Bulletin 160 to PowerFlex 4M, 4 & 40 Conversion Guide

Bulletin 160 to
PowerFlex® 4M, 4 & 40 Conversion Guide
Rockwell Automation’s Technical Representatives and highly trained
Distributor Drives Specialists will help you transition to the New,
World-Class PowerFlex 4M, 4 or 40 AC Drive
Overview of PowerFlex 4M
Providing users with powerful
motor speed control in a
compact, space saving design,
the Allen-Bradley PowerFlex
4M AC drive is the smallest
and most cost effective
member of the PowerFlex
family of drives. Ideal for
machine level speed control,
the PowerFlex 4M drive
C Frame
provides the application
B Frame
A Frame
Ratings from
Ratings from
versatility to meet the
Ratings to
7.5 to 10 HP @ 230V
3 to 5 HP
2 HP
&
demands of global OEMs and
@ 230V & 460V
7.5 to 15 HP @ 460V @ 230V & 460V
end users who require space
savings and easy-to-use AC
drives that provide application flexibility, feed-through wiring and ease-ofprogramming.
The PowerFlex 4M AC drive is available in three frame sizes (A, B and C) and power
ratings from 0.2 to 11 kW (0.25 to 15 Hp) and in voltage classes of 120, 240 and 480
volts.
Product Features
•
DIN Rail Mounting Design
•
Feed-through Wiring Design
•
Versatile Programming and Network Solutions
•
Energy Savings with Speed Control and Regulation
Contents
•
Specifications and Features - page 3
•
Dimensions - page 7
•
Terminal Block Comparison - page 9
•
Communications - page 11
•
Software - page 12
2
Specifications and Features
Drive Model
Catalog Number
120V
240V, 1-Phase
240V, 3-Phase
Power Ratings
480V
575V
Normal Duty Overload
Continuous
1 Minute
3 Seconds
Heavy Duty Overload
Continuous
1 Minute
3 Seconds
Power Wiring
Frequency Control
PWM Frequency
Enclosures Types
Specifications
Ambient Temp
Bulletin 160
160-AAxxxx
N/A
0.5-2 HP
(0.37-1.5 kW)
0.5-5 HP
(0.37-4.0 kW)
0.5-5 HP
(0.37-4.0 kW)
N/A
PowerFlex 4M
22F-xxxxxxxx
0.25 - 1.5 HP
(0.2 - 1.1 kW)
0.25 - 3 HP
(0.2 - 2.2 kW)
0.25 - 10 HP
(0.2 - 7.5 kW)
0.5 - 15 HP
(0.4 - 11 kW)
N/A
PowerFlex 4
22A-xxxxxxxx
0.25-1.5 HP
(0.2-1.1 kW)
0.25-3 HP
(0.2-2.2 kW)
0.25-5 HP
(0.2-3.7 kW)
0.5-5 HP
(0.4-3.7 kW)
N/A
PowerFlex 40
22B-xxxxxxx
0.5-1.5 HP
(0.4-1.1 kW)
0.5-3 HP
(0.4-2.2 kW)
0.5-10 HP
(0.4-7.5 kW)
0.5-15 HP
(0.4-11 kW)
1-15 HP
(0.75-11 kW)
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
100%
150%
200% for 30 Sec.
Feed through
240 Hz Max.
2-8 kHz
Open, Type IP20,
Type 12/4/4X
IP40/54/65 all
Frames Heatsink
Out the Back
100%
150%
200% for 3 Sec.
Feed through
400 Hz Max
2 - 10 kHz
Open, Type IP20
100%
150%
200% for 3 Sec.
Bottom Fed
240 Hz Max.
2-16 kHz
Open, Type IP20,
Type 1 IP30 (with
kit), Type 1/12/4/
4X IP40/54/65 all
Frames Heatsink
Out the Back
–10° to 50° C
100%
150%
200%
Bottom Fed
400 Hz Max.
2-16 kHz
Open, Type IP20,
Type 1 IP30 (with
kit), Type 1/12/4/
4X IP40/54/65 C
Frame Heatsink
Out the Back
–10° to 50° C
±2% across 40:1
Speed Range,
with Slip Comp.
N/A
N/A
N/A
1% across 80:1
Speed Range,
with Slip Comp.
N/A
15 Hp
N/A
0° to 50° C Open –10° to 50° C
0° to 40° C IP66
(NEMA 12/4/4X)
Torque Control
Open Loop Accuracy N/A
Closed Loop Accuracy N/A
Speed Control
Open Loop Accuracy 1% - 40:1
Closed Loop Accuracy
HP w/DC Link Choke
HP w/AC line Choke
Volt Tolerance
Frequency Tolerance
Compliance Marks
Maximum Altitude
±2% across 40:1
Speed Range,
with Slip Comp.
N/A
N/A
N/A
N/A
N/A
N/A
±10%
47-63 Hz
CE, UL, cUL, C-Tick
1000m
3
Specifications and Features (continued)
Bulletin 160
160-AAxxxx
External-1ø,
External-3ø
Heatsink Out the Back Yes, All Frames
Zero Stacking
Yes
Internal DB Transistor Yes, all Frames
Hardware
Drive Model
Catalog Number
EMC Filtering
PowerFlex 4
22A-xxxxxxxx
Internal-1ø,
External-3ø
Yes, All Frames
Yes
0.5-5 HP
PowerFlex 40
22B-xxxxxxx
Internal-1ø 230V
only, External- 3ø
Yes, All Frames
Yes
0.5-15 HP
No
PowerFlex 4M
22F-xxxxxxxx
Internal - 1ø & 3ø,
External - 3ø
No
Yes
C frame only (7.5
HP and higher)
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
No
1
0
0
1
No
Yes
Yes
Yes
No
100,000A
No
100,000A
No
100,000A
N/A
100,000A
5 - 24V Sink/
Source (3 - Start/
Stop/Reverse, 2 Fully Prog.)
1 unipolar (0-10 V
or 4-20 mA)
5 - 24V Sink/
Source (3 - Start/
Stop/Reverse, 2 Fully Prog.)
1 Unipolar (0-10V
or 4-20 mA)
Discrete Outputs
3 - 24V Sink/
Source (Start/
Stop/Prog. Input
Mode)
1 - (Bipolar 0-10
V or Unipolar 420 mA)
1-Form C Relay
Analog Outputs
No
No
No
Pulse Output
Optional I/O Voltage
PTC Input
Encoder Input
Pulse Input
Additional I/O
Input Timer / Counter
Functions
Output Timer /
Counter Functions
Encoder Output
No
115V
No
No
No
N/A
No
No
N/A
No
No
No
N/A
No
No
N/A
No
No
No
N/A
No
7 -- 24V Sink/
Source (3 - Start/
Stop/Reverse, 4 Fully Prog.)
1 Bipolar, ±10V or
4-20 mA, 1
Unipolar 4-20mA
1-Form C Relay,
2-optos
1 - (0-10V or 4-20
mA)
No
N/A
Yes (Analog In)
No
No
No
Yes
No
No
No
No
No
No
No
No
Internal DB Resistor
Option
Encoder Input
Standard
Additional Feedback
Options
Number of Comms.
Supported
Simultaneously in
Drive
Removable MOV to
Ground
Safe-Off
Max. Short Circuit
Rating
Standard Discrete
Inputs
Inputs/Outputs
Analog Inputs
4
1 - Form C Relay 1-Form C Relay
Specifications and Features (continued)
HIM Information
Input/Output Specifications
Drive Model
Catalog Number
Digital Input Scan
Time (Not Through
Put Time)
Analog Input
Resolution
Analog Input Scan
Time (Not Through
Put Time)
Analog Output
Resolution
Analog Output Scan
Time (Not Through
Put Time)
HIM - Local LCD
HIM - Remote LCD
HIM - Hand-held
HIM - CopyCat
function
HIM - Languages
HIM - Local LED
Features
HIM - Auto/ Manual
function
Motor Control Type
Flying Start
Bus Regulator
S - Curve
Drive Overload
Protection
Advanced Diagnostics
Input Phase Loss
User Sets
Preset Speeds
Process Control Loop
Fast Flux Up
Fast Brake to Stop
Flux Braking
Feedback Loss
Switchover
Battery Back-up
Multi-Motor
Parameters
Bulletin 160
160-AAxxxx
10m seconds
PowerFlex 4M
22F-xxxxxxxx
2 ms
PowerFlex 4
22A-xxxxxxxx
2 ms
PowerFlex 40
22B-xxxxxxx
1 ms
10 Bit
10 Bit
10 Bit
10 Bit
8 ms
12 ms
12 ms
10 ms
N/A
N/A
N/A
10 Bit
N/A
N/A
N/A
10 ms
V/Hz
(7) Remote HIM
Yes, including pot
and control keys
No (Yes - Remote
HIM)
V/Hz
(7) Remote HIM
Yes, including pot
and control keys
No (Yes-Remote
HIM)
V/Hz
No
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
No
Yes
Yes
(7) Remote HIM
Yes, including pot
and control keys
No (Yes-Remote
HIM)
V/Hz and
Sensorless
Vector
Yes
Yes
Yes
Yes
4
No
4
No
8
PID
No
Yes
Yes
Yes
(1) Remote HIM
Yes, including pot
and control keys
No
No
No
No
8
Yes
No
No
No
No
No
No
5
Specifications and Features (continued)
Application Features
Drive Model
Catalog Number
SynchLink
Motion Controller
Inertia Adaptation
Power Up Time
Speed Profiles
Position Control
6
P-jump (traverse
function)
Lifting Application
Winder Application
Electronic Gearing/
Line Shaft
Bulletin 160
160-AAxxxx
No
No
No
0.8 Sec.
No
No
No
No
No
No
PowerFlex 4M
22F-xxxxxxxx
PowerFlex 4
22A-xxxxxxxx
PowerFlex 40
22B-xxxxxxx
1.5-2.5 Sec.
No
No
1.5-2.5 Sec.
No
No
1.5-2.5 Sec.
Step Logic
Basic, Using
Digital Input
Dimensions
Bulletin 160
Frame/
Height
HP
mm
A/0.5-3
152
B/5
192.5
Width
mm
80
92
Depth
mm
165.4
193.3
PowerFlex 4
Frame/
Height
HP
mm
A/0.5-2
152
B/3-5
180
Width
mm
80
100
Depth
mm
136
136
PowerFlex 4M
Frame/
Height
HP
mm
A/0.5- 2 174
B/3-5
174
C/7.5-10 260
Width
mm
72
100
130
Depth
mm
136
136
180
PowerFlex 40
Frame/
Height
HP
mm
B/0.5-5
180
C/7.5-15 260
Width
mm
100
130
Depth
mm
136
180
7
Torque Performance
Drive
Bulletin 160
Notes
Reflects
optimized
parameter
settings
PowerFlex 4M
Reflects factory
default settings
PowerFlex 4
Reflects factory
default settings
PowerFlex 40
Reflects factory
default settings
8
Terminal Comparison
Terminal Designation
Description
Input AC Line - R(L1)
Input AC Line - S(L2)
Input AC Line - T(L3)
Motor - U (T1)
Motor - V (T2)
Motor - W (T3)
Brake Resistor
Brake Resistor
DC Bus –
DC Bus +
DC Bus Inductor Connection
DC Bus Inductor Connection
Motor Ground
Drive Ground
Analog Input 1 Comm.
Analog Input 1 (+/–)
Shield
Analog Input 2 Comm.
Analog Input 2 (+/-)
Analog Input 3 (NTC-) Com.
Analog Input 3 (NTC+)
Shield
Analog Output 1 (–)
Analog Output 1 (+)
Analog Common
Analog Output 2 (–)
Analog Output 2 (+)
+10v Reference
Reference Common
–10V Reference
Encoder A
Encoder A (Not)
Encoder B
Encoder B (Not)
Encoder Z
Encoder Z (Not)
Bulletin 160
R (L1)
S (L2)
T (L3)
U (T1)
V (T2)
W (T3)
BR+
BR–
DC–
DC+
PowerFlex 4M
R (L1)
S (L2)
T (L3)
U (T1)
V (T2)
W (T3)
BR+
BRDCDC+
PowerFlex 4
R (L1)
S (L2)
T (L3)
U (T1)
V (T2)
W (T3)
BR+
BR–
PE
PE
3
2 - (0-10V)
PE
PE
14
13
PE
PE
14
13
12
14
12
14
PowerFlex 40
R (L1)
S (L2)
T (L3)
U (T1)
V (T2)
W (T3)
BR+
BR–
DC–
DC+
P2 (C Frame Only)
P1 (C Frame Only)
PE
PE
14
13
19
3
4 - (4-20 mA)
1
3
12
14
9
Terminal Comparison (continued)
Terminal Designation
Description
Encoder Reference (+)
Encoder Reference (–)
Encoder Shield
24V DC Common (–)
24V DC Source (+)
Digital/Relay Output 1(N.O)
Digital/Relay Output 1Com.
Digital/Relay Output 1(N.C)
Digital/Relay Output 2 (N.O)
Digital/Relay Output 2 Com.
Digital/Relay Output 2 (N.C)
Digital/Relay Output 3 (NC)
Digital/Relay Output 3 Com.
Digital/Relay Output 3 (NO)
Digital/Relay Output 4 (NC)
Digital/Relay Output 4 Com.
Digital/Relay Output 4 (NO)
Digital Input 1-3 Comm.
Digital Input 1
Digital Input 2
Digital Input 3
Digital Input 4-6 Comm.
Digital Input 4
Digital Input 5
Digital Input 6
Digital Input 7
Digital Input 8
Digital Input 9
Digital Input 10
48V Control Power Supply
+24V User Output
Drive Enable (Secure
Disable Function)
HW PTC Input 1
HW PTC Input 2
10
Bulletin 160
PowerFlex 4M
PowerFlex 4
PowerFlex 40
11
R1
R2
R3
11
R1
R2
R3
11
R1
R2
R3
7
11
10
9
17
18
7
5
6
8
Enabled could be
terminal #8
4
1
2
3
4
5
6
4
1
2
3
4
5
6
4
1
2
3
4
5
6
7
8
Communications
Product Model
Number
DF1
Bulletin 160 PowerFlex 4M
Yes
Yes (with SCM
adapter)
AS-i
No
No
BACnet
No
Yes (with X-Comm)
CANopen
No
No
CC-Link
No
No
ControlNet
No
Yes (with X-Comm)
Data Highway
No
No
Yes
Yes (with X-Comm)
DeviceNet
Ethernet
No
No
EtherNet/IP
No
Yes (with X-Comm)
FIP I/O
No
No
Foundation Fieldbus No
No
Yes
No
Interbus
LonWorks
No
Yes (with X-Comm)
Metasys N2
No
No
Modbus ASCII
No
No
Modbus Plus
No
No
Modbus RTU
No
Yes (Standard)
Modbus TCP/IP
No
No
Yes
Yes (with X-Comm)
PROFIBUS DP
PROFINET
No
No
Remote I/O
No
No
SERCOS
No
No
Siemens P1
No
No
Uni-Telway
No
No
USB
No
Yes (with USB
converter)
PowerFlex 4
Yes (with SCM
adapter)
No
Yes (with X-Comm)
No
No
Yes (with X-Comm)
No
Yes (with X-Comm)
No
Yes (with X-Comm)
No
No
No
Yes (with X-Comm)
No
No
No
Yes (Standard)
No
Yes (with X-Comm)
No
No
No
No
No
Yes (with USB
converter)
PowerFlex 40
Yes (with SCM
adapter)
No
Yes
No
No
Yes
No
Yes
No
Yes
No
No
No
Yes
No
No
No
Yes (Standard)
No
Yes
No
No
No
No
No
Yes (with USB
converter)
11
Software
Description
Software Versions
Connectivity
Select Features
Used With …
12
Software Feature
Full version
'Lite' version
Pocket PC version
Palm version
Serial Point-to-Point
Serial Multi-drop
Ethernet Direct
ControlNet
DeviceNet
Profibus DP
Bluetooth
WiFi
Other / Proprietary
Offline capability
Setup Wizards
Diagram Views
User-created Views
I/O Terminal Configuration
Control
Oscilloscope / Graph
Project Management
Flash
File Conversion Tool
On-line Help
Multi-language
DriveTools SP/DriveExplorer
Yes
Yes (freeware)
Yes
No
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
No
Yes
Yes
Yes
English only
PowerFlex 7-Class, PowerFlex 4Class, SMC Flex, 160, SCANportbased products
Notes
13
Support Information
Distributor Sticker Here
Rockwell Automation Office Sticker Here
Rockwell Automation-Mequon
Tel: (1) 262.512.8200
Internet
Drives Home Page
(www.ab.com/drives)
Literature Library
(www.rockwellautomation.com/literature)
Drives Service & Support Page
(www.ab.com/support/abdrives)
PowerFlex Public Forum
(www.ab.com/support/abdrives)
PowerFlex Private Forum
(www.ab.com/support/abdrives)
Energy Savings Information
(http://www.ab.com/drives/energy_savings/index.html)
14