PowerFlex 4 Selection Guide
The PowerFlex 4 AC drive series by Allen-Bradley is the most compact and affordable product of the PowerFlex drive series. This drive offers consumers strong motor speed control in a small, space-saving design. As a standard motor control setting, these drives are equipped with a Volts-per-Hertz setting.
PowerFlex 4 AC drives with versatile architecture provide a wide range of features and settings customized for particular applications, and they are designed to meet the demands of OEMs and end users from all over the world. It provides solutions to control the speed of motors while making the system convenient and inexpensive. These drives also minimize mechanical strain on a system involving motor control, such as fans, pumps, conveyors, and tool systems for manual handling machines.
Consumers of PowerFlex 4 drives can benefit from its user-friendly interface, tools with a local potentiometer, and built-in keypad. Moreover, the Logix control platform is also used in this drive series to facilitate parameter and tag programming.
PowerFlex 4 Power Ratings
PowerFlex 4 AC drives come with different power consumption ratings ranging from 0.25 to 5.0 Hp (0.2 to 3.7 kW), with the following input voltage ratings:
- 100 to 200V AC: 0.25 to 1.5 Hp or 0.2 to 1.1kW with a current rating of 1.5 to 6 A
- 200 to 240V AC: 0.25 to 5 Hp or 0.2 to 3.7 kW with a current rating of 1.4 to 17.5 A
- 380 to 480V AC: 0.5 to 5 Hp or 0.4 to 3.7 kW with a current rating of 1.4 to 8.7 A
Specifications
- Output Power: Ranging from 0.2kW to 3.7kW
- Input Voltage: 100 to 120 V AC (single-phase), 200 to 240V AC (single-phase), 200 to 240V AC (three-phase), 380 to 480V AC (three-phase)
- Input Frequency: 48 to 63 Hz
- The output Frequency ranges from 0 and 240Hz and is programmable
- 4 pounds
- Frame Size: A and B
- Tpical efficiency is 97.5%
- The inherent keypad has 10 extra LED indicators, in addition to the 4-digit display.
- It has RS-485 integral communication, which gives its user an advantage in programming a drive from a Personal Computer and configuring a multi-drop network.
Key Features of PowerFlex 4 Drives
Motor Control Type
The PowerFlex 4 drives are set to operate in the V/Hz (Volts per Hertz) mode by default. When using this control mode for the motor, the supply voltage (V) and frequency (Hz) are maintained at a constant ratio (V/Hz). As a result, changing the supply voltage's frequency has an impact on the motor's speed, as well as its magnetomotive force (MMF). When the regularity of the supply voltage is dropped for slower speeds of the motor rotor, for example, the magnetic field rises, resulting in increased heat generation.
However, as the motor speed jumps, a reduction in the magnetic field intensity results from increased voltage frequency. A single PowerFlex 4 drive can control various motors in Volts/Hertz mode.
Importantly, these drives have an auto-drive mode that offers Auto Boost and Slip Compensation (IR Compensation). The improved speed regulation is enabled by this function even when the load is rising. Also, it provides enough torque and superb speed regulation throughout the PowerFlex drive's full-speed range. That has four preset speeds, a 24V Sink/Source control voltage requirement, and only offers open-loop speed regulation.
Power Wiring
With bottom-fed wiring, the line current and the motor are concluded at the base of the AC drive in PowerFlex 4 drives.
Inputs/Outputs
The following details show the input and output configuration for PowerFlex 4 drives:
- Standard Digital Inputs
- 5 to 24V Sink and Source input, Three Fixed Start, Stop, and Reverse input pins, and Two Fully Programmable input ports
- Analog Input Pins
- One Unipolar input with voltage input (0 to 10V), or current input (4 to 20 mA)
- Digital Output Pins
- One Form C-type Relay Output
- Analog Output Pins
- None The scan rate for PowerFlex 4 drives in case of a digital input is 2 milliseconds, while for that of an analog input, the scanning time is 12 milliseconds and 10 bits. Remember, the mentioned input scanning time is not the throughput time. Also, with the PowerFlex 4 series drives, neither the analog output resolution nor the analog output scan time is available.
Frame Sizes
There are two different frame sizes for the Allen-Bradley’s PowerFlex 4 AC drive series: A and B. The two frames are made available with the following measurements:
- For PowerFlex 4 A-Frame: 152 mm x 80 mm x 136 mm (height x width x depth)
- For PowerFlex 4 B-Frame: 180 mm x 100 mm x 136 mm (height x width x depth)
Instant Mounting and Installation
The drive can be mounted upright on a flat, vertical, or level surface in the following ways:
DIN-rail Mounting
Both frame A and B drives are built with convenient DIN-rail mounting features that make installation practically possible in seconds. The DIN-rail compatibility takes far less time than traditional screw-in mounting.
Flange and Plate Mounting
Furthermore, the two-drive series also offers panel mounting, adding even more installation possibilities. Drives with a flange mount and a plate mount are also available in the PowerFlex 4 series.
Debris Fence
The drive is designed with a plastic top lid. The user should install the panel to stop debris from falling into the drive housing's vents while it is being installed.
Zero Stacking
The PowerFlex 4 series is built for zero-stacking, which allows many drives to be placed next to each other with no space between them. Even in the zero-stacking arrangement, the drive’s cover opens completely, allowing easy installation access to the cables. The maximum ambient temperature, permitted for all frame sizes, is 40°C (104°F).
Integral Filtering
All 230V single-phase rated drives provide integral filtering, which offers a practical way to fulfill EN 55011, group A and B EMC protocols. For all members of the PowerFlex 4 family, external filters are designed and built to comply with Class A and B electromagnetic compatibility (EMC) protocols.
Environmental Specifications
With little spacing between the drives, the operating temperature range for the IP20-certified PowerFlex 4 series ranges from -10°C to 50°C. The operational ambient temperature should fall between -10°C and 40°C for NEMA 1-rated AC drives. Additionally, any PowerFlex drive that isn't being used should be kept in an area with a storage temperature ranging from -40°C to 85 °C. Allen Bradley recommends its users not store the device in a corrosive environment.
Installation Preparations
- Users need to verify that all inputs are secure and linked to the appropriate terminals.
- Users must also confirm that the disconnect device's AC line power falls within the drive's rated value.
- Ensure that any digital control power has a voltage of 24 volts.
- Make sure that the control wiring scheme matches the settings on the Sink/Source Setup DIP Switch.
- If the Stop input is missing, the drive won't turn on.
- Apply AC power and regulate the drive's voltages.
- Before adjusting any of the Program Group parameters, become familiar with the built-in keypad features.
- Direct control of start, stop, direction change, and speed is possible from the keypad without any programming.
Starting and Setting Up the Drive
It is quite easy and convenient to use PowerFlex 4 drives in multi-drop network configurations and information sharing, thanks to the inherent RS-485 connections.
The PowerFlex 4 series has a NEMA/UL Type 4X far-flung, embedded LCD (Liquid Crystal Display) keypad, and a NEMA/UL Type 1 portable LCD keypad. The local built-in LCD or remote keyboard can be employed to program and configure any one of the drive models.
Moreover, users can use PC-based programming tools to program, monitor, and operate PowerFlex 4 drives. On top of that, there is a module named Serial Converter Module, which offers communication to controllers having a DF1 port, which substantially simplifies the programming of the drive. A 4-digit display with 10 extra LED indications provides a convenient way to see information and power status.
Optimized Performance
A PowerFlex 4 drive can be installed in underground distribution systems because its removable MOV to the ground ensures trouble-free operation. A relay pre-charge minimizes the inrush current.
Apart from the model with no brakes, integral brake transistors are available on all levels and offer dynamic braking capability using basic, economical brake resistors. The DIP switch is programmable with a 24-volt DC sink or source control, and it is designed for flexible control wiring.
Strong 150 percent overload protection is offered for 60 seconds or 200 percent overload for 3 seconds. The drive manages quiet operation with its adjustable PWM frequency of up to 16 kHz.
Sensorless Vector Performance
- Slip and auto-boost (IR compensation) are provided by the drive automatically.
- Offers high degrees of speed regulation for the whole speed range of drive, and efficient speed control even with increased loading.
Communications and Versatile Programming
PowerFlex 4 AC drives are available with an integral RS-485 serial port as a standard characteristic. This port enables embedded RS-485 communications. The Modbus RTU is the typical way used to enable RS-485 serial communications in the two-drive series. Accordingly, ratings of all PowerFlex 4 products are made compatible with any device working as an RTU Master, while supporting standard 6 and 3 RTU commands.
Similarly, a Serial Conversion Module (RS-485 to RS-232) with the catalog number 22-SCM-232 is included with PowerFlex 4 AC drives. This SCM gives DF1 serial contact to any controller capable of opening DF1 messaging, like RS-232 or DF1 to RS-485 or DSI communications. It is important to notice that whenever the organizer in use serves as an RTU Master, then this Serial Converter Module can also be removed or separated.
The module can be implemented with PC-based software as well. The following are properties of an efficient, self-powered serial converter (RS-232):
- One DSI to RS-232 serialized converter
- One 22-RJ45CBL -C20 Cable
- One 1203-SCF Cable
The energy-saving drives can be used in multi-drop network configurations with integral RS-485/DSI connections.
For improving machine performance, one can install optional essential communication cards to the drive. These cards cannot be employed except with a DC-BASE outside mounting kit and an outside DSI kit for communications for 22 x comm adapters. These drives can work with a few communication cards:
- EtherNet/IP
- DeviceNet
- ControlNet
- And more
Furthermore, with a USB Converter, PowerFlex 4 drives can handle USB contacts. For use with PC-based software, this converter runs direct and separate USB connections. Notably, the USB converter must come with a USB wire (having a 2-meter length), one 22-HIM-H10 wire, and one 20-HIM-H10 wire.
Fuses and Circuit Breakers
The PowerFlex 4 series of products do not offer protection against branch short circuits. Either input fuses or an input circuit breaker should be used to install these devices. Additional criteria for these systems may be determined by local and national industrial safety rules and/or electrical codes.
Fuses
PowerFlex 4 drives have passed UL testing for use with input fuses. The ratings listed below are the minimum values that should be used with each drive rating. The equipment specified is offered as a general reference only.
- UL – RK1, or T, UL Class J
- IEC – Type BS 88 (British Standards); 600V (or 550V) or equal
UL489 Circuit Breakers/Bulletin 140M (Combination Controller with Self-Protection)
Allen Bradley recommended users of PowerFlex 4 drives adhere to some instructions to meet the NEC standards relating to the protection of branch circuits while employing Bulletin 140M or UL489-certified circuit breakers.
Both single and group motor applications can employ Bulletin 140M. It doesn't require fuses when utilized upstream from the drive.
- Only use input fuse UL Class T, J, CC, or Type BS88, 600V, or equivalent for division circuit protection.
- Connect a series fuse, type PV, 1000V fast-acting or equivalent, with the dynamic brake resistor.
EMC Instructions
To reduce electromagnetic noise transference between a PowerFlex drive and the main power supply, electromagnetic compatibility (EMC) filters are required. This ensures that the equipment being operated by the drive won't be impacted by electromagnetic interference.
Some PowerFlex 4 drives powered with single-phase signal of 230V power ratings are available with internal EMC filters. This inherent EMC filtering serves as a practical way to comply with EN55011, Class A, and class B Electromagnetic Compatibility (EMC) regulations. For all PowerFlex 4 drive grades, external EMC filters are also designed and made available, and they guarantee compatibility with Class A and Class B EMC regulations.
Precautions
For desired performance and safety of equipment, it is recommended to:
- Save the drive’s cooling fan from getting dusty and exposed to metallic particles.
- Do not expose it to a corrosive environment.
- Prevent the drives from getting wet.
- Keep the drives out of harsh sunlight.
- Use only copper wires.
- Use wire with an insulation strength of 600V or higher.
- Control and signal wires must be at least 0.3 meters away from power wires (1 foot).
- Use only the suggested line fuses/circuit breakers to prevent damage to Installation. Moreover, one must follow guidelines for wire types, conductor sizes, branch circuit protection, and disconnect devices. If you don't, you risk damaging your equipment and/or suffering bodily injuries or property.
- Unused wires in the conduit must be grounded at both ends to minimize a possible shock risk caused by induced voltages.
- The drive must only be controlled by the Digital Input Terminal Blocks and must not be used with any other DSI or network device.