The Versatile Choice: PowerFlex 40 Drives for Optimal Performance

PowerFlex 40 drives are low-voltage Variable Frequency Drives (VFDs) from Rockwell Automation. They are designed to provide end users, OEMs, and machine builders with performance-enhancing motor speed control in a space-saving, easy-to-use package. They are the most compact and cost-effective members of the Allen-Bradley PowerFlex family of adjustable frequency AC drives.

Available in a broad range of power ratings: 0.4 to 11 kW / 0.5 to 15 Hp, and in multiple voltage classes: 600-, 480-, 240-, and 120-Volts AC input, the PowerFlex 40 AC drives can be configured for speed control of various industrial applications, including machine tools, conveyors, pumps, material handling systems, and fans. Also, with versatile enclosure options and a simple programming structure, these drives can be quickly installed and easily configured for the previously mentioned applications.

Key Features

PowerFlex 40 Variable Frequency Drives feature the following:

• Inbuilt RS-485 serial communications for PC-based drive programming and multi-drop network configuration
• Optional PROFIBUS DP, DeviceNet, BACnet, EtherNet/IP, LonWorks, and ControlNet communication modules
• A comprehensive range of drive power ratings:
  • 100 to 120V AC, single-phase input: 0.5 to 1.5 Hp / 0.4 to 1.1 kW output power / 2.3 to 6.0 A output current
  • 200 to 240V AC, single- or three-phase input: 0.5 to 10 Hp / 0.4 to 7.5 kW output power / 2.3 to 33.0 A output current
  • 380 to 480V AC, three-phase input: 0.5 to 15 Hp / 0.4 to 11 kW output power / 1.4 to 24.0 A output current
  • 500 to 600V AC, three-phase input: 0.75 to 11 kW / 1 to 15 Hp output power / 1.7 to 19.0 A output current
• Internal EMC filtering is provided on all 230V AC single-phase drive ratings, providing an economical means of complying with EN55011, EMC Class A and B requirements.
• External EMC filters on all single-phase, 115V AC, and three-phase PowerFlex 40 AC drive ratings ensure adherence to Class A and B EMC requirements.
• Ramp regulation and drive overload protection features
• StepLogic functionality, which enables a given PowerFlex 40 drive to operate independently as a position controller
• Integral PID (Proportional-Integral-Derivative) Process Control Loop, Sensorless Vector Control, and Volts-per-Hertz (V/Hz) for basic motor speed control
• A 4-digit VFD display featuring ten additional LED status indicators. It provides an instinctive display of the drive’s operating parameters and status.
• A built-in LCD keypad that provides uncomplicated drive operation using the local control keys and potentiometer
• A UL Type 1/NEMA hand-held keypad and UL Type 4X/ NEMA remote LCD keypad, including the popular HIM CopyCat function. These keypads provide additional drive programming and control versatility.
• An optional Serial Converter Module (SCM), which enables connectivity to any Allen-Bradley Logix controller featuring a DF1 serial port or DF1 messaging capability. If the controller functions as an RTU (Remote Terminal Unit) Master, then the SCM will not be needed.
• Premier Integration of PowerFlex 40 AC drives into the Allen-Bradley Logix control platform. This helps simplify tag and parameter programming, ease drive startup and commissioning, reduce development time, and streamline diagnostics.
• Flying Start function that allows a PowerFlex 40 drive to reconnect to a spinning AC motor at the actual RPM speed
• Comparable PowerFlex 40 drive sizes are grouped into two different frame sizes (Frame Size B and Frame Size C) to simplify dimensioning, spare parts ordering, etc.
• Zero Stacking of PowerFlex 40 AC drives is permitted for ambient temperatures of up to 104°F (40°C). It is also allowable for 122°F (50°C) ambient temperatures but with negligible spacing between the drives. This helps save valuable panel space.
• NEMA/ IP20 /UL Type Open and NEMA/ IP66 /UL Type 4X-12 flange mount, plate drive, and DIN rail drive mounting options. Flange mount PowerFlex 40 VFDs with an external heatsink help reduce the enclosure size.
• An optional NEMA 1/IP30/UL Type 1 conversion kit that is easily acclimated to the standard NEMA/IP20/ UL Type Open PowerFlex 40 AC drive features, thereby providing higher environmental ratings
• UL /NEMA /Type 4X and UL/ NEMA Type 4 enclosure options

Note: Packaged PowerFlex 40 VFDs do provide additional power, enclosure, and control options in standardized designs. The options include:

• Input fuses, fused disconnect switch, bypass, and circuit breaker power options
• Enclosure options include auto/off/hand selector switch, speed potentiometer, door-mounted HIM (Human Interface Module), and status pilot lights
• Auxiliary transformer and output relay control options

PowerFlex 40 I/O

Listed below are the standard inputs and outputs that are available with PowerFlex 40 AC drives.

• Four Fully Programmable and Three Fixed Digital Inputs: They provide enhanced application versatility.
• Two Analog Inputs: One of the inputs is bipolar, while the other is unipolar. The two inputs are separately isolated from the other I/O points of PowerFlex 40 drives. Also, they can be toggled between using a digital input.
• One Form C Relay Output and Two Opto (Optocoupler) Outputs: These are programmable control outputs used to indicate various logic, motor, or drive conditions.
• One Analog Output: This is a 10-bit drive output that’s appropriate for power metering applications or as a speed reference for a second PowerFlex 40 VFD. It’s scalable and can be configured for either 0 to 20 mA current output or 0 to 10V voltage output via a DIP switch.

PowerFlex 40 Communications and Networking

PowerFlex 40 variable frequency drives support an extensive array of communication and networking solutions, including: 

• Inbuilt communication cards that help improve machine performance. These include DeviceNet, LonWorks, EtherNet/IP, ControlNet, and PROFIBUSDP Comms cards.
• Online EDS (Electronic Data Sheet) file creation using RSNetWorx software: This provides ease of drive setup on an EtherNet/IP, DeviceNet, or ControlNet network.
• A DSI (Drive Serial Interface) Wireless Interface Module (Catalog No. 22-WIM-N*): The module avails a wireless communication link between a laptop PC, desktop computer, or Pocket PC with Bluetooth technology, and any Allen-Bradley drive or power product that supports DSI communication protocol.
• Field-installed communication options that allow for future inclusion of stand-alone PowerFlex 40 drives to a network. The options include:
• PROFIBUS Communication Adapter (Catalog No. 22-COMM-P): The adapter can be installed in a PowerFlex 40 AC drive or mounted in a PowerFlex DSI (Drive Serial Interface) External Communication Kit (Cat. No. 22-XCOMM-DC-BASE). It is used in combination with an adapter cover (Cat. No. 22B-CCC for Frame C PowerFlex 40 drives or Cat. No. 22B-CCB for Frame B PowerFlex 40 VFDs).
• DeviceNet Communication Adapter (Catalog No. 22-COMM-D): The adapter is drive mounted, and it requires an adapter cover (Cat. No.  22B-CCC for Frame C PowerFlex 40 drives or Cat. No. 22B-CCB for Frame B PowerFlex 40 AC drives). It receives the needed power from the DeviceNet network and connects to the PowerFlex 40 drive.
• EtherNet/IP Communication Adapter (Catalog No. 22-COMM-E): It receives the required input power from the PowerFlex 40 VFD it is installed in. It is used alongside an adapter cover (Cat. No.  22B-CCC for Frame C PowerFlex 40 drives or Cat. No. 22B-CCB for Frame B PowerFlex 40 drives).
• ControlNet Communication Adapter (Catalog No. 22-COMM-C): It is drive mounted and used in conjunction with an adapter cover (Cat. No.  22B-CCC for Frame C PowerFlex 40 drives or Cat. No. 22B-CCB for Frame B PowerFlex 40 drives). The adapter is usually installed in a PowerFlex 40 VFD or used in a PowerFlex DSI External Communication Kit (Cat. No. 22-XCOMM-DC-BASE).

You can configure a network using PowerFlex 40 variable frequency drives incorporating the above-stated optional communication adapters for flexible configuration and high-performance capabilities. For example, you can achieve a multi-drive network solution by utilizing a single 22-COMM-D DeviceNet communication adapter that has the capacity to allow up to five PowerFlex 40 VFDs to reside on just one network node.

Note: PowerFlex 40 AC drives are compatible with any Allen-Bradley device acting as a Modbus-RTU Master and which supports 06 and 03 Remote Terminal Unit commands.

Optimized Performance

Here are the innovative features that enable PowerFlex 40 AC drives to achieve optimized motor control:

• Sensorless Vector Control: This motor control mode provides exceptional motor speed regulation and considerably high torque levels over the entire speed range of a specific PowerFlex 40 AC drive, consequently improving application performance. It’s ideal for low-speed motor control applications that require very high torque output across a wide speed range.

The Autotune feature allows PowerFlex 40 drives using sensorless vector control mode to adapt to the individual characteristics of connected motors readily.

• A Pre-charge Relay: This is a drive overload protection feature that limits inrush current.
• Variable Pulse Width Modulation (PWM): This feature allows PowerFlex 40 VFDs to output a higher amount of current at low input frequencies. The PWM frequency can be adjusted up to 16 kHz (kilohertz), ensuring quiet drive operation.
• A Configurable DIP (Dual In-line Package) Switch: The switch can be set as either a 24V DC Source or Sink. This enhances the flexibility of the drive’s control wiring, as using the DIP switch setting the 24 VDC control logic to a PowerFlex 40 drive can be set for either Source or Sink control.
• Integral PID Control: The PID process control functionality in PowerFlex 40 AC drives helps improve application flexibility.
• An in-built Brake (IGBT) Transistor: The transistor is available on all PowerFlex 40 drive ratings (except the No Brake versions). It is designed to provide dynamic braking ability using simple, low-cost braking resistors.
• Robust Overload Protection Features: PowerFlex 40 drives incorporate advanced drive overload protective features with a 200% overload capacity for 3 seconds or 150% overload capacity for 60 seconds. The drives also include an electronic motor overload protection system that provides Class 10 motor over-temperature and overload protection.
• A Removable Metal Oxide Varistor (MOV): PowerFlex 40 AC drives include a portable Metal Oxide Varistor– a voltage-dependent resistor– that’s grounded to provide protection against overvoltage surges, particularly in ungrounded power distribution systems.
• StepLogic, Timer, Basic Logic, and Counter Functions: These functions help simplify the control schemes and minimize the hardware design costs of PowerFlex 40 VFDs.
• StepLogic Function: This function provides logic-based velocity and position steps using predetermined speed settings. Users of PowerFlex 40 drives can program each step for a specific direction, speed, and acceleration/deceleration profile. The drive outputs can show which StepLogic step is being executed.
• Timer function: The timer function is executed by opto or relay outputs that are controlled by the PowerFlex 40 drive in use. It is initiated when the drive’s “Timer Start” digital input is activated.
• Basic Logic Function: In PowerFlex 40 drives, the Basic Logic function is performed by opto or relay outputs controlled by the status of the drives’ discrete inputs that are programmed as “Logic Inputs.” Its purpose is to execute basic Boolean logic.
• Counter Function: This function is executed by opto or relay outputs that are controlled by the PowerFlex 40 drive in use. It is initiated when the drive’s “Counter Input” digital input is activated.