User-Friendly and Efficient: PowerFlex 40P Drives in Industrial Environments

PowerFlex 40P are compact, low-voltage, adjustable-frequency AC drives from Rockwell Automation. They are designed to provide configurable closed-loop motor control for either position or speed feedback and optional Category 3/PLd Safe Torque-Off in a small footprint.

They are a low-cost solution for simple system integration and machine-level control applications, providing basic position control or improved speed regulation of AC motors used in an extensive range of diverse industrial machines, including fiber-spinning machines, palletizers, smart conveyors, drafting machines, de-palletizers, diverters, and packaging machines.

Main Features of PowerFlex 40P Drives

• An extensive range of power ratings:
  • 200…240V AC, three-phase input:  0.5…10 Hp / 0.4…7.5 kW output power / 2.3…33 A output current
  • 380…480V AC, three-phase input: 0.5…15 Hp / 0.4…11 kW output power / 1.4…24 A output current
  • 500…600V AC, three-phase input: 1…15 Hp / 0.75…11 kW output power / 1.7…19 A output current
• Speed regulation either without or with encoder feedback
• Dynamic braking capability with integral brake transistors
• Available in B Frame and C Frame sizes
• Advanced motor control techniques:
  • Sensorless Vector Control: This closed-loop motor control technique provides excellent speed control and higher amounts of output torque across the full speed range of a given PowerFlex 40P VFD.

With the Autotune feature, sensorless vector control allows PowerFlex 40P AC drives to adapt to the unique characteristics of connected AC motors. The control method includes encoder feedback or slip compensation for enhanced speed range and regulation.

• Volts-per-Hertz (V/Hz) Control: V/Hz is an open-loop motor control technique that enables users of PowerFlex 40P drives to select an adjustable speed or speeds, such that multiple motors can be controlled using just one PowerFlex 40P AC drive. This method also provides a much smoother motor startup with drive-controlled starts.
• Process PID Control: PowerFlex 40P AC drives feature integral PID (Proportional-Integral-Derivative) functionality, which enhances application flexibility.
• Integral RS-485 serial communications and support for a wide variety of optional communication cards
• Robust drive overload and surge protection features, such as a pre-charge relay circuit that limits inrush current and a removable Metal Oxide Varistor (MOV) that’s connected to the ground for surge protection
• Flying start and ramp regulation functions
• A DIP (Dual Inline Package) switch, configurable as a 24V DC source or sink, for control wiring flexibility
• Drive programming and configuration via a remote keypad, an integral LCD keypad, or certain software
• StepLogic Function that allows a PowerFlex 40P AC drive to operate as a standalone position controller
• A 4-digit display operator interface with three additional LED status indicators and a reset/scroll button
• Optional remote PC interface or Human Interface Modules (HIMs) for status monitoring and drive programming
• A Safe-Torque-Off (STO) safety option that is certified at SIL2 (Safety Integrity Level 2) Category 3/PLd (Performance Level d)
• Versatile mounting and packaging options:
  • Flexible PowerFlex 40P packaging options allow for IP66/NEMA 4 (with enclosure of similar rating) and IP30/NEMA 1 panel mount using the flange/plate-type PowerFlex 40P Variable Frequency Drives (VFDs).
  • Plate-type PowerFlex 40P VFDs also allow for a 75% cutback in enclosed Watts by reducing the required enclosure size.
  • Standard IP20/Type Open/NEMA flange mount and plate drive configurations. An optional NEMA 1/IP30 conduit box can be integrated with these mounting configurations to enhance the environmental ratings.
  • B Frame PowerFlex 40P drives include DIN rail and panel mounting features, which provide added installation flexibility.
  • Zero Stacking is permitted for up to 40°C ambient temperatures, resulting in valuable space savings
  • All PowerFlex 40P drive ratings come with external EMC/AC line filters to comply with EN55011, Class B, and A Electromagnetic Compatibility (EMC) requirements.

PowerFlex 40P Communications

PowerFlex 40P drives include inbuilt RS-485 serial communication cards that connect the drives in multi-drop network configurations. The RS-45 communication cards also enable PC-based drive programming. Other integral communication cards incorporated in PowerFlex 40P VFDs include ControlNet, PROFIBUSDP, DeviceNet, LonWorks, and EtherNet/IP cards. These communications do help improve drive performance.

The drives also have a DSI (Digital Serial Interface) Wireless Interface Module (WIM) that enables wireless communications between a desktop, laptop, or pocket PC fitted with Bluetooth technology and any DSI-enabled Allen-Bradleyproduct.

In addition, PowerFlex 40P AC drives also support ControlNet, PROFIBUSDP, DeviceNet, LonWorks, and EtherNet/IP optional communication cards, which provide flexible configuration and high-performance capabilities. With the DeviceNet option card, you can obtain a multi-drive solution using only one PowerFlex 40P adjustable frequency drive; for this setup to work, the DeviceNet option module used should be able to let up to five AC drives to occupy one network node.

Note: PowerFlex 40P variable frequency drives are compatible with any peripheral device that serves as a Modbus RTU Master and supports 16, 03, and 06 RTU commands. A serial converter module (SCM) is required to provide a communication link to any Allen-Bradleycontroller with a DF1 serial port. However, if the controller functions as a Modbus RTU Master, the SCM can be done away with.

PowerFlex 40P I/O

To meet the speed, torque, and position control requirements for various industrial motor/drive applications, PowerFlex 40P AC drivers are available with the following input and output points:

• 2 Semi-Programmable Digital Inputs: These inputs are dedicated to drive start and stop functions. They also help simplify drive wiring and troubleshooting.
• 1 Analog Input: This input point can be configured for current or voltage input using a DIP switch. It’s also isolated from the other drive I/O points and can be set to bipolar mode for better zero-cross performance.
• 5 Fully-Programmable Digital Inputs: They provide application flexibility with 27 different standard settings, nine additional settings for basic positioning enhancements and Fibers/Textiles applications, and fully programmable Reverse DI.
• 1 Analog Output: This is a scalable analog output point ideal for metering tasks or use as a speed reference for a different PowerFlex 40P VFD. A DIP switch can be calibrated for either current (0…20 mA) or voltage (0…10V) output.
• 2 Opto Outputs and 1 Programmable Form C Relay Output: These digital outputs indicate a wide array of motor or drive conditions.

Common Industrial Applications

Allen-Bradley PowerFlex 40P variable frequency drives are popularly used in the following industries:

Textiles and Fibers Industry

PowerFlex 40P drives incorporate specific functions that make them suitable for low-cost textile and fiber applications: roving machines, texturing and draw/twist machines, drafting machines, synthetic fiber and ring spinning machines, fiber winders, and carding machines. The added features exclusive to such applications include:

• Synched input ramps
• 4 Acceleration/Deceleration ramps and eight preset speeds
• Up to 500Hz output frequency
• Induction or synchronous motor control capability
• Calculation and display of slip in connected AC induction motors
• 24/12/5V DC pulse train input
• Improved pre-charge control for the drives’ Common DC Bus
• Selectable 1/2 DC Bus/line voltage operation, ideal for use in critical industrial applications requiring continuous drive output even under low voltage or brownout conditions
• Inherent current breaking and increased ride-through capacity
• +/-0.3% base speed regulation across an 80:1 drive speed range with encoder feedback
• Standard UL Type 1/NEMA/IP30 plate drive, panel mount, and flange mount options
• Standard P-Jump and traverse functions

Beverage and Brewing Industry

In the beverage and brewing industry, PowerFlex 40P VFDs are widely used in smart conveyors, palletizers, and simple indexing machines (like mixers, etc.) to precisely control the speed, torque, and position of the AC motors powering such systems/machines.

To provide a cost-effective and reliable solution for process control in this industry, the PowerFlex 40P AC drives are equipped with the following features:

• Category 3 Safe-Torque-Off function:
  • For improved zone control
  • With the DriveGuard safety solution, the Category 3 STO function combines safety with zone control to reduce the components required in a PowerFlex 40P drive system. This increases equipment/personnel safety, productivity, and cost savings.  
• An embedded high-resolution, compact encoder that:
  • Helps reduce the number of dedicated sensors used to track the position of beverage products during the production process
  • Offers better process control and higher reliability, permitting different process control instructions to be changed spontaneously
  • Provides local logic capacity with speed/position control based on the StepLogic Function

Automotive Industry

PowerFlex 40P drives are used in automotive manufacturing for simple indexing, controlling smart conveyor systems, and other VFD applications that require Category 3 Safe-Torque-Off function in conformity with EN 954-1 safety standard.

The following features are included in PowerFlex 40P AC drives to make them capable of handling the demanding application requirements of the automotive industry:

• Category 3 Safe-Torque-Off function:
  • To improve zone control
  • To reduce component count in PowerFlex 40P drive systems to ensure compliance with Cat 3 EN 954-1 safety standards
• A compact built-in encoder that:
  • Enables Sensorless Vector Control with encoder feedback, leading to increased process reliability
  • Functions as a position regulator, reducing the number of sensors required to control automotive manufacturing processes
  • Provides StepLogic (local logic) capability for digital input-based or time-based positioning

Note: The above-stated features also enable the PowerFlex 40P variable frequency drives to be used in palletizers, de-palletizers, smart conveyors, diverters, and packaging equipment for material handling and packaging uses.

PowerFlex 40P Benefits

Here are some of the benefits of using PowerFlex 40P AC drives in industrial environments:

• Application versatility as the drives have a comprehensive range of features, such as support for diverse industrial network protocols, flexible packaging and mounting options, fully programmable digital inputs, an inbuilt PID functionality, several motor control techniques, etc.
• Minimal panel space requirements due to the drives’ compact design
• Installation flexibility with panel mount, plate drive, flange mount, and DIN rail mounting options
• Ease of use with the user-friendly4-digit display operator interface, featuring LED status indicators and a reset/scroll button
• Remote monitoring using a remote PC interface or Human Interface Module
• Increased productivity resulting from precise speed/position control, enhanced process reliability, and improved equipment safety with the Cat 3 STO safety option and DriveGuard safety solution
• Reduced unplanned downtime due to increased visibility of machine level and system data, advanced diagnostics, and faster troubleshooting capabilities
• Higher system efficiency attributed to the inclusion of a Common DC Bus in PowerFlex 40P VFDs
• Cost savings because of reduced enclosure size thatallows for a 75% scale-down in enclosed Watts, as well as due to simplified drive programming and configuration and reduced wiring requirements