Rockwell Automation has extended the Allen-Bradley PowerFlex range of drives with the addition of the PowerFlex 40P, a highly flexible and cost-effective drive that addresses the requirements for closed-loop control and Category III Safe-off functionality to EN 954-1, in a compact design. The PowerFlex 40P is a general-purpose drive geared for machine level or standalone applications. Features designed to offer the user more functionality and application versatility include: dual-channel pulse-train input; DriveGuard, to achieve Category III Safe-off (as per EN954-1); and a ½ DC bus ride-through feature for use in critical applications where continued drive output is required, even in the event of a “brown-out” or reduced voltage situations.
The facility for encoder/pulse train input enables the PowerFlex 40P to be configured for simple closed-loop position control applications. In conjunction with Allen-Bradley StepLogic software, the PowerFlex 40P can operate as an independent position controller, or it can function in combination with an outer position controller, such as a CompactLogix PLC. In both configurations, the resulting systems provide powerful yet cost-effective positioning control for applications such as fibre drawing and spinning machines, materials handling, packaging machines, capping, labelling and filling machines, diverters and palletisers/de-palletisers.
The encoder facility also provides benefits in applications where the PowerFlex 40P is required to provide precise closed-loop speed control rather than positional control. In these applications, the motor feedback is configured as speed feedback, effectively replacing slip compensation with encoder input for better speed regulation.
In addition to its control versatility, the design of the PowerFlex 40P offers users and OEMs the combined benefits of enhanced safety options and reduced cost of ownership. The optional DriveGuard functionality equips users with a high-integrity means of removing power from a motor, thereby preventing it from restarting until normal operating conditions exist. This facility is particularly relevant in applications that are classified as medium risk, and those where coast-to-stop in the event of a fault is acceptable.
The DriveGuard option can enable Category III safety to be achieved with less hardware than is typically required with hardwired systems based solely on contactors. Along with reduced hardware costs, users benefit from reduced installation and cabling costs and reduced system complexity.
PowerFlex 40P shares the same communication options – via EtherNet/IP, ControlNet, DeviceNet and Profibus DP – as the popular PowerFlex 4 and PowerFlex 40 drives, and is also programmable using Allen-Bradley DriveExplorer and DriveTools software. PowerFlex 40P is compatible with the range of PowerFlex accessories, such as EMC filters and line/load rectifiers, and includes many features, such as the embedded RS485 Modbus protocol, that can help users implement a low-cost multi-drive networks.
Flexible packaging and mounting options complement the overall versatility of the PowerFlex 40P: Panel mount NEMA 1, IP20, with plate or flange mounting options, reduce overall enclosure size. The innovative design allows a high degree of environmental protection while reducing heat dissipation within the enclosure by up to 75%.
The Allen-Bradley range of PowerFlex drives was designed from the start as a family of products: Featuring an advanced, common operator interface, PowerFlex drives reduce training and simplify operation through a consistent programming structure, common software tools and consistent parameter names. The result is faster set-up, easier troubleshooting and maximum process uptime.