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- AC Drive
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- 510 × 298 × 310 mm
- 4 kg
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Product Overview
The Emerson SP4402 is an AC drive in the Unidrive SP series, used to regulate motor speed and torque in industrial machinery. It suits applications where the motor must respond to changing production speeds, load conditions or control commands. Typical installations include conveyor systems, extrusion lines, winding equipment and process machinery that require adjustable motor operation.
The SP4402 operates from a three-phase 380–480 V AC supply. Its rated output is 45 kW in Normal Duty operation and 37 kW in Heavy Duty operation, with corresponding continuous output-current ratings of 83 A and 74 A. These ratings help determine whether the drive can handle the motor’s operating current and the application’s overload requirements.
The drive supports multiple motor-control methods and can exchange operating commands and status information with an automation controller. Built-in RS-485 communication, configurable control I/O, onboard PLC functionality and compatible option modules support integration with machine-control systems. The required configuration depends on the motor, feedback arrangement, network requirements and operating conditions.
Technical Specifications
| Parameter | Specification |
|---|---|
| Manufacturer | Emerson / Control Techniques |
| Model | SP4402 |
| Product Series | Unidrive SP |
| Product Type | AC Variable Frequency & Servo Drive |
| Drive Configuration | Panel-Mount AC Drive |
| Input Voltage | 380–480 V AC |
| Input Phase | Three-phase |
| Input Frequency | 48–65 Hz |
| Normal Duty Output Power | 45 kW |
| Heavy Duty Output Power | 37 kW |
| Normal Duty Output Current | 83 A |
| Heavy Duty Output Current | 74 A |
| Control Modes | V/Hz, open-loop vector, rotor flux control and supported closed-loop control modes |
| Built-in Communication | RS-485 |
| Serial Communication Protocol | Modbus RTU |
| Control Interfaces | Configurable analog and digital I/O |
| Expansion Capability | Compatible option modules |
| Programmable Logic | Onboard drive PLC functionality |
| Parameter Storage | Smartcard support |
| Enclosure Protection | IP20 |
| Cooling Method | Forced-air cooling |
| Dimensions | 510 × 298 × 310 mm |
| Weight | 4 kg |
Product Features
- Dual duty ratings: Supports Normal Duty and Heavy Duty operation with different continuous output-current ratings.
- Motor speed and torque regulation: Adjusts motor output according to the selected control method and application requirements.
- Serial communication: Built-in RS-485 supports communication with compatible automation equipment.
- Configurable control I/O: Supports external commands, reference signals and operating-status monitoring.
- Option-module expansion: Compatible modules add communication, feedback or additional I/O functions where required.
- Onboard drive PLC: Supports drive-related logic and local sequencing tasks.
- Smartcard support: Allows compatible drive parameters and programs to be stored and transferred.
- Drive diagnostics: Status information and fault indications help technicians investigate operating problems.
- Application-specific configuration: Motor data, control mode, current limits and ramp settings can be adjusted for the machine.
Working Principle
The SP4402 converts incoming three-phase AC power into a controlled electrical output for the connected motor. It varies output voltage and frequency according to the selected control strategy, motor parameters and requested operating conditions.
In a winding application, for example, the machine controller can send a speed reference to the drive as production speed changes. The SP4402 adjusts motor operation according to the configured reference and ramp settings, helping coordinate material movement with the rest of the line. The appropriate control method depends on the required speed response, torque characteristics and feedback arrangement.
Open-loop control can be used when encoder feedback is not required. Applications that need closed-loop regulation require compatible feedback hardware and the correct drive configuration. The onboard PLC can execute supported local logic, while the serial interface and option modules support communication with the wider automation system.
During commissioning, the motor’s rated data, drive duty classification, current limits, speed references and acceleration and deceleration settings must be matched to the application. Correct configuration helps prevent unsuitable operating limits from interfering with the machine’s required performance.
Role in a Unidrive SP Motor-Control Architecture
The SP4402 serves as the motor-regulation stage between the incoming electrical supply and the driven machine. It receives operating commands from a PLC or another configured control source and regulates the electrical output delivered to the motor.
Three-Phase AC Supply → SP4402 AC Drive → AC Motor → Industrial Machinery
| System Component | Function | Relationship to the SP4402 |
|---|---|---|
| SP4402 AC Drive | Regulates motor speed and torque | Controls the electrical output delivered to the motor |
| Three-Phase AC Supply | Supplies electrical power | Feeds the drive input |
| AC Motor | Converts electrical energy into mechanical motion | Drives the connected machinery |
| PLC or Machine Controller | Executes machine sequencing and interlocks | Sends commands and speed references |
| Encoder or Feedback Device | Measures speed or position where required | Supports compatible closed-loop configurations |
| RS-485 Communication Interface | Exchanges serial data | Connects the drive to compatible control equipment |
| Analog Reference Source | Supplies a configured speed or process reference | Provides an input for motor regulation |
| Digital Control Signals | Carry enable, run, stop and status signals | Support external control and monitoring |
| Braking Resistor | Dissipates braking energy where required | Supports applications with demanding deceleration requirements |
| Communication Option Module | Adds supported network connectivity | Extends the available communication interfaces |
| Feedback or I/O Option Module | Adds compatible feedback or signal-handling functions | Adapts the drive to application requirements |
| Electrical Protection Devices | Provide electrical protection and isolation | Form part of the surrounding motor installation |
Industrial Applications
| Application | Typical Equipment | Role of the SP4402 |
|---|---|---|
| Conveyor Systems | Production conveyors and material-transfer lines | Regulates motor speed to coordinate material movement |
| Extrusion Machinery | Plastic extrusion and material-processing lines | Controls motor operation during continuous production |
| Winding Equipment | Web handling and winding machines | Supports speed regulation and compatible feedback control |
| Pumping Systems | Industrial process and utility pumps | Adjusts motor speed according to process demand |
| Industrial Fans | Ventilation and process-air equipment | Regulates airflow through variable-speed operation |
| Packaging Machinery | Automated packaging and conveying systems | Coordinates motor operation with production sequences |
| Printing Machinery | Printing presses and web-handling equipment | Regulates motor speed during production |
| Material Handling | Industrial transfer and movement equipment | Controls motor operation according to the required movement profile |
| Cutting and Processing Machinery | Industrial cutting and processing equipment | Regulates motor speed during machine cycles |
| General Manufacturing | Machines with variable-speed AC motors | Provides adjustable motor control for production operations |
Installation and Maintenance
- Verify the drive identification: Confirm the SP4402 model and its electrical ratings before installation.
- Check the supply requirements: Verify that the three-phase supply is compatible with the specified 380–480 V AC input range.
- Inspect the installation location: Ensure the panel arrangement provides the required ventilation, clearance and environmental protection.
- Select suitable electrical protection: Check protective devices, conductors, isolation arrangements and earthing against the installation requirements.
- Isolate power before wiring: Disconnect the supply and follow the required discharge and safe-working procedures before handling drive terminals.
- Verify motor connections: Check motor nameplate data, cable connections, earthing and output-terminal wiring before energizing the drive.
- Configure motor parameters: Enter the applicable motor data and select the control mode required by the application.
- Check feedback and option modules: Verify installed communication modules, feedback devices and additional I/O where applicable.
- Set operating references: Configure run commands, speed references, acceleration and deceleration ramps, and operating limits.
- Test communication and I/O: Confirm that controller commands, status signals and configured communication functions operate as expected.
- Perform a controlled commissioning test: Check motor direction, speed response, stopping behavior and fault handling before returning the machine to production.
- Record the configuration: Document parameter settings, installed options, commissioning results and maintenance history for future servicing.
Related Components
| Component | Function | Relationship to the SP4402 |
|---|---|---|
| Unidrive SP Keypad | Provides local parameter access and operating-status information | Supports local setup and monitoring when fitted |
| Smartcard | Stores compatible parameters and programs | Supports configuration backup and transfer |
| Encoder Feedback Module | Interfaces with compatible motor feedback devices | Enables supported closed-loop configurations |
| Communication Option Module | Adds supported industrial network interfaces | Connects the drive to compatible automation systems |
| I/O Option Module | Adds compatible input and output functions | Extends signal-handling capabilities |
| Braking Resistor | Dissipates braking energy where required | Supports demanding deceleration applications |
| AC Motor | Converts electrical power into mechanical motion | Serves as the controlled load |
| PLC | Coordinates machine logic and interlocks | Sends commands and receives drive-status information |
| Electrical Isolation Device | Provides isolation for servicing | Supports safe maintenance procedures |
| Motor Protection Devices | Provide protection for the motor circuit | Complement the wider electrical installation |
Recommended Related Models
| Model / Product | Product Type | Relationship | Selection Consideration |
|---|---|---|---|
| Emerson SP4402 | Unidrive SP AC Drive | Main product | Match the 380–480 V supply and required duty rating |
| Emerson SP4401 | Unidrive SP AC Drive | Related model in the same frame family | Compare motor current and power requirements |
| Emerson SP4403 | Unidrive SP AC Drive | Related model in the same frame family | Evaluate the required output current and load characteristics |
| Emerson SP3403 | Unidrive SP AC Drive | Related drive in a smaller frame family | Consider only if its output ratings meet the application requirements |
| Unidrive SP Feedback Option Modules | Drive Feedback Modules | Related configuration components | Select according to the required encoder or feedback interface |
| Unidrive SP Communication Option Modules | Drive Communication Modules | Related configuration components | Match the required industrial network and protocol |
| Unidrive SP Braking Components | Drive Braking Accessories | Related application components | Evaluate the load’s braking and stopping requirements |
Key Advantages
- Supports multiple motor-control methods for industrial AC applications.
- Provides separate Normal Duty and Heavy Duty output ratings.
- Includes built-in RS-485 serial communication.
- Supports compatible feedback, communication and I/O expansion modules.
- Includes onboard PLC functionality for supported drive-related logic.
- Supports storage and transfer of compatible drive configurations.
- Integrates with PLC-based machine-control systems.
Technical FAQs
What are the rated output currents of the SP4402?
The SP4402 is rated at 83 A in Normal Duty operation and 74 A in Heavy Duty operation. The appropriate rating depends on motor current, load characteristics and the application’s overload requirements.
How does the SP4402 differ from the SP4401?
Both models belong to the Unidrive SP series, but the SP4402 has higher rated output-current and power capabilities. Confirm the exact motor requirements and duty classification when selecting between them.
Can the SP4402 communicate with a PLC?
The drive includes an RS-485 serial interface for communication with compatible control equipment. The communication settings and protocol must be configured to match the connected system.
What should be checked before replacing an SP4402?
Verify the supply voltage, motor current, duty classification, control mode, feedback arrangement and installed option modules. The replacement configuration must support the application’s electrical and control requirements.