PowerFlex 40
PowerFlex 40 are adjustable, compact AC devices with the help of which motors can be controlled. These motor drivers work on the principle of variable frequency drive mode. In MEP, this drive is also called a sensorless vector drive. There are many variable frequency drives (VFDs) available in the market, and PowerFlex 40 drives have many advantages over others. In this guide, a detailed comparison of different models of the PowerFlex 40 series will be discussed in detail.
PowerFlex 40, PowerFlex 4, and PowerFlex 4m series are misunderstood to have the same specifications, but these series are different from each other. PowerFlex 40 is an upgraded version of PowerFlex 4 with better horsepower (up to 15 Hp at 480 volts), whereas PowerFlex 4m is a more upgraded version with different feedback functions and other features.
General Specification of PowerFlex 40
All the models of the PowerFlex 40 series have some specifications in common. These specifications are as follows.
- These devices have removable MOV, which helps to provide a trouble-free operation environment while the user must deal with ungrounded systems.
- Relay In-charge has been used to prevent an inrush current.
- They have brake transistors, which provide a low-cost solution for dynamic braking. This feature is available in every model except in the no-brake version of PowerFlex 40**.**
- 24V sink and source dip switches are available for control.
- With the help of these devices, we can control the speed of output (motors) as they have adjustable PWM frequencies of up to 16kHz.
- PowerFlex 40 AC Drives are equipped with a Sensorless Vector Control (SVC) system that can keep precise control over speed even when the output of the torque varies.
- These devices' autotune features guarantee that the controller will adjust to the motor's characteristics.
- They have excellent current regulation.
- They are extremely reliable and have a high response time.
- At 100% load, the drive will run at the synchronous speed of the motor.
1) Power Specification
Power consumption rates for each motor are different. For this reason, every motor needs a different kind of drive according to its characteristics. The following information shows us the relevant models of PowerFlex 40 that can be used depending on the power rating of the motor.
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Model Number: 22B-V2P3N104, 22B-V2P3F104, 22B-V2P3C104
- 120 volts; Single-phase; No filter; 0.4 kW; 0.5 Hp; 2.3 amperes
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Model Number: 22B-A012N114
- 240 volts; Three-phase; EMC; 2.2 kW; 3.0 Hp; 12.0 amperes
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Model Number: 22B-A5P0N104, 22B-A5P0F104, 22B-A5P0C104
- 240 volts; Single-phase; No filter; 0.75 kW; 1.0 Hp; 5.0 amperes
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Model Number: 22B-B017N104, 22B-B017F104, 22B-B017C104
- 240 volts; Three-phase; No filter; 3.7 kW; 5.0 Hp; 17.5 amperes
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Model Number: 22B-D010N104, 22B-D010F104, 22B-D010C104
- 480 volts; Three-phase; No filter; 4.0 kW; 5.0 Hp; 10.5 amperes
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Model Number: 22B-E019N104, 22B-E019F104
- 600 volts; Three-phase; No filter; 11.0 kW; 15.0 Hp; 19.0 amperes
The above-mentioned models are simple drives that can be selected depending on the requirement of the user’s applications. There are other modules of PowerFlex 40, as well in which braking transistors, have been used. These modules have 5% duty cycle-based resistors embedded inside them which stops the inrush current and provides safety to the main circuitry. Following are the complete specifications of different models.
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Model Number: AK-R2-091P500
- 120 V, Single-phase; 1.1 kW; 1.5 Hp; 48-Ohm Minimum Resistance
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Model Number: AK-R2-091P500
- 240 V, Single-phase; 1.5 kW; 2.0 Hp; 48-Ohm Minimum Resistance
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Model Number: AK-R2-047P500
- 240 V, Three-phase; 3.7 kW; 5.0 Hp; 19-Ohm Minimum Resistance
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Model Number: AK-R2-030P1K2
- 240 V, Three-phase; 5.5 kW; 7.5 Hp; 13-Ohm Minimum Resistance
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Model Number: AK-R2-120P1K2
- 480 V, Three-phase; 5.5 kW; 7.5 Hp; 55-Ohm Minimum Resistance
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Model Number: AK-R2-120P1K2
- 480 V, Three-phase; 7.5 kW; 10 Hp; 39-Ohm Minimum Resistance
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Model Number: AK-R2-120P1K2
- 480 V, Three-phase; 11..0 kW; 15.0 Hp; 24-Ohm Minimum Resistance
These modules may be equipped with a variety of accessories to boost their functionality. Inductors for DC Buses, EMC Line Filters, external series line reactors, and other Human Interface Kits like LCDs and keypads are among the modules that help with better understanding.
2) Communication Adapters
Communication is crucial for controllers and HMIs. Communication in these drives can be done with the help of external modules. There are several modules available that may be used to carry out communication. The following information provides information on communication adapters of different models which need to be ordered separately according to the requirements.
- 22-COMM-P: PROFIBUS DP
- 22-COMM-E: Ethernet/IP
- 22-COMM-D: ControlNet
- 22-COMM-B: DeviceNet
- And more
3) Communication Performance
In the previous section, the communication of drives with external devices was discussed. Internal communication, which is also referred to as operational communication is another important feature of these drives. In PowerFlex 40 drives, RS-485 protocols have been used. RS-485 protocol ensures reliable communication during operations. With the help of this protocol, 40 drives can communicate in a single channel when connected to a single controller in a single system. This mode is known as RTU mode in which different drives can communicate with each other, this mode is required in applications like HVACs where many drives work synchronously. With the help of this mode, the drives can send feedback to the controller, error codes can also be generated using the same mode, and with the help of this mode both the controller and the drives can read and understand the static logic data.
4) Performance of PowerFlex 40
There are different parameters involved in PowerFlex 40, such as.
- For high torque with wide speed arrange the performance can be achieved by SVC
- PWM helps to drive the motors at variable frequencies.
- PID enhances the flexibility of the applications.
- These drives have built-in timers, counters, basic logics, and step logics with the help of which they can work very well as compared to those drives which depend on the controller for logic. They can set their speed according to the demand of the motor, turn off the supply when there is some abnormality observed from the output side (motor), drives can accelerate and decelerate the speed on their own depending on the requirements, the feedback from the output i.e., motors help the drive to determine which step will be performed next.
5) Programming Capabilities
The programming of these drives is very versatile. One can program these drives from the devices which work on the pattern on RTU master and slave and can receive RTU commands. With the help of the DeviceNet protocol, one node of the controller can control five drives. Any controller can be used for controlling them externally which works on the RS-485 protocol.
6) Control Wiring
Control wiring is another important aspect of PLCs, SCADA, and drives. For PowerFlex 40, these control wires can be triggered at either a high or low voltage. This can be achieved by using a dip switch setting. If the dip switch is set at 1, then control wires will work on the high trigger, otherwise, they work on the low trigger. The following are the features of the control wiring of these drives.
- Start, stop, and reverse operations are assigned to input and output terminals 1, 2, and 3, respectively. Depending on the application, terminals 2 and 3 can be utilized for different applications with the assistance of programming.
- The input & output terminals 5, 6, 7, and 8 are programmable terminals. These terminals provide programmable flexibility for local control of these drives.
- These drives' output speeds may be controlled by adjusting the voltage (0-10 volts) or current (4-20 mA). Both inputs are independent and isolated from the rest of the circuitry. These features can be used for PID-related applications, and voltage input parameters can be programmed for bipolar operations.
7) Electrical Features
Some more features must be addressed in addition to those covered in the preceding sections so that the user has a thorough understanding of the drives. These features are as follows.
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Property: Frequency
- Value: 0-400 Hz
- The frequency can be controlled using PWM and can vary from 0-400 Hz through programming. There are extensions available that need to be purchased separately to increase the frequency range.
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Property: Digital Inputs (SRC)
- Value: 18-24V = ON; 0-6 V = OFF
- When working in source mode, 18-24 volts refers to as high mode, in which input state is ON and when input is 0-6 volts then the input is in OFF state.
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Property: Digital Inputs (SINK)
- Value: 0-6 V = ON; 18-24 V = OFF
- When working in sink mode, 18-24 volts, which is high mode, is set as OFF and when the input is 0-6 volts, then the input is in the ON state.
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Property: Opto Outputs (Resistive Rating)
- Value: 30 VDC; 50 mA
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Property: Opto Outputs (Inductive Rating)
- Value: Non-inductive
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Property: Analog Outputs (Resistive Rating)
- Value: 0-10 V; 1 k ohms min
- The resistance that must be set when adjusting voltage should be a minimum of 1K Ohm.
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Property: Analog Outputs (Inductive Rating)
- Value: 4-20 mA; 525 ohms max
- The maximum resistor value that can be set for current control is 525 ohms
8) Comparison Between PowerFlex 4 and PowerFlex 40
Even though the manufacturer of both drives is the same, PowerFlex 40 is preferred by most businesses since it has more functions than PowerFlex 4. Here is a comparison between the two series.
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Properties: Control Type
- PowerFlex 4: V/Hz
- PowerFlex 40: Sensorless Vector & V/Hz
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Properties: Preset Speed
- PowerFlex 4: 4
- PowerFlex 40: 8
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Properties: Process Control Loop
- PowerFlex 4: Not Available
- PowerFlex 40: Available (PID)
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Properties: Step Logic Functionality
- PowerFlex 4: Not Available
- PowerFlex 40: Available
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Properties: Time Counter Functions
- PowerFlex 4: Not Available
- PowerFlex 40: Available
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Properties: Discrete Inputs
- PowerFlex 4: 3 Fixed; 2 Fully Programmed
- PowerFlex 40: 3 Fixed; 4 Fully Programmed
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Properties: Analog Response
- PowerFlex 4: 2 Hz (500ms)
- PowerFlex 40: 100 Hz (10ms)
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Properties: Analog Outputs
- PowerFlex 4: Not Available
- PowerFlex 40: Available (can be controlled from 0-10 V or 4-20 mA)
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Properties: Skip Frequency
- PowerFlex 4: Not Available
- PowerFlex 40: Available
The key distinctions between PowerFlex 4 and PowerFlex 40 are listed above**.** PowerFlex 40 was launched with more features than PowerFlex 4.
9) Extensions and Kits for PowerFlex 40
PowerFlex 40 has additional features that may be improved by combining various kits and extensions with them. The brief descriptions of these kits and their specifications are provided below.
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Model Number: 22 JBCB and 22 JBCC
- Kits/Extensions: IP30/ NEMA 1 Kit with communication Option
- Specifications: These are field installed kits; they can enhance communication options for the drives
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Model Number: 22-HIM-C25, 22-HIM-A3, 22-WIM-N1
- Kits/Extensions: Remote HMIs
- Specifications: There are so many options in HMIs, which include LCDs and keypads, as well as optional bezel kits.
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Model Number: 22-SCM-232
- Kits/Extensions: Serial Convertor Module
- Specifications: This module is used for conversion of RS-485 to RS-232
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Model Number: 1203 - USB
- Kits/Extensions: USB Convertors
- Specifications: Provide USB connection, so that external USB can be attached for data transfer or file sharing
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Model Number: 1769 - SM2
- Kits/Extensions: Compact I/O Module
- Specifications: This module can provide 3 channels so that the drive can be used in single, multi or RTU modes.
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Model Number: 32RB001, 40RB001
- Kits/Extensions: DC BUS Inductors
- Specifications: For 240 V, 3 Phase, 50/60 Hz
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Model Number: 25RB005, 32 RB003
- Kits/Extensions: DC BUS Inductors
- Specifications: For 480 V, 3 Phase, 50/60 Hz
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Model Number: 25 RB005, 18RB005
- Kits/Extensions: DC BUS Inductor
- Specifications: For 600 V, 3 Phase, 50/60 Hz
10) EMC Filters in PowerFlex 40
EMC filters are a very important aspect of electronics. These are low-pass filters with the help of which only low-frequency signals can pass and high-frequency signals can be stopped. In variable frequency drives, EMC signals are also important. In VFDs, the user must deal with the electromagnetic noise from the output (motors). To eliminate these noises, there are EMC filters available that can increase efficiency, and hence there is minimal interference between the drive and the power supply. These filters are composed of an inductor and a capacitor. The value of these filters is set according to the specification of the drive so that the efficiency of the drive is not compromised. There are two types of filters available that can be added to the original drives to increase the efficiency of the system. The selection of an EMC filter is based on the input rating of the system. The ratings and their corresponding filter are mentioned in the information below.