex 40 Configured Drives
PowerFlex 40 Configured Drives simplify installation and start up by allowing users
to order drive packages that combine operator interface, control, communications
and power options in pre-packaged assemblies. Offering a number of commonly
requested pre-engineered options, as well as more complex custom-engineered
combinations, this program provides a wide range of motor control options.
Now we’re talking…
low cost communications!
Simple RS485 Solutions
• Controls and monitors
from a PC using
DriveExplorer™ or
DriveTools™ SP software
DF1
RTU
Multiple PowerFlex Component
Class AC drives
SCM
Up to 15 PowerFlex Component
Class AC drives on 1769-SM2 in
DSI mode
• Requires use of Serial
Converter Module
(SCM)
• Simple network
control with any
logic controller
using DSI
DSI
RTU
1769-SM2 is configurable in DSI mode or
RTU mode
• Compatible with any
device that acts as
RTU Master
• Drive supports
standard 03 and
06 RTU commands
RTU
Network PowerFlex Component
Class AC drives
Advanced Network Solutions
DeviceNet
• Multi-drive solution using
a single PowerFlex 40
DeviceNet option
• Significantly reduces
node count and
system cost
RTU
PowerFlex Component Class
AC drives
DeviceNet
Node 1
PowerFlex 40 AC Drive
with DeviceNet
Node 2
PowerFlex 40 AC Drive
with DeviceNet
Node 3
PowerFlex 40 AC Drive
with DeviceNet
• Network configuration
using PowerFlex 40
drives with DeviceNet
option cards
• Provides highest
performance and most
flexible configuration
capabilities
And, even lower cost machine level control.
Timer and Counter
Functions
Ideal for:
• Digital inputs control
digital outputs based
on timer or counter
function
1 Form C
Relay Output
Mixers
Fillers
Limit Switch
2 Opto
Outputs
Shrink-wrap
machines
Photoelectric Sensor
Basic Logic
Functions
Ideal for:
1 Form C
Relay Output
• Digital inputs control
digital outputs based
on Boolean logic
• AND and OR logic
inputs provide
application flexibility
Packaging
machines
Conveyors
Limit Switch
AND
OR
2 Opto
Outputs
Palletizers
PowerFlex 40
Photoelectric Sensor
StepLogic® Function
• Logic controlled steps using
preset speed settings
Ideal for:
1 Form C
Relay Output
• Each step can be
programmed to:
• Step based on digital input
status including AND, OR and
NOT logic
Limit Switch
Shuttle
transfer
cars
AND
OR
NOT
2 Opto
Outputs
• Step based on specific time
• Control speed, direction
and accel/decel rate
Positioning
Machine
tool
Batch
process
Photoelectric Sensor
PowerFlex 40
• Control the status of
an output
• Make deterministic jumps
NEMA/UL Type 4X/12
(IP66/54)
Ideal for washdown or dust-
• NEMA/UL Type 4X/12 for
Washdown application
Standards met:
tight areas in:
Food and Beverage Applications
Pulp and Paper
Machine Tool
Textile
Pharmaceutical
• UL Type 4X (high
pressure water)
• UL Type 12 (dust)
• IP66/54 (dust and
high pressure water)
• C-Tick, CE
• NSF
• Communication options
do not require additional
accessories.
PowerFlex 40 NEMA / UL Type 4X/12
IP66/54
PowerFlex 4 AC Drive
PowerFlex 40 AC Drive
Integral keypad with 4 digit, 10 additional LED indicators and
local potentiometer, remote Human Interface Modules (HIM) optional
Operator Interface
Integral keypad with 4 digit, 10 additional LED indicators and
local potentiometer, remote Human Interface Modules (HIM) optional
(IP66 does not include local potentiometer)
Standards
UL, C-Tick, CE, EMC EN61800-3, Low Voltage EN60204-1/EN50178
Electrical
Maximum Short Circuit Rating: 100,000 Amps Symmetrical
Electronic Motor Overload Protection: I2t protection – 150% for 60 seconds, 200% for 3 seconds (Provides Class 10 protection)
Protection
Input Specifications
Phase
Voltage: 100 - 120V / 200 - 240V
1 Phase Voltage: 100 - 120V /1200
- 240V
1 Phase Voltage: 100 - 120V / 200 - 240V
Voltage: 200 - 240V / 380 - 480V
3-Phase Voltage: 200 - 240V 3-Phase
/ 380 - 480V
3-Phase Voltage: 200 - 240V / 380 - 480V / 480 - 600V
Frequency: 47 to 63 Hz
Frequency: 47 to 63 Hz
Frequency: 47 to 63 Hz
Logic Control Ride Through: >0.5 seconds, 2 seconds typical
Logic Control Ride Through: >0.5 seconds, 2 seconds typical
Logic Control Ride Through: >0.5 seconds, 2 seconds typical
Voltage: Adjustable from 0V to rated motor voltage
Voltage: Adjustable from 0V to rated motor voltage
Intermittent Current: 150% for 60 seconds
Intermittent Current: 150% for 60 seconds
Output Voltage Range/
Overload Capacity
Voltage: Adjustable from 0V to rated motor voltage
Intermittent Current: 150% for 60 seconds, 200% for 3 secs
Enclosure and Ambient
Operating Temperature
Open Type / IP20: -10° to 50° C (14° - 122°F) with specified distance between drives or
Open Type / IP20: -10° to 40° C (14° - 104°F) Zero Stacked
NEMA/UL Type 1 / IP30: -10° to 40° C (14° - 104°F) with optional
conduit box kit
Open Type / IP20: -10° to 50° C (14° - 122°F) with specified distance between drives or
Open Type / IP20: -10° to 40° C (14° - 104°F) Zero Stacked
NEMA/UL Type 1 / IP30: -10° to 40° C (14° - 104°F) with optional
conduit box kit
NEMA/UL Type 4X/12 / IP66: -10° to 40° C (14° - 104° F)
Frequency Range
0 - 240 Hz
0 - 400 Hz
Control I/O
24V sink or source control
3 dedicated inputs for start, stop and reverse
2 programmable inputs for functions such as preset speed, jog, etc.
0 - 10V or 4 - 20mA input
1 programmable form C relay output
24V sink or source control
3 dedicated inputs for start, stop and reverse
4 programmable inputs for functions such as preset speeds, jog, etc.
± 10V (bipolar), 0 - 10V and 4 - 20mA
1 programmable form C relay output
1 analog output (0 - 10V or 4 - 20mA)
2 programmable opto outputs
Dynamic Braking
7th IGBT included on all ratings (except no brake drives)
Carrier Frequency
2-16 kHz. The drive rating is based on 4 kHz
Frequency Accuracy
Ratings
7th IGBT included on all ratings
Digital input within + 0.05% of set frequency
Analog input within 0.5% of maximum output frequency
Input Voltage Class
100…120V, 1Ø
200…240V, 1Ø
200…240V, 3Ø
380…480V, 3Ø
Output Voltage Class
0…230V, 3Ø
0…230V, 3Ø
0…230V, 3Ø
0…460V, 3Ø
A Frame Ratings
0.2…0.37 kW (0.25…0.5 Hp)
0.2…0.75 kW (0.25…1 Hp)
0.2…1.5 k0W (0.25…2 Hp)
0.37…1.5 kW (0.5…2 Hp)
B Frame Ratings
0.75…1.1 kW (1…1.5 Hp)
1.5…2.2 kW (2…3 Hp)
2.2…3.7 kW (3…5 Hp)
2.2…3.7 kW (3…5 Hp)
Input Voltage Class Output Voltage Class
100…120V, 1Ø 0…230V, 3Ø
200…240V, 1Ø 0…230V, 3Ø
200…240V, 3Ø 0…230V, 3Ø
380…480V, 3Ø 0…460V, 3Ø
480…600V, 3Ø 0…575V, 3Ø
B Frame Ratings
C Frame Ratings (IP20 only)
0.4…1.1 kW (0.5…1.5 Hp)
0.4…1.5 kW (0.5…2 Hp)2.2 kW (3 HP)
0.4…3.7 kW (0.5…5 Hp)5.5…7.5 kW (7.5…10 Hp)
0.4…4.0 kW (0.5…5 Hp)5.5…11 kW (7.5…15 Hp)
0.75…4.0 kW (1…5 Hp) 5.5…11 kW (7.5…15 Hp)
Dimensions
mm (inches)
A Frame: 152 (5.98) H X 80 (3.15) W X 136 (5.35) D
B Frame: 180 (7.09) H X 100 (3.94) W X 136 (5.35) D
B Frame: 180 (7.09) H X 100 (3.94) W X 136 (5.35) D
B Frame: (IP66 - NEMA/UL Type 4X/12): 170 (10.6) H X 165 (6.50) W X 198 (7.8) D
C Frame: 260 (10.2) H X 130 (5.1) W X 180 (7.1) D
Communications
Integral RS485 with Modbus RTU/DSI
Optional:
- PROFIBUS™ DP 1
- DeviceNet™ 1.
- EtherNet/IP™ 1.
- BACnet® 1
- ControlNet™ 1.
- Bluetooth® 1.
- LonWorks™ 1.
1. Optional network for use only with External DSI Communications Kit.
Integral RS485
Optional:
- DeviceNet™ .
- EtherNet/IP™ .
- PROFIBUS™ DP
- ControlNet™ .
Flying Start
Sensorless vector control
Process PID
StepLogic™ functions (relay and timer)
PTC input compatible
Features
Additional Accessories
- LonWorks™
- BACnet®
- Bluetooth®
.
EMC line filters, Line reactors
Dynamic brake resistors, DSI cable accessories
PowerFlex, Zero Stacking, DriveExplorer, StepLogic, RSLogix and DriveTools SP are trademarks of Rockwell Automation. Trademarks not belonging to Rockwell Automation are property
of their respective companies.
Publication 22-PP001K-EN-P – January 2009
Supersedes Publication 22-PP001J-EN-P February 2008
Copyright ©2009 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

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