Technical data

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Technical Data

PowerFlex 4 and 40 AC Drives

Original Instructions

Topic Page

Product Overview 2

Reference Materials 2

Packaging and Mounting 3

Start Up, Programming and Operation 3

Optimized Performance 4

Sensorless Vector Performance 4

Sensorless Vector Control 4

Performance 4

I/O 5

Communications 5

Versatile Programming and Network Solutions 6

PC Programming Software 6

Catalog Number Explanation 8

Product Selection 9

User Installed Options 10

Installation Considerations 14

Control Wiring 15

Specifications 19

Parameter Descriptions 22

Product Dimensions 25

PowerFlex 4 and 40 Configured Drives 32

Summary of content (38 pages)

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Technical Data PowerFlex 4 and 40 AC Drives Original Instructions Topic Product Overview Reference Materials Packaging and Mounting Start Up, Programming and Operation Optimized Performance Sensorless Vector Performance Sensorless Vector Control Performance I/O Communications Versatile Programming and Network Solutions PC Programming Software Catalog Number Explanation Product Selection User Installed Options Installation Considerations Control Wiring Specifications Parameter Descriptions Product Dimensio
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PowerFlex 4 and 40 AC Drives Product Overview Providing users with powerful motor speed control in a compact, space saving design, the Allen-Bradley® PowerFlex® 4 and 40 AC drives are the smallest and most cost-effective members of the PowerFlex® family of drives. Available in power ratings from 0.2 to 11 kW (0.
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PowerFlex 4 and 40 AC Drives Packaging and Mounting • Installation can be a virtual snap using the DIN rail mounting feature on A and B frame drives. Panel mounting is also available, providing added flexibility. • 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.
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PowerFlex 4 and 40 AC Drives Optimized Performance • Removable MOV to ground provides trouble-free operation when used on ungrounded distribution systems. • A relay pre-charge limits inrush current. • Integral brake transistor, available on all ratings (except no brake version), provides dynamic braking capability with simple low cost brake resistors. • DIP switch settable 24V DC sink or source control for control wiring flexibility.
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PowerFlex 4 and 40 AC Drives Performance • Sensorless Vector Control develops high torque over a wide speed range and adapts to individual motor characteristics. • Variable PWM allows the drive to output more current at low frequencies. • Integral PID functionality enhances application flexibility. • Timer, Counter, Basic Logic and StepLogic™ functions can reduce hardware design costs and simplify control schemes. – Timer function: Relay or opto outputs controlled by drive performing timer function.
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PowerFlex 4 and 40 AC Drives Versatile Programming and Network Solutions • PowerFlex 4 and PowerFlex 40 are compatible with any device that acts as a RTU Master and supports standard 03 and 06 RTU commands. • A network can be configured using PowerFlex 40 drives with optional communication cards for high performance and flexible configuration capabilities.
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PowerFlex 4 and 40 AC Drives Use the chart below to assist in determining which product is most appropriate for an application. Feature Catalog Reference 22A (1.1) 1.5 HP/115V, 1ø (2.2) 3 HP/230V, 1ø (3.7) 5 HP/230V, 3ø (3.
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PowerFlex 4 and 40 AC Drives Catalog Number Explanation Position 1-3 4 22A – a 5 6-8 9 10 11 12 13-14 A 1P5 N 1 1 4 AA b c d e f g h a c4 e Drive Rating HIM 380-480V Three-Phase Input Code Type 22A PowerFlex 4 Code Amps kW (Hp) 22B PowerFlex 40 1P4 1.4 0.4 (0.5) 2P3 2.3 0.75 (1.0) 4P0 4.0 1.5 (2.0) 6P0 6.0 2.2 (3.0) 010 10.5 4.0 (5.0) 012 12 5.5 (7.5) 017 17 7.5 (10) 024 24 11 (15) b Voltage Rating Code Voltage Ph.
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PowerFlex 4 and 40 AC Drives Product Selection Drive Ratings Input Voltage 120V 50/60 Hz 1-Phase No Filter 240V 50/60 Hz 1-Phase NO BRAKE No Filter 240V 50/60 Hz 1-Phase NO BRAKE With Integral “S Type” EMC Filter (1) 240V 50/60 Hz 1-Phase With Integral “S Type” EMC Filter (1) 240V 50/60 Hz 1-Phase No Filter 240V 50/60 Hz 3-Phase No Filter 480V 50/60 Hz 3-Phase No Filter 600V 50/60 Hz 3-Phase No Filter kW 0.2 0.4 0.75 1.1 0.2 0.4 0.75 1.5 2.2 0.2 0.4 0.75 1.5 2.2 0.2 0.4 0.75 1.5 2.2 0.2 0.4 0.75 1.
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PowerFlex 4 and 40 AC Drives User Installed Options IP30/NEMA 1/UL Type 1 Conversion Kit Item IP30/NEMA 1/UL Type 1 Kit IP30/NEMA 1/UL Type 1 Kit with Communication Option Drive Description Frame Field installed kit. Converts drive to IP30/NEMA 1/UL Type 1 enclosure. Includes conduit box with mounting A screws and plastic top panel. B C Field installed kit. Converts drive to IP30/NEMA 1/UL Type 1 enclosure. Includes communication option B conduit box with mounting screws and plastic top panel.
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PowerFlex 4 and 40 AC Drives PC Programming Software Item Description Catalog Number DriveTools SP Software “Windows” based software package that provides an intuitive means for monitoring or configuring Allen-Bradley drives and communications adapters online and offline. Compatibility: Windows 98, ME, NT, 4.0 (Service Pack 3 or later), 2000 and XP.
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PowerFlex 4 and 40 AC Drives Dynamic Brake Resistors 3% Line Reactors Drive Ratings Input Voltage 120V 50/60 Hz 1-Phase Input Voltage 240V 50/60 Hz 3-Phase 240V 50/60 Hz 1-Phase 240V 50/60 Hz 3-Phase 480V 50/60 Hz 3-Phase 600V 50/60 Hz 3-Phase No Filter kW 0.2 0.4 0.75 1.1 0.2 0.4 0.75 1.5 2.2 0.2 0.4 0.75 1.5 2.2 3.7 5.5 7.5 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 0.75 1.5 2.2 4.0 5.5 7.5 11.0 HP 0.25 0.5 1.0 1.5 0.25 0.5 1.0 2.0 3.0 0.25 0.5 1.0 2.0 3.0 5.0 7.5 10.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.
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PowerFlex 4 and 40 AC Drives PowerFlex 4 EMC Filters Drive Ratings Input Voltage 120V 50/60 Hz 1-Phase 240V 50/60 Hz 1-Phase 240V 50/60 Hz 3-Phase 480V 50/60 Hz 3-Phase kW 0.2 0.4 0.75 0.2 0.4 0.75 1.5 0.2 0.4 0.75 1.5 2.2 3.7 0.4 0.75 1.5 2.2 4.0 HP 0.25 0.5 1.0 0.25 0.5 1.0 2.0 0.25 0.5 1.0 2.0 3.0 5.0 0.5 1.0 2.0 3.0 5.
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PowerFlex 4 and 40 AC Drives Installation Considerations PowerFlex 4 and 40 drives have the following built in protective features to help simplify installation.
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PowerFlex 4 and 40 AC Drives Control Wiring PowerFlex 4 • The control logic is 24V DC and can be set for either Sink or Source control via a DIP switch setting. • Control terminal screws are sized for a conventional blade screw driver. • I/O Terminals 1, 2 and 3 are dedicated for Stop, Start and Reverse operation respectively. These I/O Terminals can be programmed for 2- or 3-Wire operation to meet application requirements. • I/O Terminals 4 and 5 are programmable and provide added flexibility.
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PowerFlex 4 and 40 AC Drives No. R1 R2 R3 Signal Relay N.O. Relay Common Relay N.C. Sink/Source DIP Switch Default Fault – Fault Description Normally open contact for output relay. Common for output relay. Normally closed contact for output relay. Source (SRC) Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch setting. The factory installed jumper or a normally closed input must be present for the drive to start. Command comes from the integral keypad by default.
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PowerFlex 4 and 40 AC Drives PowerFlex 40 • The control logic is 24V DC and can be set for either Sink or Source control via a DIP switch setting. • Control terminal screws are sized for a conventional blade screw driver. • I/O Terminals 1, 2 and 3 are dedicated for Stop, Start and Reverse operation respectively. These I/O Terminals can be programmed for 2- or 3-Wire operation to meet application requirements. • I/O Terminals 5, 6, 7 and 8 are programmable and provide added flexibility.
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PowerFlex 4 and 40 AC Drives No. Signal Default Description R1 Relay N.O. Fault Normally open contact for output relay. R2 Relay Common – Common for output relay. R3 Relay N.C. Fault Normally closed contact for output relay. Analog Output Select DIP Switch 0…10V Sets analog output to either voltage or current. Setting must match A065 [Analog Out Sel]. Sink/Source DIP Switch Source (SRC) Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch setting.
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PowerFlex 4 and 40 AC Drives Specifications Drive Ratings — PowerFlex 4 Output Ratings Input Ratings Voltage Catalog Number kW (HP) Amps Range kVA 100…120V AC – 1-Phase Input, 0…230V 3-Phase Output 22A-V1P5N104 0.2 (0.25) 1.5 90…126 0.75 22A-V2P3N104 0.4 (0.5) 2.3 90…126 1.15 22A-V4P5N104 0.75 (1.0) 4.5 90…126 2.25 22A-V6P0N104 1.1 (1.5) 6.0 90…126 3.00 200…240V AC – 1-Phase Input, 0…230V 3-Phase Output (No Brake) (1) 22A-A1P4N103 0.2 (0.25) 1.4 180…265 0.7 22A-A2P1N103 0.4 (0.5) 2.1 180…265 1.
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PowerFlex 4 and 40 AC Drives Drive Ratings — PowerFlex 40 Output Ratings Input Ratings Voltage Catalog Number kW (HP) Amps Range kVA 100…120V AC – 1-Phase Input, 0…230V 3-Phase Output 22B-V2P3N104 0.4 (0.5) 2.3 90…132 1.15 22B-V5P0N104 0.75 (1.0) 5.0 90…132 2.45 22B-V6P0N104 1.1 (1.5) 6.0 90…132 3.0 200…240V AC – 1-Phase Input, 0…230V 3-Phase Output (1) 22B-A2P3N104 0.4 (0.5) 2.3 180…264 1.15 22B-A5P0N104 0.75 (1.0) 5.0 180…264 2.45 22B-A8P0N104 1.5 (2.0) 8.0 180…264 4.0 22B-A012N104 2.2 (3.0) 12.
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PowerFlex 4 and 40 AC Drives Input/Output Ratings Output Frequency: PowerFlex 4: 0…240 Hz (Programmable) PowerFlex 40: 0…400 Hz (Programmable) 97.5% (Typical) Efficiency: Approvals TED 966X LIS UL ® IN Control Inputs Control Output – Programmable Output (form C relay) Fuses and Circuit Breakers Protective Features Dynamic Braking Environment Control Electrical D CO T EQ N TED 966X LIS UL508C C UL ® IN CSA C 22.2 No.
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PowerFlex 4 and 40 AC Drives Parameter Descriptions Parameter Number Display Group d001 d002 d003 d004 d005 d006 d007…d009 d010 d012 d013 d014 d015 d016 d017 d018 d019 d020 d021 d022 d023 d024 d025 d026 d028 Parameter Name Output Freq Commanded Freq Output Current Output Voltage DC Bus Voltage Drive Status Fault x Code Process Display Control Source Contrl In Status Dig In Status Comm Status Control SW Ver Drive Type Elapsed Run Time Testpoint Data Analog In 0-10V Analog In 4-20mA Output Power Output Powe
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PowerFlex 4 and 40 AC Drives Parameter Number A055 Parameter Name Relay Out Sel A056 A058 Relay Out Level Opto Out1 Sel A059 A061 Opto Out1 Level Opto Out2 Sel A062 A064 A065 A066 A067 A068 A069 Opto Out2 Level Opto Out Logic Analog Out Sel Analog Out High Accel Time 2 Decel Time 2 Internal Freq A070 Preset Freq 0 A071 Preset Freq 1 A072 Preset Freq 2 A073 Preset Freq 3 A074 A075 A076 A077 A078 A079 A080 Preset Freq 4 Preset Freq 5 Preset Freq 6 Preset Freq 7 Jog Frequency Jog Accel/Decel
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PowerFlex 4 and 40 AC Drives Parameter Number Parameter Name Advanced Program Group, Continued A096 Flying Start En A097 Compensation A098 SW Current Trip A099 Process Factor A100 Fault Clear A101 Program Lock A102 Testpoint Sel A103 Comm Data Rate A104 Comm Node Addr A105 Comm Loss Action A106 Comm Loss Time A107 Comm Format A108 Language A109 Anlg Out Setpt A110 Anlg In 0-10V Lo A111 Anlg In 0-10V Hi A112 Anlg In4-20mA Lo A113 Anlg In4-20mA Hi A114 Slip Hertz @ FLA A115 Process Time Lo A116 Process Time
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PowerFlex 4 and 40 AC Drives Product Dimensions Approximate Dimensions A D C F E B G 5.5 (0.22) Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds). Frame A B C A 80 (3.15) 100 (3.94) 130 (5.1) B (1) 152 (5.98) 180 (7.09) 260 (10.2) C 136 (5.35) 136 (5.35) 180 (7.1) D 67 (2.64) 87 (3.43) 116 (4.57) E 140 (5.51 168 (6.61) 246 (9.7) F 59.3 (2.33) 87.4 (3.44) – G (2) 185 (7.28) 213 (8.39) 320 (12.6) Shipping Weight 1.4 (3.1) 2.2 (4.9) 4.3 (9.
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PowerFlex 4 and 40 AC Drives Flange Mount Drive 8 (0.31) 114 (4.49) 5.3 (0.21) 175 (6.89) 92.8 (3.65) 145 (5.71) 54.7 (2.15) 195 (7.68) 179 (7.05) 210 (8.27) 97.5 (3.84) 16 (0.63) 49 (1.93) 8 (0.31) 98 (3.86) 130 (5.12) Frame A — PowerFlex 4 only 119.3 (4.70) 214 (8.43) 145 (5.71) 6.5 (0.26) 244 (9.61) 23.5 (0.93) 197 (7.76) 210 (8.27) 225 (8.86) 250 (9.84) 98.5 (3.88) 5.3 (0.21) 22B-CCB 14 (0.55) 31 (1.22) 49 (1.93) 98 (3.86) 7.5 (0.30) 160 (6.
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PowerFlex 4 and 40 AC Drives Flange Mount Drive Continued 130.3 (5.13) 300 (11.81) 138.2 (5.44) 5.3 (0.21) 164 (6.46) 8 (0.31) 105.8 (4.17) 307.5 (12.11) 230.6 (9.08) 291.5 (11.48) 325 (12.8) 153.8 (6.06) 76.9 (3.03) 90 (3.54) 180 (7.09) 22B-CCC 8 (0.31) Frame C—PowerFlex 40 only IP 66, NEMA/UL Type 4X/12 165 (6.50) 146 (5.75) 6.5 (0.26) 46 (1.81) 23 (0.91) 270 (10.63) 198 (7.80) 253 (9.96) 28 (1.10) 124 (4.88) 89 (3.50) 22 (0.87) 82.5 (3.
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PowerFlex 4 and 40 AC Drives IP 30, NEMA/UL Type 1 Option Kit without Communication Options PowerFlex 4 uses Frames A and B. PowerFlex 40 uses Frames B and C. 59.2 (2.33) 40.0 (1.57) 20.7 (0.81) 0 22.2 (0.88) 34.0 (1.34) 75.3 (2.96) 33.0 (1.30) Frame A — 22-JBAA 79.1 (3.11) 64.1 (2.52) 40.6 (1.60) 25.6 (1.01) 107.0 (4.21) 66.0 (2.60) 24.0 (0.94) 0 22.2 (0.87) 0 28.5 (1.12) 0 22.2 (0.87) 152.2 (5.99) 109.9 (4.33) 111.2 (4.38) 74.3 (2.93) 60.0 (2.36) 33.0 (1.
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PowerFlex 4 and 40 AC Drives Dynamic Brake Resistors Dimensions are in millimeters and (inches) Frame A 30.0 (1.18) 60.0 (2.36) 31.0 (1.22) Frame A B 59.0 (2.32) Catalog Number AK-R2-091P500, AK-R2-047P500, AK-R2-360P500 AK-R2-030P1K2, AK-R2-120P1K2 C US C US 17.0 (0.67) Frame B 61.0 (2.40) 316.0 (12.44) 335.0 (13.19) 386.0 (15.20) 405.0 (15.94) SURFACES MAY BE 13.0 (0.51) Bulletin 1321-3R Series Line Reactors Dimensions are in millimeters and (inches).
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PowerFlex 4 and 40 AC Drives EMC Line Filters Frame A EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF5P7-AS, -AL; 22-RF9P5-AS, -AL; 22-RF010-AL 29.8 (1.17) 50 (1.97) 80 60 (3.15) (2.36) Frame B EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF8P0-BL, 22-RF012-BS, -BL; 22-RF018-BL; 22-RF021-BS, -BL 29.8 (1.17) 220 (8.66) 50 (1.97) 100 78 (3.94) (3.07) 217 (8.54) 208 (8.19) 17.8 (0.70) 216 (8.50) 5.5 (0.22) 24 (0.94) 17.
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PowerFlex 4 and 40 AC Drives Human Interface Module (HIM) Dimensions NEMA Type 1 Bezel – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-B1 93 (3.66) 25.2 (0.99) 11.1 (0.44) NEMA Type 4X/12 Remote (Panel Mount) HIM – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-C2S 25,0 (0.98) 93,0 (3.66) mm (in.) 180,0 (7.08) 180 (7.09) 2.0m 2m 67 (2.64) 67 (2.64) 60 (2.36) 60 (2.36) 154 (6.06) 154 (6.06) 4.8 (0.19) 4.8 (0.19) 77 (3.03) 77 (3.03) 19.1 (0.75) 19.
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PowerFlex 4 and 40 AC Drives PowerFlex 4 and 40 Configured Drives The heart of every Configured Drive is an Allen-Bradley standard drive. These world class products help to provide a single solution for virtually all of your motor speed control requirements. Configured Drive programs provide you with an offering of factory mounted options enhancing the Standard Drive program. The options defined within the programs are pre-engineered for consistency of design.
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PowerFlex 4 and 40 AC Drives Standard Features • This package integrates the PowerFlex 40 Standard Drive as the base power/control component. • Enclosure features include… – NEMA Type 4/12 and 4X (IP66) indoor and outdoor applications (1) – Heat out the back design reduces enclosure size – Viewing window-drive display and all indicators are visible. – Mounting feet-orientation is adjustable per customer requirements • The drive can be removed from the front of the enclosure for ease of assembly or repair.
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PowerFlex 4 and 40 AC Drives Drive Ratings — PowerFlex 40 Configured Drives Input Ratings Output Ratings Catalog Number kW (HP) Voltage Amps Voltage Amps 23B-D1P4 0.4 (0.5) 480 1.8 460 1.4 23B-D2P3 0.75 (1.0) 480 3.2 460 2.3 23B-D4P0 1.5 (2.0) 480 5.7 460 4.0 23B-D6P0 2.2 (3.0) 480 7.5 460 6.0 23B-D010 4.0 (5.0) 480 13.0 460 10.5 23B-D012 5.5 (7.5) 480 14.2 460 12.0 23B-D017 7.5 (10.0) 480 18.4 460 17.0 23B-D024 11.0 (15.0) 480 26.0 460 24.
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PowerFlex 4 and 40 AC Drives Specifications for Standard PowerFlex 40 Drives Electrical Voltage Tolerance: Frequency Tolerance: Displacement Power Factor: Maximum Short Circuit Rating: 120V, 200…240V, 380…480V, 460…600V: ±10% 48…63 Hz 0.
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PowerFlex 4 and 40 AC Drives Enclosure Options and Approximate Dimensions 405.9 (15.98) 9.4 (0.37) 393.2 (15.48) 355.6 (14.00) 298.5 (11.75) 336.6 (13.25) 177.8 (7.00) 69.3 (2.73) 355.1 (13.98) 342.4 (13.48) 304.8 (12.00) 285.8 (11.25) 6.35 (0.25) Optional mounting bracket orientation.
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PowerFlex 4 and 40 AC Drives P3 Option 383.3 (15.09) Frame C 16.0 (0.63) 457.2 (18.00) 425.2 (16.74) P6 Option 375.2 (14.77) 177.8 (7.00) 146.1 (5.75) 460.8 (18.14) 427.2 (16.82) 406.4 (16.00) Detail 19.1 (0.75) 9.7 (0.38) 19.1 (0.75) Rockwell Automation Publication 22-TD001I-EN-P - June 2013 12.7 (0.
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Important Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.