what’s new in powerflex drives

What’s new in PowerFlex Drives

Rotec Seminar - Pomorie 2019

PUBLIC | Copyright ©2019 Rockwell Automation, Inc. 2

Today’s PowerFlex family of AC

drives offer customers more

than any other drive

portfolio in the market !

connectivity

productivity

PowerFlex Drives Family !

flexibility

PowerFlex® 520-Series AC Drives

Portfolio Overview


COMPACT EASY TO USE INNOVATIVE DESIGN

The Next Generation of Powerful Performance. Flexible Control.

PowerFlex 520-Series AC Drives

PowerFlex

523

PowerFlex

525

LEARN MORE ABOUT. . .

PowerFlex

527


Compact Market Product Positioning

Performance / Functionality

Va

lue

PowerFlex 523• 30HP

• Standard USB connectivity

• Comms: Embedded DSI

• Comm Options: Dual port EtherNet/IP with DLR, DeviceNet,

Profibus

• Motor Control options: V/Hz, SVC, Economizer SVC

• AppView & CustomView Application Configuration

• CCW Programming Software

PowerFlex 520 Series: Common Attributes

Innovative Design Simplified Configuration

• Modularity design

• Common Power Module

• Smallest clearance requirement

• Zero-stack

• Extreme ambient temperatures

• Simplified programming

• QuickView HIM

• Seamless integration into Logix with

add-on-profiles for Studio 5000

PowerFlex 525• 30HP

• Standard USB connectivity

• Comms: Embedded DSI + Single port Ethernet/IP

• Comms Options: Dual port EtherNet/IP with DLR, DeviceNet, Profibus

• Safety: Embedded Safe Torque Off SIL2/PLd

• Motor Control options: V/Hz, SVC, Economizer SVC, Closed Loop

Velocity Vector, PM*

• Incremental Encoder Option

• AppView & CustomView Application Configuration

• CCW Programming Software

PowerFlex 527• Integrated Motion

• 30HP

• Communication: Embedded Dual Port Ethernet/IP

• Safety: Embedded Safe Torque Off SIL3/Ple for both

hardwired and Integrated Network Safety

• Motor control Option: V/Hz, SVC, Closed Loop Velocity

Vector, PM*

• Incremental Encoder Option

• Removable terminal blocks

• Programmed via embedded motion instructions

Connected Components Mid-Range Offering


Innovative Design

Modular design helps reduce installation and configuration time

Compact footprint

No penalty for adding option cards

Small mounting clearances at the top and bottom of drive

High ambient temperature operation up to 70°C (158°F)

Flexible installation with both vertical and horizontal

and side-by-side installation

PowerFlex 525 has built in: single port for EtherNet/IP

and Safe Torque Off

PowerFlex 527 has built in: dual ports

for EtherNet/IP, hardwired Safe Torque Off and Network safety



Modular Design

Removable control module helps speed installation

One control module supports entire power range

No size penalty when adding option cards

Ease of Programming

Studio 5000™ Logix Designer: AOPs & ADC

Connected Component Workbench software (PowerFlex 523 and 525 only)

Dedicated application parameter groups (PowerFlex 523 and 525 only)

MainsFree™ programming

Flexible Installation

Requires only 50mm (1.96 in) space for top and bottom

Horizontal mounting

Zero Stacking up to 45oC (113oF)

Din rail mounting for frames A, B and C and high ambient temperature up to 70oC (158oF)

Energy Saving

Reduce energy costs with Economizer control mode

CIP Energy - Energy sensing capability (PowerFlex 527 only)

Global Voltages

100V, 200V, 400V, 600V

Multiple EMC filtering options

Embedded EMC filtering at 1ph 200V & 3ph 400V class

Optional external EMC filtering for longer cable length

Robustness

Allow -15% / +10% input voltage

Conformal Coating to 3C2 specification (Chemical Gases only)


Common Attributes

Ideal for standalone and simple-to-standard machine builders and simple system integration



EtherNet/IP Topologies

Rockwell Automation® supports rings at the device level (DLR)

Linear

Star

Ring

PowerFlex 750-Series AC DrivesPortfolio Overview


PowerFlex® 750-Series Drives

Commercial Release 2 Scalable Solutions

PowerFlex 753 PowerFlex 755 PowerFlex 755TR PowerFlex 755TMPowerFlex 755TL1–400 Hp/ 0.75–270 kW

Regeneration

& Low Harmonic

Common Bus

Drive SystemLow Harmonic

Speed & Torque

Control

1–2000 Hp/ 0.75–1500 kW 10–1800 Hp / 7.5 to 1400 kW

Speed, Torque

& Position Control

10 to 6000 Hp / 7.5 to 4500 kW 250 to 6000 Hp / 160 to 4500 kW

6-pulse Drive

Speed, Torque

& Position Control

Speed, Torque

& Position Control

Speed, Torque

& Position Control

6-pulse Drive


PowerFlex® 753, 755 - Series Drives

Input Voltage

Power Range

Current Range

200…240V

0.5 to 200 Hp

0.37 to 132 kW

2.2 to 477 A

400…480V

2.1 to 2330 A

1 to 2000 Hp

0.75 to 1400 kW

1.7 to 1530 A

1 to 1500 Hp

0.75 to 1500 kW

600…690V

PowerFlex ® 753,755-Series drives offer scalable solutions from 200V

to 690V


PowerFlex 753

Speed and torque control

Premier Integration to Rockwell Automation Architecture

Embedded I/O and 3 option slots

General purpose applications

Predictive diagnostics to extend the life of cooling fans and relay outputs

DeviceLogix for standalone applications

Wall mount construction

IP00/IP20 NEMA/UL Type Open, flange mount, IP54 NEMA/UL Type 12

Power ratings:

200...240V: 0.37…132 kW / 0.5…200 Hp / 2.2…477 A

380…480V: 0.75…250 kW / 1.0…350 Hp / 2.1…456 A

600V: 1.0…300 Hp / 1.7…289 A

690V: 7.5…250 kW / 12…263 A


PowerFlex 755 Speed, torque and advanced position control – PMM control

Embedded EtherNet/IP port and 5 option slots

Performance applications

Coordinated drive systems applications Positioning applications Torqueprove (lifting)

DeviceLogix to complement system capabilities

Use of embedded instructions within Studio 5000 (CIP Motion)

Predictive diagnostics to extend the life of cooling fans and relay outputs

Wall mount and floor mount construction

IP00/IP20 NEMA/UL Type Open, flange mount, IP54 NEMA/UL Type 12

Power ratings:

200...240V: 0.37...132 kW / 0.5…200 Hp / 2.2…477 A

380…480V: 0.75…1400 kW / 1.0…2000 Hp / 2.1…2330 A

600V: 1.0…1500 Hp / 1.7…1530 A

690V: 7.5…1500 kW / 12…1485 A


PowerFlex 750-Series

Control and Option slots

Control Board

Option Slots

PowerFlex 753

3 option slots for communications,

safety, feedback and additional I/O

Standard embedded I/O

Control Board

Option Slots

PowerFlex 755

5 option slots for communications, safety, feedback, I/O, and auxiliary power supply

3 option slots for frame 1

Standard embedded EtherNet/IP port


PowerFlex 755 Floor MountedVoltag

e

Frame 8 Frame 9 Frame 10

400 V 200 to 450 kW 400 to 900 kW 710 to 1400 kW

480 V 300 to 700 HP 600 to 1350 HP 1100 to 2000 HP

600 V 250 to 550 HP 500 to 1100 HP 1000 to 1500 HP

690 V 200 to 530 kW 450 to 1000 kW 900 to 1500 kW

Common experience from low to high power

Highly Robust & Reliable

Conformal coating as standard Efficient cooling with use of external air (sealed

cooling channel)

Application Flexibility

AC or Common DC Bus input NEMA 1, NEMA 12, Open Type IP00, IP20 and IP54 Enclosures Top and/or bottom cable entry Segregated power and control wire channels


PowerFlex 755 Floor Mounted Easy to Install & Use

Roll Out Design

Adjustable Wire Terminations

N-1 Operation

Remote Mountable Control Chassis

Easy to Maintain & Service

Modular Design - Low MTTR

Replaceable Surge Protectors

Easy to Monitor & Diagnose

Surge Protector & Fuse Feedback

Blower / Fan Feedback

Enhanced Sensing

Smart Features for Extra Savings

Integrated Fusing

Built-In EMC Filtering

Pre-Engineered Power Option Packages


Roll out design provides easy access for installation or service

Field power wiring stays in place while unit is rolled out

Drive assembly rolls out completely

Option to roll out inverter only(converter & control stays in place)

PF 755 Floor Mounted: Design Details


Frame 9

600…1350 HpFrame 10

1100…2000 Hp

Frame 8

350…700 Hp

PF 755 Floor Mounted: Basic Architecture


PF 755 Floor Mounted - Design Details

INVERTER FAN w/DUCT

CONVERTER DUCT

CABINET DUCT (2 PIECE)

Converter

Inverter

Side View

Air Flow

Air Flow

Sealed cooling channel uses external air

for main cooling

Reduces electrical component exposure to

contamination from environmental

elements

High volume fan pulls air into cooling

channel

Forked fin heat sink helps

dissipate heat


Product Versions

PowerFlex®

755T Product Details

PowerFlex 755TL

Low Harmonic Drive

PowerFlex 755TR

Regenerative Drive

PowerFlex 755TM

Drive System


Features

PowerFlex 755T

Ideal for applications requiring low harmonics and/or regeneration up to 4000 kW New

Core capabilities aligned with PowerFlex 755 drives

Additional capabilities:

Hardware platform designed for common bus drive systems

Total harmonic distortion levels of less than 5%

Embedded dual-port EtherNet/IP communications

Offers configuration and programming via HIM, Studio 5000 Logix Designer®,

or Connected Components Workbench™ software

TotalFORCE motor control capability

Offers a variety of motor control options that include permanent magnet motor support

Includes adaptive control capabilities that allows the drive to monitor machine

characteristics that can change over time and automatically compensate for

the changes that occur

Offers predictive maintenance features that provide real-time information about

the health of the drive. The drive is able to calculate the remaining life of critical

components and notify users

PowerFlex 755TL,

TR, TM

Low Harmonic, Regenerative,

Common DC Bus

Speed, Torque,

Position Control

7.5 to 4000 kW


TotalFORCE® Technology

The next generation of FORCE motor control

Advanced power control capabilities

Differentiated motor control performance

Predictive analytics for maintenance

Patented Adaptive Control

PowerFlex® 755T Drives

Enhanced Motor Control


Active Front End technology provides advanced capabilities for AC drives, helping provide better performance and more efficient use of energy

PowerFlex® 755T Drives – TotalFORCE® Technology

Advanced Power Control Capabilities

Requirements 3-phase AC power

LCL filter and Active converter

Inverter

Capabilities Regeneration

Harmonic Mitigation

Power Factor

Voltage Boost



Advanced Power Control Capabilities – Regeneration

Braking Resistor

Non-regenerative

ConverterInverterAC Power

Line

Regenerative

Power

Motoring

Power

Motoring

Power

Motor

Regenerative

ConverterInverterAC Power

Line

Regenerative

Power

Motoring

Power

Regenerative

Power

Motoring

Power

Motor

Regeneration leverages bi-directional flow of current through the active converter enabling more efficient use of energy

Ideal for applications that have:

Overhauling loads

Frequent stops/starts

Constant deceleration


The Control and User Performance Architecture is a platform that leverages state-of-the-art hardware technology integrated with modern design techniques


Differentiated Motor Control Performance

Motor Shaft Performance Bandwidth

Velocity Tracking

Disturbance Rejection

Modern and efficient model-based software

techniques

Fast multicore microprocessors

Fast control and system loop speeds Position Loop

Speed Loop ~ 4 times faster than the position loop

Torque Loop ~ 2 times faster than the speed loop


Premier Integration – AnalyticsPowerFlex® 750-Series Predictive Maintenance

Maintenance

Reactive

Preventative

Predictive

Cost

Predictive Maintenance monitors drive and system components

All PowerFlex 750-Series drives Fans – heat sink, internal, cabinet

Digital output relay contacts

Motor and machine bearing and lubrication

PowerFlex 755T drives DC bus capacitors

LCL filter capacitors

Power module IGBTs — Thermal Manager

Precharge contactors and switches

Predictive algorithms calculate remaining component life based on application

factors:

Temperature, air quality, vibration, drive size, runtime & cycles

Drive provides notification before the predicted components life

MAINTAIN


Premier Integration – AnalyticsReduce Downtime with PowerFlex® 755T Adaptive Control

Adaptive Control reduces the need for tuning by delivering capabilities that automatically adapt and compensate for system dynamics

Load Observer - Improved performance and time savings

Automatically compensates for unknown mechanics and compliance

Helps save time by eliminating the need for tuning each axis

Adaptive Tuning – Helps save time and improve ease of use

Automatically adapts to changes in resonance frequency over time


Premier Integration – AnalyticsPowerFlex® 750 Predictive Maintenance Configuration

MAINTAIN

Predictive Maintenance can be used in both integrated and standalone applications

to help reduce downtime

Enabled and configured via parameters

PowerFlex HIM

Studio 5000®

Connected Components Workbench™

Configurable notification on upcoming maintenance via drive alarm or fault

Controller can read Predictive Maintenance parameters and monitor alarms


Hardware Design

PowerFlex®


Designed for efficient installation and maintenance

while optimizing floor space required

Modular design with roll in/out units

Power wiring stays connected while unit is rolled out

Access to service areas and simplified removal of parts

Enclosure types IP21 (Type 1) and IP54 (Type 12)

IP00 for selected customers

Common spare parts throughout product range

Reduced spare part inventory


PowerFlex 755TL Low Harmonic Drive

PowerFlex®


Power range 7,5..1400 kW / 10..1800 HP

Designed to mitigate harmonics with active front end

technology and internal harmonic filter

Complete solution

Line side converter

Harmonic filter

Inverter

Delivered complete with a non-regenerative AFE converter

Mitigates harmonics to meet IEEE 519

(< 5% total harmonic distortion)


PowerFlex 755TR Regenerative Drive

PowerFlex®


Power range 7,5..4000 kW / 10..6000 HP

Regeneration and low harmonics with active front end technology

Complete solution

Regenerative line side converter

Harmonic filter

Inverter

Reuse of dissipated energy for other applications

Elimination of braking resistors and costs associated with installation,

cooling, and maintenance


PowerFlex 755TR Regenerative Drive

PowerFlex®


1. AC Pre-charge regulates the

input AC current from the

incoming power source, greatly

reducing stress on the power

components during power up.

2. LCL filter is a 230 mm wide

module that provides low

harmonic capability and

minimizes the current distortion

into the utility grid.

3. 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.

4. Motor side inverter is a 230

mm wide module that controls

the voltage and current of the

motor.

5. IP21/IP54 enclosures provide

a choice of packaging options to

meet the environmental

requirements of your

application.

6. 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.


PowerFlex 755TM Drive System

PowerFlex®


Power range 160..4000 kW / 250..6000 HP

World-class coordinated multi-motor systems

Best-in-class footprint, usability, and motor control performance

Common DC bus inverters

One common bus inverter per motor

Patented common mode noise reduction

Common DC bus supplies

Input power for entire common bus system

Single point of AC connection and protection

Support of contemporary PowerFlex 750-Series


PowerFlex 755TM Drive System

1. AC Pre-charge module regulates the

input

AC current from the incoming power

source, greatly reducing stress on the

power components during power-up.

2. LCL Filter is a 230 mm wide module

that provides low harmonic capability

and minimizes the current distortion

into the utility grid.

3. 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.

4. Motor side inverter is a 230 mm

wide module that controls the voltage

and current of the motor.

5. IP21/IP54 enclosures provide a

choice of packaging options to meet

the environmental requirements of

your application.

6. 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.

7. 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.

8. 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.

9. Power wiring can stay connected

while unit is rolled out.


Common Features

PowerFlex®

755T Functions & Features

Programming

Dynamic Human Interface Module (HIM)

Connected Components Workbench™

Studio 5000 Logix Designer™

Network communication

Built-in dual port for EtherNet/IP

Options for additional industrial networks

Safety

Network safety (Safe Torque-Off)

Hardwired safety (Safe Torque-Off and Speed Monitoring)


PowerFlex Drives - Safety Solutions


Safety continues to emerge as core system function

Value of Functional Safety:

Increased productivity

Systematic MTTR reduction

Improved competitiveness

Reduced floor space and direct labor

Reduced costs

Global compliance

Common designs

Improved ergonomics

Reduced injuries

Why Safety?

Rockwell Automation is committed to delivering world class safety products

& solutions


Networked Safety SIL3/Ple (20-

750-S3)

Hardwired Safety SIL3/Ple (20-

750-S)

Safe Torque Off PowerFlex 755 AC Drives Safety Solutions Offerings

SensaGuard

Non-Contact

Interlocks

GuardLogix

Controller

Guardmaster

Safety Relay

Stratix Switch

PointGuard I/O GuardLogix

Controller

SensaGuard

Non-Contact

Interlocks

Stratix Switch

Eliminate field wiring

and safety relays


Safety Solutions via Hardware (IO & Relay)Flexible Options for All Applications

Safe Torque OffSafe Speed Monitor

PowerFlex 525 drive

PowerFlex 527 drive

PowerFlex 755 drive*


Kinetix 5500

ArmorStart ST


Kinetix 5700



* Via Option Card

PowerFlex 755T drive*

PowerFlex 755T drive*


Networked Safe Torque Off Product Overview

Designed for the PowerFlex 755 and 755T AC drives

Safely removes power from the gate firing circuits of the drive’s output power

devices (IGBT)

Provides networked Safe Torque Off over EtherNet/IP

TÜV Rheinland Approved for networked and hardwired STO

PLe, CAT 3 per ISO 62061

SIL3 per IEC EN 61800-5-2

Stop Category 0 per EN 61800-5-2


Networked Safety SIL3/PLe

Reduced overall

panel footprint

One node for safety

& drive

Reduced hardware,

wiring & labor costsField installable

Networked Safe Torque Off Product Benefits


Scalable Software Safety Solutions Control and Safety on the same wire

PowerFlex 527 drive

Kinetix 5500 servo drive

PowerFlex 755T drive S3*

PowerFlex 755 drive S3*


Networked Safe Torque Off

* Via Option Card

Networked Safety Functions


PowerFlex 755 drive S4*

PowerFlex 755T drive S4*


Integrated Safety Functions Opt. Module Product Overview for 20-750-S4

SLS Safely-Limited Speed

SDI Safe Direction

SBC Safe Brake Control

SLP Safely-Limited Position*PF755T only

Designed for the PowerFlex 755 and 755T AC drives

Provides networked Safety Functions over EtherNet/IP

SIL3, PLe, CAT4

Supported IEC 61800-5-2 Safety Functions:

STO Safe Torque Off

SS1 Safe Stop 1

SS2 Safe Stop 2*

SOS Safe Operational Stop*


PointGuard

I/OTM

GuardLogix® Integrated

Safety System Controller

PowerFlex 755 with

Networked Safe Monitor

Stratix 5700TM Industrial

Ethernet switch

Integrated Safety Functions Option Module Example

Feedback Options(20-750-UFB-1 or

20-750-DENC-1)

20-750-S4

Integrated Safety Functions

Option Module


PF 753/755 Firmware Version 14.002Overview

New features include:

Drive support for Integrated Advanced Safety Card

CIP Motion instructions with Networked Safety

Emergency Override capability in drive

Auto Clear Fault functional enhancements

Top of Frame ADC functionality

Unfiltered Feedbacks

Home to Torque

www.rockwellautomation.com

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