• PowerFlex® 4 and 40


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PowerFlex® 4 and 40
Technical Data
ADJUSTABLE FREQUENCY AC DRIVES
PowerFlex 4 and 40 Technical Data
Product Overview
Providing users with powerful motor speed control in a compact, space saving
design, the Allen-Bradley® PowerFlex® 4 and 40 AC drives are the smallest
and most cost-effective members of the PowerFlex® family of drives. Available
in power ratings from 0.2 to 11 kW (0.25 to 15 HP) and in voltage classes of
120, 240, 480 and 600 volts, PowerFlex 4 and 40 are designed to meet global
OEM and end-user demands for flexibility, space savings, ease of use and are
cost-effective alternatives for speed control of applications such as machine
tools, fans, pumps and conveyors and material handling systems
Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
Packaging and Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Start Up, Programming and Operation . . . . . . . . . . . . . . . . . . . . . . . .3
Optimized Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Sensorless Vector Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Sensorless Vector Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Versatile Programming and Network Solutions . . . . . . . . . . . . . . . . .6
PC Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Product Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
User Installed Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Product Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
PowerFlex 4 and 40 Configured Drives . . . . . . . . . . . . . . . . . . . . . .31
Reference Materials
For additional PowerFlex 4 and 40 data and general drive information, refer to the following publications:
Title Publication Available Online at . . .
PowerFlex 4 User Manual 22A-UM001… www.rockwellautomation.com/literature
PowerFlex 40 User Manual 22B-UM001…
Wiring and Grounding Guidelines for PWM AC Drives DRIVES-IN001…
Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001…
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1
For other information, contact Allen-Bradley Drives Technical Support:
Title Online at . . .
Allen-Bradley Drives Technical Support www.ab.com/support/abdrives
Shaded areas are applicable to PowerFlex 40 only.
2 Publication 22-TD001G
PowerFlex 4 and 40 Technical Data
Packaging and Mounting
• Installation can be a virtual snap using the DIN rail mounting feature on A
and B frame drives. Panel mounting is also available, providing added
flexibility.
• Flange mount drives are available to reduce overall enclosure size.
• Zero Stacking™ is allowable for ambient temperatures up to 40°C, saving
valuable panel space. 50°C ambient temperatures are permitted with
minimal spacing between drives.
• Integral filtering is available on all 230V single phase ratings, providing a
cost-effective means of meeting EN55011, Class A and B EMC
requirements. External filters provide compliance to Class A and B
requirements for all PowerFlex 4 and 40 ratings.
• An optional IP30, NEMA/UL Type 1 conduit box is easily adapted to the
standard IP20 (NEMA Type Open) product, providing increased
environmental ratings.
• IP66, NEMA/UL Type 4X/12 (Indoor) for mounting directly in the
product environment. Listed by UL to resist dust, dirt, etc. and survive high
pressure water spray. Also certified by NSF to ensure conformity with
international food equipment standards.
Start Up, Programming and Operation
• An integral keypad provides out of the box operation using the local
potentiometer and control keys.
• The 10 most common application parameters are contained in the Basic
Program Group, making programming fast and easy.
• The programming keys have the same function as all other PowerFlex
drives, so if you can program one PowerFlex drive, you can program them
all.
• 4 digit display with 10 additional LED indicators provides an intuitive
display of drive status and information.
• Integral RS-485 communications can be used for programming from a
PC. It can also be used in a multi-drop network configuration. A serial
converter module provides connectivity to any controller with a DF1 port.
• A NEMA/UL Type 4X remote and NEMA/UL Type 1 hand-held LCD
keypad provide additional programming and control flexibility, both
featuring the popular CopyCat function.
Publication 22-TD001G 3
PowerFlex 4 and 40 Technical Data
Optimized Performance
• Removable MOV to ground provides trouble-free operation when used on ungrounded
distribution systems.
• A relay pre-charge limits inrush current.
• Integral brake transistor, available on all ratings (except no brake version), provides dynamic
braking capability with simple low cost brake resistors.
• DIP switch settable 24V DC sink or source control for control wiring flexibility.
• 150% overload for 60 seconds or 200% overload for 3 seconds provides robust overload
protection.
• Adjustable PWM frequency up to 16 kHz ensures quiet operation.
Sensorless Vector Performance
PowerFlex 4
• Drive automatically provides auto boost (IR
compensation) and slip compensation.
• Provides excellent speed regulation and high levels of
torque across the entire speed range of the drive, and
improved speed regulation even as loading increases.
Sensorless Vector Control
AB PowerFlex 40 3Hp - High Speed
PowerFlex 40 3.0
2.5
Torque (Per-Unit)
• Sensorless Vector Control provides exceptional speed 2.0
regulation and very high levels of torque across the 1.5
entire speed range of the drive. 1.0
0.5
• The Autotune feature allows the PowerFlex 40 to adapt
0.0
to individual motor characteristics. 0 10 20 30 40 50 60 70 80 90 100
Frequency (HZ)
Performance
• This graph depicts the ability of a PowerFlex 40 drive to
accelerate into at least 150% load. A PowerFlex 4 will Current
perform similarly, but with a slightly higher acceleration
time.
Speed
• At 100% motor load, the drive will run the motor at
synchronous speed.
Torque
• Excellent current regulation.
• Linear acceleration.
• Best in class digital input response time and repeatability.
4 Publication 22-TD001G
PowerFlex 4 and 40 Technical Data
Performance
• Sensorless Vector Control develops high torque over a wide speed range
and adapts to individual motor characteristics.
• Variable PWM allows the drive to output more current at low frequencies.
• Integral PID functionality enhances application flexibility.
• Timer, Counter, Basic Logic and StepLogic™ functions can reduce
hardware design costs and simplify control schemes.
- Timer function: Relay or opto outputs controlled by drive performing
timer function. Timer is initiated by activating a digital input
programmed as “Timer Start.”
- Counter function: Relay or opto outputs controlled by drive
performing counter function. Counter function is activated by a digital
input programmed as “Counter Input.”
- Basic Logic: Relay or opto outputs controlled by status of digital inputs
programmed as “Logic Inputs.” Performs basic Boolean logic.
- StepLogic: Logic-based steps using preset speed settings. Each step can
be programmed for a specific speed, direction and accel/decel profile.
Drive outputs can be used to indicate which step is being performed.
I/O
Analog Signal Follwer
• Two (2) Analog Inputs (one unipolar and one bipolar) are Drive 1 Drive 2
independently isolated from the rest of the drive I/O. These inputs Analog Out Analog In
can be toggled between via a digital input.
• Three (3) fixed and four (4) fully programmable Digital Inputs -/+ 10V 13
Common 14 Common 14
provide application versatility.
+ 16
• One (1) Analog Output is DIP switch selectable for either 0-10V
or 0-20mA. This scalable, 10-bit output is suitable for metering or
as a speed reference for another drive.
• Two (2) Opto Outputs and one (1) form C relay output can be
used to indicate various drive, motor or logic conditions.
Communications
• Integral communication cards such as DeviceNet™, EtherNet/IP™,
PROFIBUS™ DP, LonWorks® and, ControlNet™ can improve machine
performance.
• The DSI Wireless Interface Module (WIM) provides a wireless
communication interface between a Pocket PC, laptop computer or desktop
computer equipped with Bluetooth® wireless technology, and any Allen-
Bradley® product supporting the DSI™ protocol.
• Field installed option allows for future addition of stand-alone drives to a
network.
• Online EDS file creation with RS NetWorx™ providing ease of set-up on a
network.
Publication 22-TD001G 5
PowerFlex 4 and 40 Technical Data
Versatile Programming and Network Solutions
• PowerFlex 4 and PowerFlex 40 are compatible
with any device that acts as a RTU Master and
supports standard 03 and 06 RTU commands.
• A network can be configured using PowerFlex 40
drives with optional communication cards for high RTU
performance and flexible configuration up to 31 PowerFlex 4 or PowerFlex 40 drives
capabilities. Network Communication
- BACnet Node 1 Node 2 Node 3
- ControlNet
- DeviceNet
PowerFlex 40 PowerFlex 40 PowerFlex 40
- EtherNet/IP with Comms card with Comms card with Comms card
- LonWorks DeviceNet
- PROFIBUS DP
• A multi-drive solution can be reached using a
single PowerFlex 40 DeviceNet option, with the
ability for up to five (5) drives to reside on one (1) RTU
node. up to 4 PowerFlex 4 or PowerFlex 40 drives
• Integral RS485 communications enable the drives
to be used in a multi-drop network configuration.
A serial converter module (SCM) provides
connectivity to any controller with a DF1 port. The DF1
RTU
SCM can be eliminated if the controller acts as a
up to 31 PowerFlex 4 or PowerFlex 40 drives
RTU Master. SCM
PC Programming Software
Through the use of a Serial Converter Module and
DriveExplorer™ or DriveTools™ SP software,
programming can be greatly simplified.
DriveExplorer Software
• View and modify drive and adapter parameters in a
method similar to the file management capability of
Microsoft Windows Explorer.
• Operate the drive via an on-screen Control Bar,
which is a tool that allows you to start, stop, and
change the speed reference of the drive.
• Save, restore and print parameter information.
• Compare current parameters with factory defaults
or previously saved parameter values.
• Edit, upload and download parameters.
DriveTools SP Software
• Online and offline programming capability
• In-grid and dialog-based parameter editing
• Immediate visual indication of drive and communication status when viewing online drive
• Integrated HTML Help architecture
6 Publication 22-TD001G
PowerFlex 4 and 40 Technical Data
Use the chart below to assist in determining which product is most appropriate for an application.
Feature
Catalog Reference 22A… 22B…
Maximum (kW)HP Rating/Input Voltage (1.1)1.5 HP/115V, 1ø (1.1) 1.5 HP/115V, 1ø
(2.2) 3 HP/230V, 1ø (2.2) 3 HP/230V, 1ø
(3.7) 5 HP/230V, 3ø (7.5) 10 HP/230V, 3ø
(3.7) 5 HP/460V, 3ø (11.0) 15 HP/460V, 3ø
(11.0) 15 HP/600V, 3ø
Overload Capacity 150% for 60 seconds 150% for 60 seconds
200% for 3 seconds 200% for 3 seconds
IP30, NEMA/UL Type 1 Option ● ●
IP66, NEMA/UL Type 4X/12 (Indoor) ●➋
EMC Filtering Internal - 1ø, 230V Internal - 1ø, 230V
External - All 1ø, 115V and 3ø Ratings External - All 1ø, 115V and 3ø Ratings
DIN Rail Mounting Standard ● ●
(Through 5 HP)
Integral Keypad with Speed Pot ● ●
Keypad - Remote LCD ● ●
Keypad CopyCat Function ● ●
Control Type V/Hz Sensorless Vector & V/Hz
Internal DB Transistor ● ●
Not available on no brake models.
Preset Speeds 4 8
Carrier Frequency 2-16 kHz 2-16 kHz
Skip Frequency ●
Process Control Loop ●
(PID)
StepLogic Functionality ●
Timer/Counter Functions ●
Control Voltage 24V sink/source 24V sink/source
Discrete Inputs 3 fixed for START/STOP/REV 3 fixed for START/STOP/REV
2 fully programmable 4 fully programmable
Analog Input - Unipolar 1 2
(0-10V or 4-20 mA) (0-10V and 4-20 mA)
Analog Input - Bipolar 1
(+/- 10V) ➌
Analog Response 2 Hz (500 ms) 100 Hz (10 ms)
Relay Output 1 - N.O/N.C. dry contact 1 - N.O./N.C. dry contact
Digital/Optocoupler Output 2
Analog Output ●
(0-10V or 4-20 mA)
Integral RS485 ● ●
RS232 (Requires use of Serial Converter Module) ● ●
BACnet ●➊ ●
ControlNet ●➊ ●
DeviceNet ●➊ ●
EtherNet/IP ●➊ ●
LonWorks ●➊ ●
PROFIBUS DP ●➊ ●
➊ With 22-XCOMM-DC-BASE External mounting kit.
➋ Frame B only.
➌ When using bipolar input, the 0-10V unipolar input cannot be used.
Publication 22-TD001G 7
PowerFlex 4 and 40 Technical Data
Catalog Number Explanation
Position
1-3 4 5 6-8 9 10 11 12 13-14
22A – A 1P5 N 1 1 4 AA
a b c d e f g h
a c4 e
Drive Rating HIM
Code Type 380-480V Three-Phase Input Code Interface Module
22A PowerFlex 4 Code Amps kW (Hp) 1 Fixed Keypad
22B PowerFlex 40 1P4 1.4 0.4 (0.5)
2P3 2.3 0.75 (1.0) f
b 4P0 4.0 1.5 (2.0)
Emission Class
6P0 6.0 2.2 (3.0)
Voltage Rating Code Rating
010 10.5 4.0 (5.0)
Code Voltage Ph. 0 Not Filtered
012 12 5.5 (7.5)
V 120V ac 1 1 Filtered
017 17 7.5 (10)
A 240V ac 1
024 24 11 (15)
B 240V ac 3 g
D 480V ac 3
Brake IGBT
E 600V ac 3 c5
Code Description
Rating
3 Without Brake
c1 460-600V Three-Phase Input
4 With Brake
Code Amps kW (Hp)
Rating
1P7 1.7 0.75 (1.0)
100-120V Single-Phase Input
3P0 3.0 1.5 (2.0) h
Code Amps kW (Hp)
4P2 4.2 2.2 (3.0) Optional
2P3 2.3 0.4 (0.5)
6P6 6.6 4.0 (5.0) Code Purpose
5P0 5.0 0.75 (1.0)
9P9 9.9 5.5 (7.5) Reserved for custom
6P0 6.0 1.1 (1.5) AA through ZZ
firmware
012 12 7.5 (10)
019 19 11 (15)
c2
Rating
d
200-240V Single-Phase Input
Enclosure
Code Amps kW (Hp)
Code Enclosure
2P3 2.3 0.4 (0.5)
C IP66, NEMA/UL Type 4X *
5P0 5.0 0.75 (1.0)
Flange Mount - IP20, NEMA/UL
8P0 8.0 1.5 (2.0) F
Type Open
012 12 2.2 (3.0)
Replacement Plate Drive - IP20,
NEMA/UL Type Open
H
Contact factory for ordering
c3 information.
Rating Panel Mount - IP20, NEMA/UL Type
200-240V Three-Phase Input N
Open
Code Amps kW (Hp)
* Check availability before ordering.
2P3 2.3 0.4 (0.5)
5P0 5.0 0.75 (1.0)
8P0 8.0 1.5 (2.0)
012 12 2.2 (3.0)
017 17.5 3.7 (5.0)
024 24 5.5 (7.5)
033 33 7.5 (10)
8 Publication 22-TD001G
PowerFlex 4 and 40 Technical Data
Product Selection
Drive Ratings PowerFlex 4 IP 20 Flange PowerFlex 40 IP 66, UL Type IP 20 Flange
Mount ➋ 4X Panel Mount Mount ➋
Input Voltage kW HP Output Catalog Frame Catalog Output Catalog Frame Catalog Catalog Number
Current Number Size Number Current Number Size Number
120V 50/60 Hz 0.2 0.25 1.5A 22A-V1P5N104 A 22A-V1P5F104 — — — — —
1-Phase 0.4 0.5 2.3A 22A-V2P3N104 A 22A-V2P3F104 2.3A 22B-V2P3N104 B 22B-V2P3C104 22B-V2P3F104
No Filter
0.75 1.0 4.5A 22A-V4P5N104 B 22A-V4P5F104 5.0A 22B-V5P0N104 B 22B-V5P0C104 22B-V5P0F104
1.1 1.5 6.0A 22A-V6P0N104 B 22A-V6P0F104 6.0A 22B-V6P0N104 B 22B-V6P0C104 22B-V6P0F104
240V 50/60 Hz 0.2 0.25 1.4A 22A-A1P4N103 A — — — — — —
1-Phase 0.4 0.5 2.1A 22A-A2P1N103 A — — — — — —
NO BRAKE
0.75 1.0 3.6A 22A-A3P6N103 A — — — — — —
No Filter
1.5 2.0 6.8A 22A-A6P8N103 B — — — — — —
2.2 3.0 9.6 22A-A9P6N103 B — — — — — —
240V 50/60 Hz 0.2 0.25 1.4A 22A-A1P4N113 A — — — — — —
1-Phase 0.4 0.5 2.1A 22A-A2P1N113 A — — — — — —
NO BRAKE
0.75 1.0 3.6A 22A-A3P6N113 A — — — — — —
With Integral
“S Type” EMC 1.5 2.0 6.8A 22A-A6P8N113 B — — — — — —
Filter ➊ 2.2 3.0 9.6 22A-A9P6N113 B — — — — — —
240V 50/60 Hz 0.2 0.25 1.5A 22A-A1P5N114 A — — — — — —
1-Phase 0.4 0.5 2.3A 22A-A2P3N114 A — 2.3A 22B-A2P3N114 B — —
With Integral
0.75 1.0 4.5A 22A-A4P5N114 A — 5.0A 22B-A5P0N114 B — —
“S Type” EMC
Filter ➊ 1.5 2.0 8.0A 22A-A8P0N114 B — 8.0A 22B-A8P0N114 B — —
2.2 3.0 — — — — 12.0A 22B-A012N114 C — —
240V 50/60 Hz 0.2 0.25 1.5A 22A-A1P5N104 A 22A-A1P5F104 — — — — —
1-Phase 0.4 0.5 2.3A 22A-A2P3N104 A 22A-A2P3F104 2.3A 22B-A2P3N104 B 22B-A2P3C104 22B-A2P3F104
No Filter
0.75 1.0 4.5A 22A-A4P5N104 A 22A-A4P5F104 5.0A 22B-A5P0N104 B 22B-A5P0C104 22B-A5P0F104
1.5 2.0 8.0A 22A-A8P0N104 B 22A-A8P0F104 8.0A 22B-A8P0N104 B 22B-A8P0C104 22B-A8P0F104
2.2 3.0 — — — — 12.0A 22B-A012N104 C — 22B-A012F104
240V 50/60 Hz 0.2 0.25 1.5A 22A-B1P5N104 A 22A-B1P5F104 — — — — —
3-Phase 0.4 0.5 2.3A 22A-B2P3N104 A 22A-B2P3F104 2.3A 22B-B2P3N104 B 22B-B2P3C104 22B-B2P3F104
No Filter
0.75 1.0 4.5A 22A-B4P5N104 A 22A-B4P5F104 5.0A 22B-B5P0N104 B 22B-B5P0C104 22B-B5P0F104
1.5 2.0 8.0A 22A-B8P0N104 A 22A-B8P0F104 8.0A 22B-B8P0N104 B 22B-B8P0C104 22B-B8P0F104
2.2 3.0 12.0A 22A-B012N104 B 22A-B012F104 12.0A 22B-B012N104 B 22B-B012C104 22B-B012F104
3.7 5.0 17.5A 22A-B017N104 B 22A-B017F104 17.5A 22B-B017N104 B 22B-B017C104 22B-B017F104
5.5 7.5 — — — — 24.0A 22B-B024N104 C — 22B-B024F104
7.5 10.0 — — — — 33.0A 22B-B033N104 C — 22B-B033F104
480V 50/60 Hz 0.4 0.5 1.4A 22A-D1P4N104 A 22A-D1P4F104 1.4A 22B-D1P4N104 B 22B-D1P4C104 22B-D1P4F104
3-Phase 0.75 1.0 2.3A 22A-D2P3N104 A 22A-D2P3F104 2.3A 22B-D2P3N104 B 22B-D2P3C104 22B-D2P3F104
No Filter
1.5 2.0 4.0A 22A-D4P0N104 A 22A-D4P0F104 4.0A 22B-D4P0N104 B 22B-D4P0C104 22B-D4P0F104
2.2 3.0 6.0A 22A-D6P0N104 B 22A-D6P0F104 6.0A 22B-D6P0N104 B 22B-D6P0C104 22B-D6P0F104
3.7 5.0 8.7A 22A-D8P7N104 B 22A-D8P7F104 — — — — —
4.0 5.0 — — — — 10.5A 22B-D010N104 B 22B-D010C104 22B-D010F104
5.5 7.5 — — — — 12.0A 22B-D012N104 C — 22B-D012F104
7.5 10.0 — — — — 17.0A 22B-D017N104 C — 22B-D017F104
11.0 15.0 — — — — 24.0A 22B-D024N104 C — 22B-D024F104 ➌
600V 50/60 Hz 0.75 1.0 — — — — 1.7A 22B-E1P7N104 B 22B-E1P7C104 22B-E1P7F104
3-Phase 1.5 2.0 — — — — 3.0A 22B-E3P0N104 B 22B-E3P0C104 22B-E3P0F104
No Filter
2.2 3.0 — — — — 4.2A 22B-E4P2N104 B 22B-E4P2C104 22B-E4P2F104
4.0 5.0 — — — — 6.6A 22B-E6P6N104 B 22B-E6P6C104 22B-E6P6F104
5.5 7.5 — — — — 9.9A 22B-E9P9N104 C — 22B-E9P9F104
7.5 10.0 — — — — 12.0A 22B-E012N104 C — 22B-E012F104
11.0 15.0 — — — — 19.0A 22B-E019N104 C — 22B-E019F104
➊ This filter is suitable for use with a cable length of at least 10 meters for Class A and 1 meter for Class B environments.
➋ Meets IP40/54/65 (NEMA 1/12/4/4X) when installed in an enclosure of like rating.
➌ Requires use of external DC Bus Inductor or AC Line Reactor.
Shaded areas are applicable to PowerFlex 40 only.
Publication 22-TD001G 9
PowerFlex 4 and 40 Technical Data
User Installed Options
IP30/NEMA 1/UL Type 1 Conversion Kit
Item Description Drive PowerFlex 4 PowerFlex 40
Frame Catalog Catalog
Number ➊ Number ➊
IP30/NEMA 1/UL Type 1 Kit Field installed kit. Converts drive to IP30/NEMA 1/UL Type 1 enclosure. Includes conduit box A 22-JBAA –
with mounting screws and plastic top panel. B 22-JBAB 22-JBAB
C – 22-JBAC
IP30/NEMA 1/UL Type 1 Kit Field installed kit. Converts drive to IP30/NEMA 1/UL Type 1 enclosure. Includes B – 22-JBCB
with Communication Option communication option conduit box with mounting screws and plastic top panel. C – 22-JBCC
Human Interface Module Option Kits and Accessories
Item Description Catalog Number ➊
Remote Human Interface LCD Display, Remote Panel Mount, Digital Speed Control, CopyCat capable, IP66 22-HIM-C2S
Modules (HIMs) (NEMA Type 4X/12) indoor use


Use: 0.0323