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