B&R 4D1042.00-090

Product Introduction

The B&R 4D1042.00-090 is a single-axis AC servo drive from the B&R ACOPOS series. It drives permanent magnet synchronous motors (PMSM) and synchronous reluctance motors with a continuous power rating of 2.2 kW and a peak power of 6.6 kW (3× overload for 5 seconds). The drive features an integrated Safe Torque Off (STO) function compliant with SIL 3 / PLe per IEC 61800-5-2 and ISO 13849-1. It is used in high-precision motion control applications including CNC machines, robotics, printing presses, and packaging systems.

Category:
Description

Technical Specifications

Parameter Value
Manufacturer B&R Industrial Automation (ABB Group)
Part Number 4D1042.00-090
Series ACOPOS 1042
Axes 1
Continuous Power 2.2 kW
Peak Power 6.6 kW (5 s duration)
Input Voltage 380–480 V AC, 3-phase, 50/60 Hz
Output Current (Continuous) 6.5 A RMS per phase
Output Current (Peak) 19.5 A RMS per phase (5 s)
Motor Types PMSM, SynRM
Encoder Input Incremental (HTL/TTL), 1 Vpp to 11 Vpp, up to 20 MHz
STO Function SIL 3 / PLe, IEC 61800-5-2, dual-channel
Communication POWERLINK, EtherCAT, PROFINET, CANopen, USB
Braking Integrated brake chopper (200 W), external brake resistor option
Supply Voltage (Control) 24 V DC
Operating Temperature 0°C to +45°C (derating above 40°C)
Protection Class IP20 (with cover: IP54 optional)
Dimensions (W × H × D) 140 mm × 260 mm × 185 mm
Weight 3.8 kg
Standards CE, UL 508, EN 61800-5-2, ISO 13849-1

Functional Features

  • Field-Oriented Control (FOC) with automatic motor identification
  • Safe Torque Off (STO) — SIL 3 / PLe, dual-channel, no external relay required
  • Electronic gear ratio: 1:1 to 1:10,000,000
  • Cam profile control with up to 32 cams
  • Positioning modes: PTP (point-to-point), CSP (continuous path), CT (continuous torque)
  • Integrated brake chopper — 200 W dissipation, external resistor up to 1 kW
  • Automatic motor parameter detection (resistance, inductance, back-EMF)
  • Dual encoder inputs for multi-turn absolute or dual-loop control

Performance Parameters

Parameter Specification
Current Loop Bandwidth 1.6 kHz
Speed Loop Bandwidth 400 Hz
Position Loop Bandwidth 200 Hz
Positioning Accuracy (repeatability) ±1 encoder count
Following Error (steady state) < 0.01°
STO Response Time < 10 ms (to safe state)
STO Diagnostic Coverage > 99% (dual-channel comparison)
MTBF > 100,000 hours
Efficiency (at rated load) > 95%

Material Composition

Component Material
Power Stage IGBTs Infineon FF600R12ME4 (1200 V, 600 A)
DC Bus Capacitors Electrolytic, 450 V DC, 2200 µF (Nippon Chemi-Con)
Heat Sink Extruded aluminum, anodized
PCB FR-4, 4-layer, 2 oz copper, ENIG finish
Enclosure Die-cast aluminum with powder-coat finish
Connectors Phoenix Contact, rated 32 A, 600 V
STO Relays TE Connectivity, gold-contact, 6 A rated

Structural Features

  • Wall-mount or DIN rail mounting (brackets included)
  • Front-facing terminal blocks for power, motor, encoder, and STO
  • LED status indicators: Power, Ready, Fault, STO Active
  • Integrated cooling fan (80 mm, 24 V DC, 0.3 A)
  • EMC filter on AC input (common mode + differential mode)
  • Optional IP54 cover with gasket seal

Working Principle

The 4D1042.00-090 receives 3-phase 400 V AC power which is rectified to a DC bus (~540 V DC). The IGBT inverter stage (6 IGBTs in a 3-phase bridge) synthesizes a 3-phase AC output using Space Vector PWM (SVPWM) at 16 kHz switching frequency. The FOC algorithm runs on a 32-bit DSP (Texas Instruments TMS320F28379D) that controls the d-axis (flux) and q-axis (torque) current components independently. The STO function uses two independent hardware channels that disable the IGBT gate drivers simultaneously — if either channel detects a fault, the drive enters a safe state within 10 ms, cutting torque to zero regardless of software state.


Advantages & Highlights

  • SIL 3 / PLe STO built-in — eliminates external safety relay, reduces BOM cost by ~€150 per axis
  • 2.2 kW continuous in a compact 140 × 260 × 185 mm form factor
  • Automatic motor ID — commissioning time reduced by 70% vs. manual parameter entry
  • POWERLINK + EtherCAT dual protocol — works with B&R and third-party controllers
  • 6.6 kW peak (3× overload) — handles short-duration high-torque demands
  • > 95% efficiency — low heat generation, reduced cooling requirements
  • Dual encoder support — enables multi-turn absolute positioning without external gearbox

Applicable Industries

Industry Application
CNC Machining Spindle drive, axis feed drive
Robotics Joint actuation, linear axis
Printing Web tension control, register control
Packaging Servo-driven cutting, sealing, labeling
Textile Yarn tension, loom drive
Semiconductor Wafer stage positioning

Model Series

Part Number Power Input Voltage STO
4D1042.00-090 2.2 kW 400 V AC SIL 3 / PLe
4D1070.00-090 5.5 kW 400 V AC SIL 3 / PLe
4D1102.00-090 8.2 kW 400 V AC SIL 3 / PLe
4D1042.01-090 2.2 kW 200 V AC SIL 3 / PLe

Installation Requirements

  • Mount on a vertical surface or DIN rail with minimum 100 mm clearance above and below for airflow
  • Connect 3-phase 400 V AC power via a 6 A miniature circuit breaker (Type C)
  • Motor cable: shielded, 4-core, maximum length 20 m (use output reactor for > 20 m)
  • Encoder cable: shielded twisted pair, maximum length 50 m
  • STO wiring: dual-channel, use 24 V DC, 6 A rated safety relay contacts
  • Brake resistor: connect to P+/P- terminals if deceleration energy exceeds 200 W
  • Ground the drive chassis to protective earth (PE) with ≤ 0.1 Ω resistance

Usage Precautions

  • Never operate without the cooling fan connected — thermal shutdown occurs at 85°C heatsink temperature
  • STO must be wired with dual-channel redundancy — single-channel wiring voids SIL 3 certification
  • Do not exceed 6.6 kW peak for more than 5 seconds — IGBT thermal limit is 125°C junction temperature
  • Motor cable length > 20 m requires an output reactor (B&R 8LVR002.0000-0) to limit dv/dt and protect motor insulation
  • Commissioning must be performed via Automation Studio 4.5+ — parameter backup is mandatory before first power-on
  • Replace the DC bus capacitors every 8 years regardless of operating hours — electrolytic degradation is time-dependent, not usage-dependent
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