PowerFlex 40P Drives
Allen-Bradley’s portfolio of industrial control products encompasses so many technology categories that their core offerings at times get lost in the woodwork. PLCs, PACs, and Drives are arguably Allen-Bradley’s strongest products (though that is not to say that the rest of their catalog is substandard). AB’s PowerFlex line is one of their longest-running hardware families, and for good reason – these motor and drive control devices are the de-facto industry standard thanks to their competitive costs, broad technological features, long-life reliability, and application-specific benefits. We’ll pick out one model in the family – the PowerFlex 40P Low Voltage AC Drive – to discuss in this article, covering details around identifying, comparing, and selecting 40P drives for your applications.
Allen-Bradley PowerFlex Low Voltage Drives Family
The PowerFlex family of Low Voltage Drives is extensive, spanning a huge range of horsepower ratings with specialized configurations that touch practically every industrial application imaginable. To provide a sense of the current lineup, we’ve compiled the below table of available PowerFlex offerings as of Q3 2022, pulled from Allen-Bradley’s PowerFlex Low Voltage Drive Selection Guide, publication number PFLEX-SG002O-EN-P, dated February 2022.
- PowerFlex 4M: Basic motor control. Smallest, most cost-effective drive in the lineup.
- PowerFlex 400: OEM fan and pump applications, ideal for building system integration.
- PowerFlex 523: Streamlined installation for simple, modular motor controls.
- PowerFlex 525: Expanded options in modular form, with embedded Ethernet/IP.
- PowerFlex 527: First compact drive designed exclusively for Logix controllers and more.
- PowerFlex 755TS: Scalable, next-gen PowerFlex drive with TotalFORCE.
- PowerFlex 755TL/TR: Up to 6,000 HP capacity, with harmonic mitigation and regeneration applications.
- PowerFlex 753: General purpose OEM drive with advanced control capabilities.
- PowerFlex 755: Machine-level drive with safety, flexibility, connectivity, and productivity in mind.
- PowerFlex 70: Compact drive designed for tight spaces, simplicity, and reliability.
- PowerFlex 700: Global OEM drive designed for cost efficiency and size, with an onboard interface.
- PowerFlex DC Drives: Powerful performance and flexible control for DC applications.
AB’s PowerFlex Low Voltage drive family doesn’t stop at drives alone. Users can also find DC Field Controllers, Common Bus Solutions, complete Drive Systems, Non-Regenerative Solutions, and a full suite of optional accessories in the lineup.
Navigating PowerFlex Selection
Readers will have noticed that the PowerFlex 40P model did not appear in the list of drive series above. If we know anything about Allen-Bradley’s history, it’s that they are seldom consistent or intuitive in their naming practices given how so much of their product offerings are in constant flux. Taking a trip back to the early 2000s may help.
In the early-2000’s, Allen-Bradley’s documentation reflected a drive list that was predominantly two-digit in nature, such as the PowerFlex 40 and 70 models. By the mid-2010s, catalog sheets were shifting to show mostly three-digit models, adding new models such as the 700S and 700L to the list. Older models such as the 4M and 40 were still displayed on the list but were categorized together as “4-Class Drives” alongside a new, seemingly related variant 400 models. Looking now at today’s lineup (in the above list), we see mostly three-digit figures. The change appears to be that two- and three-digit individual models are being migrated into three-digit series. For example, the models 523, 525, and 527 are now referred to as the 520 Series. Older models such as the 4M, 40, and 40P are today relegated to only a few catalog pages after the 400 model’s section, suggesting that these being grouped into a 400 Series (even though there already is a 400 model), and/or that they will soon be phased out. For sake of simplicity, we will carry forward the grouping name of “4-Class” for this article. In coming years, readers are encouraged to always check AB’s website and annual catalogs to watch out for obsoletion and nuanced naming changes.
In a separate category, Allen-Bradley uses four-digit series numbers for their Medium Voltage Drive products, similar to the PowerFlex 6000 and 7000 series.
To make matters even more confusing, Allen-Bradley uses another descriptive standard to refer to their drives: Compact-Class and Architecture-Class.
- Compact Class: A simple and cost-effective solution for standalone machine-level control applications or simple system integration. Designed for ease of use, this general-purpose class of drives provides a compact package to optimize panel space and application versatility. Includes the 4M model, 400 model, and 520 series.
- Architecture Class: This class provides a broad set of features and application-specific parameters, ideal for high-performance applications. They were designed to meet various application requirements for both speed and torque control, up to 270 kilowatts or 400 horsepower. DC input options are available. Includes the 70, 753, and 755 models.
To summarize all the above, we suggest considering drive selection in this sequence:
- Select Class – small, machine-level (Compact Class) or advanced, plant-level (Architecture Class).
- Select Application – single application models are different from multi-application models, such as a PowerFlex 400 for simple motor control or a PowerFlex 755 for advanced torque-prove control.
- Select Features – choose attributes such as non-regenerative, common bus, safety integrated, etc., which will further refine the selection to a single model.
- Select Catalog Number – now you can build an individual catalog number by selecting voltage, rating, enclosure type, interface, and other options.
PowerFlex 4-Class Drives
To best convey the benefits of the PowerFlex 40P drive, we should first understand how this particular model fits into its adjacent models. The PowerFlex 40P belongs to a group of drives referred to as ‘4-Class Drives’, made up of the following three models:
- PowerFlex 4M – This product series is designed to meet global OEM and end-user demands for cost-efficiency, simplicity, and space savings. These drives have a vast array of features, such as an integral keypad with local potentiometer and control keys. 120VAC-480VAC, 1/4 to 5 HP.
- PowerFlex 40 - The PowerFlex 40 series of AC drives give OEMs, end users, and machine builders performance-enhancing motor control in a compact package that is easy to use. These products feature Sensorless Vector Control to meet the low-speed torque demands that help improve application performance. These drives are easily installable and can be configured for a variety of applications. 120VAC-600VAC, 1/2 to 15 HP.
- PowerFlex 40P - The PowerFlex 40P AC drives address user needs for closed-loop control with an option for Category 3 Safe Torque Off in a compact and cost-effective design. Based on the PowerFlex 40 product series, these drives were designed to meet global OEM and end-user demands for ease of use, space savings, and flexibility. These drives are a cost-effective alternative for speed or basic position control of applications, such as smart conveyors, packaging machines, and many more. These products share similar options and accessories to those in the PowerFlex 40 product series. 240VAC-600VAC, 1/2 to 15 HP.
We can see from the above that the 4-Class series is a small format, low horsepower range of component drives offered to machine builders and OEMs. The 40P model is the option that offers integrated safety for manned machinery, providing an economical entry point to safety protection without getting into architecture-level safety provisions.
Common Features of the PowerFlex 40P Drive Series
The overall PowerFlex 40P series offers the below features and benefits:
- Power ratings:
- 200 - 240V: 0.4 - 7.5 kW; 0.5 - 10 Hp; 2.3 - 33 A
- 380 - 480V: 0.4 - 11 kW; 0.5 - 15 Hp; 1.4 - 24 A
- 500 - 600V: 0.75 - 11 kW; 1 - 15 Hp; 1.7 - 19 A
- IP20 NEMA/UL Open-type enclosure; Plate drive; Flange-mountable
- Optional IP30 NEMA/UL Type 1 conversion kit
- V/Hz control, sensorless vector control, as well as process PID
- Internal RS-485 and Common Industrial Protocol (CIP) communication
- 4-digit display, 3 additional status indicators, and scroll/reset button
- Optional Remote Human Interface Modules (HIM) or PC interface for programming
- Speed control with and without encoder feedback
- Drive overload protection, ramp regulation, and flying start
- Fiber application-specific features
- Configuration and programming via an integral LCD keypad, remote keypad, etc.
- Premier Integration with PowerFlex® AC drives uses the Logix control platform to simplify parameter and tag programming and reduces development time
- Optional Safety Feature: Safe Torque-Off
Startup, Programming, and Operational Benefits:
- An integral display and reset button allow the user to change the display parameters, as well as reset the drive if a fault occurs.
- Information and drive statuses are displayed via a 4-digit display with ten (10) additional light-emitting diode (LED) indicators.
- 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 Type 4X remote and NEMA Type 1 hand-held LCD keypad provide additional programming and control flexibility.
Communication Options:
- PowerFlex 40P AC drives are compatible with devices that act as an RTU Master and support standard 03, 06, and 16 RTU commands.
- Networks can be configured using PowerFlex 40P AC drives with optional communication cards for high performance and flexible configuration capabilities.
- DeviceNet
- EtherNet/IP
- ControlNet
- And more
- A multi-drive solution can be reached using a single PowerFlex 40P AC drive with the DeviceNet option, with the ability for up to 5 drives to reside on 1 node.
- Integral RS-485 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 SCM can be eliminated if the controller acts as an RTU Master.
What is the DriveGuard Safe Torque Off Option?
- Provides the “Safe torque off (STO)” function.
- It blocks gate firing signals from reaching the drive’s IGBT output power devices.
- It can be used in combination with other safety devices to fulfill the requirements of a system “safe torque off” function.
PowerFlex 40P Options
The PowerFlex 40P has a wide array of User-Installed options available – we suggest reading the most current Allen-Bradley PowerFlex 40P User Manual to see a complete list. Some of the most popular options are described below.
Converting an existing PowerFlex 40P drive from an IP20 to an IP30 / NEMA 1 enclosure rating can be easily accomplished using a Conversion Kit - Catalog number 22-JBCB for drive frame B, or Catalog number 22-JBCC for drive frame C, both of which include a communication option conduit box.
Adding a Remote Human Interface Module (HIM) allows users to interact with the drive without opening the drive panel. The Catalog number 22-HIM-C2S Panel Mount version is the most popular, installed right on the face of the drive enclosure near operator stations, rated for IP66 / NEMA 4X washdown conditions. Bluetooth wireless options such as the Catalog number 22-WIM-N4S are available as well, this version also in an IP 66 / NEMA 4X rating.
To add the DriveGuard Safe-Off feature in the field, select Catalog number 20A-DG01, which helps protect against unintentional drive restarts (when paired with the appropriate field and control-side components to fully protect the entire circuit).
Many communication adaptors can be field-added to expand the drive’s networking capabilities, such as Catalog number 22-COMM-E for EtherNet I/P, Catalog number 22-COMM-D for DeviceNet, and Catalog number 22-COMM-C for ControlNet.
Many other accessories are available as well – replacement parts, dynamic brake resistors, input line reactors, EMC filters, cables, and more.
