powerflex 755t drive solutions low harmonic regenerative ... · pdf filepowerflex® 755t...

PowerFlex® 755T Drive Solutions

Low Harmonic, Regenerative and Modular Drive System Solutions

Information is preliminary, subject to change

PowerFlex 755T Drive SolutionsThe Next Step in Powerful Performance. Flexible Control.

The new Allen-Bradley PowerFlex 755T products expand the proven portfolio of the PowerFlex 753 and 755 AC drives. These powerful new additions offer precise motor control along with solutions for regeneration, low harmonics and flexible drive system configurations.

The PowerFlex 755T products use TotalFORCE technology, our patented field oriented control for accurate torque control. With TotalFORCE, the PowerFlex 755T products deliver fast, precise, responsive control of position, velocity and torque.

Designed and built using a modular approach, the PowerFlex 755T products allow you to select the ratings and capabilities your application needs. The modular construction also offers the added advantage of fast and easy parts replacement and simplified management of a common set of spares.

PowerFlex 755TL Drive – Provides low AC input harmonics and power factor correction through the use of active front end technology.

PowerFlex 755TR Drive – Provides an energy efficient solution that uses regenerative active front end technology to deliver energy back to the incoming supply. This drive also provides low AC input harmonics and power factor correction.

PowerFlex 755TM Drive System – Select from a series of pre-designed configurations for regenerative common bus supplies and common bus inverters to optimize your system design and power consumption.

PowerFlex 755TL low harmonic drive PowerFlex 755TR low harmonic, regenerative drive

2 Information is preliminary, subject to change

The highly differentiated control technology in the PoweFlex 755T products is complemented with innovative power control elements that help deliver valuable solutions for a wide range of applications in variable speed control.

• Our active front end technology enables the PowerFlex 755T products with the ability to regulate active current and reactive power to correct power factor

• PowerFlex 755TL, PowerFlex 755TR and PowerFlex 755TM products are all designed to meet the IEEE 519 standard

• Keep your equipment running through most power quality disturbances with active front end ride-through control that regulates the DC bus voltage independently of the incoming AC voltage

• Reduce commissioning time and mechanical wear with Load Observer and Adaptive Tuning

• Standard built-in dual EtherNet/IP ports provide topology flexibility

• Flexible slot-based hardware architecture allows you to select option modules for safety, feedback, communications and I/O

• The modular design provides a faster way to install and maintain your drive while providing common spare parts throughout the product line

• Safety options help protect personnel and assets while enabling increased machine uptime

• Predictive diagnostics help reduce unplanned downtime and improve productivity

• Complete your configuration and programming with one software tool – use either Studio 5000 Logix Designer or Connected Components Workbench software

PowerFlex 755TM low harmonic, regenerative drive system for control of multiple motors

3Information is preliminary, subject to change

PowerFlex 755TL DriveThe PowerFlex 755TL drive is designed to mitigate harmonics using active front end technology and an internal harmonic filter. Harmonic distortion created by an electrical piece of equipment will affect all other equipment sharing the same source of electrical power and can lead to increased repair and replacement costs. The PowerFlex 755TL drive provides a complete solution that includes a line side converter, harmonic filter and inverter to help reduce the adverse effects of harmonic distortion on adjacent electrical equipment and control system instrumentation.

Negative impacts of harmonic distortion may include motors that run at higher temperatures, leading to increased repair and replacement costs. Circuit breakers may trip erratically. Interference in communications and consequent improper operation of sensitive control equipment such as programmable controllers, computers and field instrumentation are also very common.

Beyond your facility, harmonic power distortion may cause problems for commercial or residential neighbors on your electrical grid. As a result, you may be required to conform to standards for low harmonic distortion at a Point of Common Coupling (PCC). PowerFlex 755TL, PowerFlex 755TR and PowerFlex 755TM products are designed to meet and exceed global standards like IEEE 519 in terms of maximum allowable % of THD (total harmonic distortion).

PowerFlex 755TL Drive

400/480V 160…1250 kW / 250…1800 Hp

600/690V 250…1500 Hp / 200…1400 kW

Communications Standard built-in dual ports for EtherNet/IP Additional industrial network options

Safety Options Safe Torque Off Safe Speed Monitor

Ambient Temperature Ratings

40 °C Up to 55 °C w/deratings

TotalFORCE TechnologyMotor Control

Flux Vector Control Sensorless Vector Control V/Hz Economizer

Enclosure Type IP21, UL Type 1 IP54, UL Type 12

• Corrected power factor helps reduce energy-related expenses

• The combination of lower harmonics and power factor correction reduces the need to oversize your electrical power equipment

• Maintain operation through most line disturbances with AFE ride-through control

• Eliminate the need for external multi-phase transformers or filters along with the associated wiring, labor, installation and maintenance costs

• Decrease floor space requirements with built-in components

• Use one interface to configure and program the converter and inverter using Studio 5000 Logix Designer or Connected Components Workbench software

• Meets IEEE 519 standard (5% or less of total harmonic distortion)


AC Pre-charge regulates the input AC current from the incoming power source, greatly reducing stress on the power components during power up.

LCL filter is a 230 mm wide module that provides low harmonic capability and minimizes the current distortion into the utility grid.

Line side converter is a 230 mm wide module. In the PowerFlex 755TL, it draws energy from the AC line without harmonic distortion and converts it to DC power.

Motor side inverter is a 230 mm wide module that controls the voltage and current of the motor.

IP21/IP54 enclosures provide a choice of packaging options to meet the environmental requirements of your application.

Control pod contains the control platform that is responsible for motor control, system control and communications. Five option slots allow you to add I/O, safety and feedback.

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PowerFlex 755TL Drive

Roll in/roll out design makes the drive easy to install and service by allowing complete removal of a module from cabinet, providing generous room for wiring behind the drive. Power wiring can stay connected while unit is rolled out.

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PowerFlex 755TR DriveThe PowerFlex 755TR drive provides regenerative and low harmonic capability with active front end technology. With built-in regeneration, the PowerFlex 755TR drive helps reduce energy consumption by delivering energy back to the incoming supply rather than wasting it as heat, resulting in a more energy efficient solution.

PowerFlex 755TR Drive

400/480V 160…2000 kW / 250…3000 Hp

600/690V 250…2500 Hp / 200…2300 kW



Ambient Temperature Ratings 40 °C Up to 55 °C w/deratings




• The drive is able to put energy back on the incoming power supply, providing a far more energy efficient solution than resistive braking

• Reduce the adverse effects of harmonic distortion on adjacent electrical equipment and control system instrumentation





• Recover dissipated energy and re-use that energy for other applications, creating energy savings that increase the return on investment made in the drive

• Reduce the need for braking resistors and cooling equipment along with associated wiring, labor, installation and maintenance costs

• Reduce floor space requirements with built-in components necessary for reducing harmonics and providing regeneration




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AC Pre-charge module regulates the input AC current from the incoming power source, greatly reducing stress on the power components during power up.

LCL filter is a 230 mm wide module that provides low harmonic capability and minimizes the current distortion into the utility grid.

Line side converter is a 230 mm wide module. In the PowerFlex 755TR, it draws energy from the AC line without harmonic distortion and converts it to DC power. It also provides a means of regeneration back to the AC line.



Control pod contains the control platform that is responsible for motor control, system control and communications. Five option slots allow you to add I/O, safety and feedback.

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PowerFlex 755TR Drive


PowerFlex 755TM Drive SystemThe PowerFlex 755TM drive system has been designed to enable coordination of multiple motors based on two main building blocks: regenerative common bus supplies and common bus inverters. The common DC bus allows you to optimize the sizing of the bus supply so that energy consumption remains strictly matched with the requirement of the application.

PowerFlex 755TM Drive Systems

Common Bus Inverters Regenerative Bus Supplies

400/480V 160…2000 kW / 250…3000 Hp 160…2000 kW / 250…3000 Hp

600/690V 250…2500 Hp / 200…2300 kW 250…2500 Hp / 200…2300 kW



Ambient Temperature Ratings 40 °C Up to 55 °C w/deratings




• By packaging the combination of inverters and bus supplies in different arrangements and ratings, you can optimize a high power density system with a small footprint

• Reduce the adverse effects of harmonic distortion on adjacent electrical equipment and control system instrumentation





• Minimize floor space requirements with built-in components



• Optimize floor space, installation and hardware with drives connected via common bus

– Removes the need to wire AC power to each drive individually

– Reduces installation time, labor and cabling costs – DC bus built into each unit allows for easy

connection to adjacent units – Integrated control bus in each unit for efficient

distribution of auxiliary 24V, 240V, and an optional 120V throughout a cabinet line up

• Gain energy efficiency with coordinated motors that share energy between regenerating and motoring loads

• Scale your system with the ability to use the smaller PowerFlex 753 and PowerFlex 755 drives in your common bus system


A system of common bus drives (inverters) receives electrical power from a common DC bus powered by the regenerative bus supply. This system supports multiple combinations of inverters to the limit established by the capacity of the regenerative bus supply.

AC Pre-charge module regulates the input AC current from the incoming power source, greatly reducing stress on the power components during power up.

LCL Filter is a 230 mm wide module that provides low harmonic capability and minimizes the current distortion into the utility grid.

Line side converter is a 230 mm wide module. In the PowerFlex 755TM, it draws energy from the AC line without harmonic distortion and converts it to DC power. It also provides a means of regeneration back to the AC line.



Control pod contains the control platform that is responsible for motor control, system control and communications. Five option slots allow you to add I/O, safety and feedback. There is one control pod for each common bus inverter and one for the regenerative bus supply.

DC Pre-charge regulates the input DC current from the incoming power source, greatly reducing stress on the power components during power up. It also provides a means of isolating the inverter from the DC bus for service or maintenance.


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Regenerative Bus Supply Common Bus Inverters


Control• Active Front End ride-through control helps reduce downtime

by regulating the DC bus voltage independently of the incoming AC voltage. This allows your equipment to keep running through many power quality disturbances

• Achieve high performance without tuning by using Load Observer and Adaptive Tuning

• Drive control modes include speed, torque and position control to support multiple application types

• Patented common mode noise reduction

• Selectable high-performance motor control algorithms with TotalFORCE Technology includes flux vector, sensorless vector, V/Hz and Economizer

• DeviceLogix™ embedded control technology

• Application specific features: TorqProve™ helps confirm control of the load in lifting and hoisting applications

• Thermal manager provides dynamic control of your power components for increased thermal life

• Predictive maintenance features help improve productivity by predicting remaining life span of fans, relay contacts, power devices and capacitors

Communications• Built-in dual ports for EtherNet/IP

• Options available for: ControlNet, DeviceNet, BACNet, PROFIBUS DP, PROFINET

Feedback• Universal feedback, encoder and dual encoder feedback

options

• Universal feedback option includes two channels for encoder feedback. Encoder support includes incremental, EnDat, Hiperface, SSI and BiSS

• Automatic switchover to secondary encoder or encoderless mode in the event of feedback loss

Energy Savings• Regeneration

• Power factor correction

Safety OptionsHelp protect personnel and assets while reducing downtime with the safety option that best fits your application.

• Safe Torque Off is ideal for safety-related applications that benefit from removal of rotational power to the motor without removing power from the drive. It provides a quick return to operation after a demand on the safety system and helps reduce wear from repetitive machine start-ups.

• Safe Speed Monitor provides a solution for applications that can benefit from access to a safety zone while there is limited motion. It helps you safely monitor and control the speed of your application which allows operators to perform process or maintenance work without stopping the machine

Hardware• Select the enclosure type to best meet the environmental

requirements of your application

– IP21 enclosure – IP54 enclosure

• Modular construction for ease of installation and maintenance

• Roll in / roll out design makes the drive easy to install and service by allowing complete removal of a module from cabinet. Power wiring stays connected while unit is rolled out

• PowerFlex 755T control pod is common across all drives

• Patented slot-based hardware structure for control and selectable I/O, feedback, communication and safety options

• Auxiliary control power available

• Standard conformal coating on all printed circuit boards

• Regenerative and non-regenerative Active Front End

• Option for built-in DV/T filters to reduce reflective wave

• High capacity bus option for PowerFlex 755TM up to 4700A distribution

• Blown fuse indication and feedback

Programming and Commissioning• LCD Human Interface Module (HIM) features an assisted start-

up utility to reduce start-up time and allow easy configuring and tuning of the drive

• Software tools to assist with programming, configuration, monitoring, and troubleshooting: Studio 5000 Logix Designer and Connected Components Workbench

• Flash upgradeable

PowerFlex 755T Drive Solutions Maximize System Performance


PowerFlex 755TL Drives PowerFlex 755TR Drives PowerFlex 755TM Drive Systems

Ratings 400V 160…1250 kW 160…2000 kWCommon Bus Inverter: 160…2000 kWRegenerative Bus Supplies: 160…2000 kW

Ratings 480V 250…1800 Hp 250…3000 HpCommon Bus Inverter: 250…3000 HpRegenerative Bus Supplies: 250…3000 Hp

Ratings 600V 250…1500 Hp 250. . . 2500 HpCommon Bus Inverter: 250…2500 HpRegenerative Bus Supplies: 250…2500 Hp

Ratings 690V 200…1400 kW 200…2300 kWCommon Bus Inverter: 200…2300 kWRegenerative Bus Supplies: 200…2300 kW

Communications• Built-in dual EtherNet/IP ports • ControlNet

• DeviceNet • BACNet

• PROFIBUS DP• PROFINET

Safety Options• Safe Torque Off• Safe Speed Monitor

Ambient Temperature Ratings

• 40 °C without derating• Up to 55 °C with derating

Storage Temperature -40…70 °C (-40…158 °F)

Relative Humidity Operation: 0…95% non-condensing


Flux vector, sensorless vector, V/Hz and Economizer

Motor Control Bandwidth*

Velocity Regulator Bandwidth 300 Hz (1885 Radians per second)Position Regulator Bandwidth 207 Hz (1301 Radians per second)

Standards and Certifications

• DNV• ABS• Lloyd’s Register • ATEX• IEC60721-3-3• ISA 71.04-1985

• SEMI F47• AC156 Seismic Standard• UL61800-5-1 (cULus)• CAN/CSA• Regulatory Compliance Mark

• EAC Mark• UkrSepro Mark• KC Mark• CE Mark• ODVA EtherNet/IP

Efficiency 94% at rated amps 94% at rated ampsBus Supplies: 96% at rated ampsCommon Bus Inverters: 96% at rated amps

Output Frequency Range

• 0…325 Hz @ 1.33 kHz carrier• 0…325 Hz @ 2 kHz carrier• 0…590 Hz @ 4 kHz carrier

Torque AccuracyAbove 5% of motor base speed: 2% of rated torque Below 5% of motor base speed: 5% of rated torque

EMC Category C3 when system is solidly grounded

Altitude 1000 m without derate; up to 5000 m with derate

Shock & Vibration Power core, drive in cabinet with option bay – 1.000 mm (0.040 in.) displacement, 1 g peak

Technical Specifications - Preliminary Information, Subject to Change

* -3 dB Crossing (Closed Loop) specifications


Input Voltage

Normal Duty Rating

Width Combined Width - Drive with Optional Wiring Bays Depth Height Weight

Drive with Entry Bay

with Exit Bay

with Both Bays IP21 IP54 IP21 IP54 with

Filterwithout

Filter

400 160…400 kW

1200 (47.2) * 1600 (63.0) * 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 861.8 (1900)

920.8 (2030)

480 250…650 Hp

600 250…550 Hp

690 200…500 kW

400 400…800 kW

2000 (78.7) * 2400

(94.5) * 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 1360.8 (3000)

1419.7 (3130)

480 650…1100 Hp

600 550…1000 Hp

690 500…900 kW

400 800…1250 kW

3200 (126.0)

3600 (141.7)

3600 (141.7)

4000 (157.5) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 2925.7

(6450)3043.6 (6710)

480 1100…1800 Hp

600 1000…1500 Hp

690 900…1400 kW

Simplify installation with optional entry and exit wiring bays. Entry and exit wiring bay options provide the flexibility and convenience for cable entry and exit through the top of the cabinet.

755TL Drive

Depth

Height

Combined Width

Entry Wiring

Bay Exit Wiring

Bay

PowerFlex 755TL Drives Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).

* Optional wiring bay is not required for top entry of power cables.


Input Voltage

Normal Duty Rating

Width Combined Width - Drive with Optional Wiring Bays Depth Height Weight

Drive with Entry Bay

with Exit Bay

with Both Bays IP21 IP54 IP21 IP54 with

Filterwithout

Filter400 160…400 kW

1200 (47.2) * 1600 (63.0) * 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 861.8

(1900)920.8 (2030)

480 250…650 Hp600 250…550 Hp690 200…500 kW400 400…800 kW

2000 (78.7) * 2400

(94.5) * 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 1360.8 (3000)

1419.7 (3130)

480 650…1100 Hp600 550…1000 Hp690 500…900 kW400 800…1250 kW

3200 (126.0)

3600 (141.7)

3600 (141.7)

4000 (157.5) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 2925.7

(6450)3043.6 (6710)

480 1100…1800 Hp600 1000…1500 Hp690 900…1400 kW400 1200…1650 kW

3800 (149.6)

4600 (181.1)

4600 (181.1)

5400 (212.6) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 3447.3

(7600)3565.2 (7860)

480 1800…2400 Hp600 1500…2000 Hp690 1400…1800 kW400 1650…2000 kW

4600 (181.1)

5400 (212.6)

5400 (212.6)

6200 (244.1) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 4286.0

(9450)4463.3 (9840)

480 2400…3000 Hp600 2000…2500 Hp690 1800…2300 kW

Simplify installation with optional entry and exit wiring bays. Entry and exit wiring bay options provide the flexibility and convenience for cable entry and exit through the top of the cabinet.

755TR Drive

Depth

Height

Combined Width

Entry Wiring

Bay Exit Wiring

Bay

PowerFlex 755TR Drives Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).



Input Voltage

Normal Duty Rating

Width Depth Height Weight Control

Bay *Inverter

BayExit Wiring

Bay IP21 IP54 IP21 IP54 DC Fuse

DC Precharge

400 160…400 kW

300 (11.8) 400 (15.7) 400 (15.7) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 250.0 (551) 286.0 (630)480 250…650 Hp600 250…550 Hp690 200…500 kW400 400…800 kW

300 (11.8) 600 (23.6) 400 (15.7) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 499.0 (1100) 571.5 (1260)480 650…1100 Hp600 550…1000 Hp690 500…900 kW400 800…1250 kW

300 (11.8) 800 (31.5) 400 (15.7) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 748.4 (1650) 857.3 (1890)480 1100…1800 Hp600 1000…1500 Hp690 900…1400 kW400 1200…1650 kW

300 (11.8) 1200 (47.2) 800 (31.5) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 997.9 (2200) 1143.1 (2520)

480 1800…2400 Hp600 1500…2000 Hp690 1400…1800 kW400 1600…2000 kW

300 (11.8) 1400 (55.1) 800 (31.5) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 1247.4 (2750)

1428.8 (3150)

480 2400…3000 Hp600 2000…2500 Hp690 1800…2300 kW

Exit wiring bay option provides the flexibility and convenience for cable exit through the top of the cabinet.

Common BusInverter

Depth

Height

Combined Width

The Common Bus Inverter is positioned to the right of the Common Bus Supply.

Exit Wiring

Bay

ControlBay

PowerFlex 755TM Common Bus Inverter Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).

* Each inverter requires a control pod. A control bay can hold two control pods.

Select one inverter for each motor. For every inverter, a control pod is required. A control bay can hold up to two control pods.


Input Voltage Normal Duty Rating Width of Bus

Supply

Width with Optional Entry Bay

Depth Height Weight

IP21 IP54 IP21 IP54 with Filter

without Filter

400 160…400 kW

1000 (39.4) * 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 648.6 (1430) 589.7 (1300)480 250…650 Hp600 250…550 Hp690 200…500 kW400 400…800 kW

1400 (55.1) * 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 920.8 (2030) 861.8 (1900)480 650…1100 Hp600 550…1000 Hp690 500…900 kW400 800…1250 kW

2400 (94.5) 2800 (110.2) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 2295.2 (5060) 2177.2 (4800)480 1100…1800 Hp600 1000…1500 Hp690 900…1400 kW400 1200…1650 kW

2600 (102.4) 3400 (133.9) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 2567.3 (5660) 2449.4 (5400)480 1800…2400 Hp600 1500…2000 Hp690 1400…1800 kW400 1650…2000 kW

3200 (126.0) 4000 (157.5) 675 (26.6) 720 (28.3) 2132 (83.9) 2291 (90.2) 3216.0 (7090) 3039.1 (6700)480 2400…3000 Hp600 2000…2500 Hp690 1800…2300 kW

Entry wiring bay option provides the flexibility and convenience for cable entry through the top of the cabinet.

Common Bus Supply

The Common Bus Supplyis positioned to the left of the Common Bus Inverter.

Depth

Height

Combined Width

Entry Wiring

Bay

PowerFlex 755TM Common Bus Supplies Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).



Publication 755T-BR001A-EN-P - February 2016 Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Allen-Bradley, Connected Component Workbench, DeviceLogix, Integrated Architecture, LISTEN. THINK. SOLVE, PowerFlex, Studio 5000, Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc. ControlNet, DeviceNet and EtherNet/IP are trademarks of the ODVA. PROFIBUS is a trademark of PROFIBUS & PROFINET International. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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