PowerFlex 4M Selection Guide
PowerFlex 4M adjustable frequency AC drives are more compact and economical as compared to other PowerFlex AC drives families. This space-saving AC drive family is ideal for controlling the speed of machines and meeting the requirements of global OEMs. It is also suitable for users who require feed-through wiring and little hassle of programming. This family of drives comes with a user-friendly design that reduces mechanical machine stress and increases application versatility. This family includes drives with various frame sizes (A, B, and C), voltage classes, and power ratings from 0.2 kilowatts to 11 kilowatts.
This guide discusses the features of PowerFlex 4M drives that will help users to select a suitable drive model according to their application requirements.
Salient Features of PowerFlex 4M AC Drives:
Some of the most significant features of PowerFlex 4M are as follows.
Inputs and Outputs:
The PowerFlex 4M drive has 5 standard discrete inputs with an input voltage rating of 24 volts Sink/Source. The following are the discrete inputs:
- Stop
- Start/Run FWD
- Direction/Run REV
- Fully Programmable
- Fully Programmable
It has 1 unipolar analog input with a resolution of 10 bits and a scan time of 12 milliseconds. This input can be used as voltage input ranging from 0 to 10 volts or current input ranging from 4 to 20 milliamperes.
The PowerFlex 4M drive has only one Form C Relay discrete output.
Size:
Allen-Bradley’s PowerFlex 4M AC drive series is designed to effectively control the speed of the motor while maintaining a small overall drive size.
Control Specifications:
PowerFlex 4M drives are by default configured for the Volts per Hertz (V /Hz) operating mode. A single PowerFlex 4M drive can control multiple motors while operating in Volts /Hertz mode.
When using the V/Hz motor control mode, the supply voltage (V) and frequency are maintained at a constant ratio (Hz). As a result, changing the supply voltage's frequency has an impact on the motor's speed and its magnetic field's intensity. An excessive amount of heat is produced, for instance, when the supply voltage frequency is decreased for slower motor speeds. On the other hand, when the motor's speed rises, raising the voltage frequency weakens the magnetic field.
Improved Speed Regulation:
PowerFlex 4M drives include a feature that offers Auto Boost and Slip Compensation. Improved speed regulation is a result of this feature even when the load is increasing. This drive series only offers open-loop speed regulation.
Control Voltage:
These drives need a control voltage of 24 volts (sink or source).
Speed Presets:
The PowerFlex 4M AC drive family has four preset speeds.
Operating Voltages:
Each drive from this series has a specific operating voltage and corresponding power rating. Examples include 0.25 to 1.5 horsepower at 100 to 120 volts AC, 0.25 to 1.5 horsepower at 200 to 240 volts AC, 0.5 to 15 horsepower at 38 to 480 volts AC, and so on.
Communication Protocols:
It's crucial to consider communication protocols while working with AC drives. To control a motion system effectively, the drive must communicate not only with the primary controller but also with the inputs, outputs, and other parallel devices. PC to drive communication can be done in a variety of ways. They all help in extracting the data from the product and programming it.
All the drives from the PowerFlex 4M series come with an integral RS-485 serial port. Internal RS-485 communications are supported by this port.
Besides the integrated RS485 communication protocol, several communication protocols can be used by attaching compatible communication modules to these drives. Some of the Communication Protocols available for these drives are listed below.
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Communication Protocol: DF1
- Catalog Number: 22-SCM-232
- Serial Converter Module (SCM) enables RS-232/DF1 to RS-485/DSI communications
-
Communication Protocol: BACnet
- Catalog Number: 22-XCOMMDC-BASE with 22-COMM-B adapter
- Use for network communications.
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Communication Protocol: ControlNet
- Catalog Number: 22-XCOMMDC-BASE with 22-COMM-C adapter
- Open industrial network protocol. Use for network communications.
-
Communication Protocol: DeviceNet
- Catalog Number: 22-XCOMMDC-BASE with 22-COMM-D adapter
- Application-level protocol. Use for network communications.
-
Communication Protocol: EtherNet/IP
- Catalog Number: 22-XCOMMDC-BASE with 22-COMM-E adapter
- Use for network communications. Higher Bandwidth than ControlNet.
-
Communication Protocol: LonWorks
- Catalog Number: 22-XCOMMDC-BASE
- Node communicating with other nodes. Use for network communications.
-
Communication Protocol: Modbus RTU
- Standard RS485/DSI = Modbus RTU
-
Communication Protocol: PROFIBUS DP
- Catalog Number: 22-XCOMMDC-BASE with 22-COMM-P adapter
- Standard Fieldbus communication. Use for network communications.
-
Communication Protocol: USB
- Catalog Number: 1203-USB
- Use for Peripherals Connections
Zero Stacking:
It is possible to mount many drives next to one another with no spacing between them. Zero stacking allows for saving valuable space on panels.
Environmental Specifications:
These adjustable frequency AC drives can perform well within a temperature range of -10 to 50 degrees Celsius (℃). However, the operating temperature is -10 to 40 degrees Celsius (℃) for IP 20 zero stacking drives. The drivers can be stored at temperatures between - 40 and 85 degrees Celsius (℃).
Feed-through Wiring:
In Feed-through wiring, the motor is linked to the bottom of the AC drive and the line voltage is connected to the top.
This design has two primary benefits:
- Feed-through wiring is the ideal choice for small retrofit applications needing variable speed control.
- It is both affordable and time efficient.
Circuitry Protection:
These drives must be properly safeguarded and protected to reduce the risk of damage.
The recommended fuses and circuit breakers, depending on the user's application, that can be installed for the protection of these drives are listed below.
- IEC British standard, EN60269-1, UL class RK 1. (fuses)
- IEC and UL (circuit breakers)
Human-Machine Interface:
PowerFlex 4M supports the following HMI options:
- IP66-rated remote (Panel Mount) liquid crystal display with digital speed control for indoor use.
- IP30-rated remote Handheld (Panel Mount) LCD with full numeric keypad for operator input, digital speed control, and more.
- IP30-rated remote handheld (Panel Mount) wireless interface module featuring Bluetooth technology.
- IP66-rated remote handheld (Panel Mount) wireless interface module featuring Bluetooth technology for indoor use.
Ease of Setup:
Users can use the multidrop network configuration enabled by RS485 connections for ease of setup. A NEMA/UL Type 4X remote control and a NEMA/UL Type 1 handheld LCD keypad.
Safe Operation:
These drives are equipped with removable metal oxide varistors (MOV) to protect the drive against voltage surges. MOV also guarantees safe and reliable operation with ungrounded or resistive distribution systems.
Limited Inrush Current:
These drives avoid the inrush current by relay pre-charge.
Brake Transistor:
Dynamic braking transistors are used in AC drives to disperse regenerated energy and prevent overvoltage failures. Frame C drives from PowerFlex 4M series have an integral brake transistor that makes dynamic braking efficient while keeping the cost minimum using cost-effective brake resistors.
Overloading:
These drives can withstand 150% overloading for 60 seconds and 200% overloading for 3 seconds.
Additional Functionalities:
An intellectual operation is performed on these drives with the help of potentiometer and control keys, provided with the integrated keypad. A 4-digit display with 10 additional LED indicators is used to display the actual status and condition of the drive. A NEMA/UL Type 4X remote and NEMA/UL Type 1 hand-held LCD keypad provide additional flexibility.
General Specifications:
Some general specifications of PowerFlex 4M are listed below.
- Power Wiring: Feed through
- Flying Start: Yes
- Bus Regulator: Yes
- S - Curve: Yes
- Drive Overload Protection: Yes
- Frequency Control: 400 Hz Max
- PWM Frequency: 2 - 10 kHz
- Open Loop Accuracy: +/- 2%
- Volt Tolerance: +/- 10%
- Frequency Tolerance: 47 - 63 Hz
- Zero Stacking: Yes
- Removable MOV to Ground: Yes
- Dimensions (Height x Width x Depth):
- Frame A: 174 mm x 72 mm x 136 mm
- Frame B: 174 mm x 100 mm x 136 mm
- Frame C: 260 mm x 130 mm x 180 mm
Remarks
PowerFlex 4M has been widely used in an industry where motor control is an important factor. PowerFlex 4M series is an upgraded version of the PowerFlex 4. One can use PowerFlex 4M to replace PowerFlex 4 for better control, accuracy, and precision.