What’s new in PowerFlex Drives

Rotec Seminar - Pomorie 2019

PowerFlex Drives Family !

Today’s PowerFlex family of AC

drives offer customers more
flexibility
connectivity
productivity
than any other drive
portfolio in the market !
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PowerFlex® 520-Series AC Drives

Portfolio Overview
PowerFlex 520-Series AC Drives
The Next Generation of Powerful Performance. Flexible Control.

COMPACT EASY TO USE INNOVATIVE DESIGN

LEARN MORE ABOUT. . .

PowerFlex PowerFlex PowerFlex

523 525 527

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Compact Market Product Positioning
Connected Components Mid-Range Offering
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
PowerFlex 525 Vector, PM*
• 30HP • Incremental Encoder Option
• Standard USB connectivity • Removable terminal blocks
• Comms: Embedded DSI + Single port Ethernet/IP • Programmed via embedded motion instructions
• Comms Options: Dual port EtherNet/IP with DLR, DeviceNet, Profibus
Value

• Safety: Embedded Safe Torque Off SIL2/PLd

• Motor Control options: V/Hz, SVC, Economizer SVC, Closed Loop
Velocity Vector, PM*
PowerFlex 523 • Incremental Encoder Option
• 30HP • AppView & CustomView Application Configuration
• Standard USB connectivity • CCW Programming Software
• 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

Performance / Functionality

PowerFlex 520 Series: Common Attributes

Innovative Design Simplified Configuration
• Modularity design • Smallest clearance requirement • Simplified programming • Seamless integration into Logix with
• Common Power Module • Zero-stack • QuickView HIM add-on-profiles for Studio 5000
• Extreme ambient temperatures
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PowerFlex 520-Series AC Drives
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

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PowerFlex 520-Series AC Drives
Common Attributes
Modular Design
Removable control module helps speed installation Energy Saving
One control module supports entire power range Reduce energy costs with Economizer control mode
No size penalty when adding option cards CIP Energy - Energy sensing capability (PowerFlex 527
Ease of Programming only)

Studio 5000™ Logix Designer: AOPs & ADC Global Voltages

Connected Component Workbench software 100V, 200V, 400V, 600V
(PowerFlex 523 and 525 only) Multiple EMC filtering options
Dedicated application parameter groups (PowerFlex Embedded EMC filtering at 1ph 200V & 3ph 400V class
523 and 525 only)
Optional external EMC filtering for longer cable length
MainsFree™ programming
Robustness
Flexible Installation
Allow -15% / +10% input voltage
Requires only 50mm (1.96 in) space for top and bottom
Conformal Coating to 3C2 specification (Chemical
Horizontal mounting Gases only)
Zero Stacking up to 45oC (113oF)
Din rail mounting for frames A, B and C and high
ambient temperature up to 70oC (158oF)

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

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PowerFlex 520-Series AC Drives
EtherNet/IP Topologies

Linear

Star

Rockwell Automation® supports rings

Ring at the device level (DLR)

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PowerFlex 750-Series AC Drives
Portfolio Overview
PowerFlex® 750-Series Drives
Commercial Release 2 Scalable Solutions

PowerFlex 753 PowerFlex 755 PowerFlex 755TL PowerFlex 755TR PowerFlex 755TM
1–400 Hp/ 0.75–270 kW 1–2000 Hp/ 0.75–1500 kW 10–1800 Hp / 7.5 to 1400 kW 10 to 6000 Hp / 7.5 to 4500 kW 250 to 6000 Hp / 160 to 4500 kW

Speed & Torque Speed, Torque Speed, Torque Speed, Torque Speed, Torque
Control & Position Control & Position Control & Position Control & Position Control

Regeneration Common Bus

6-pulse Drive 6-pulse Drive Low Harmonic
& Low Harmonic Drive System

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 PowerFlex® 753, 755 - Series Drives

Input Voltage 200…240V 400…480V 600…690V

0.5 to 200 Hp 1 to 2000 Hp 1 to 1500 Hp

Power Range
0.37 to 132 kW 0.75 to 1400 kW 0.75 to 1500 kW

Current Range 2.2 to 477 A 2.1 to 2330 A 1.7 to 1530 A

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

to 690V PUBLIC | Copyright ©2019 Rockwell Automation, Inc. 11
 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

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 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

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PowerFlex 750-Series
Control and Option slots
PowerFlex 755
 5 option slots for communications,
safety, feedback, I/O, and auxiliary power
Control Board supply
 3 option slots for frame 1
 Standard embedded EtherNet/IP port
Option Slots

Control Board
PowerFlex 753
 3 option slots for communications, Option Slots
safety, feedback and additional I/O
 Standard embedded I/O

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PowerFlex 755 Floor Mounted
Voltag Frame 8 Frame 9 Frame 10
e
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
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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

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PF 755 Floor Mounted: Design Details

 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)

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PF 755 Floor Mounted: Basic Architecture

Frame 8 Frame 9 Frame 10

350…700 Hp 600…1350 Hp 1100…2000 Hp PUBLIC | Copyright ©2019 Rockwell Automation, Inc. 18
PF 755 Floor Mounted - Design Details

 Sealed cooling channel uses external air

for main cooling
Air Flow
 Reduces electrical component exposure to CABINET DUCT (2 PIECE)
contamination from environmental
elements Converter
 High volume fan pulls air into cooling CONVERTER DUCT

channel

 Forked fin heat sink helps

dissipate heat
Inverter

INVERTER FAN w/DUCT

Air Flow

Side View
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 ®
PowerFlex 755T Product Details
Product Versions

PowerFlex 755TL PowerFlex 755TR PowerFlex 755TM

Low Harmonic Drive Regenerative Drive Drive System
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 PowerFlex 755T
Features
 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 PowerFlex 755TL,
the changes that occur TR, TM
7.5 to 4000 kW
 Offers predictive maintenance features that provide real-time information about
Speed, Torque,
the health of the drive. The drive is able to calculate the remaining life of critical Position Control
components and notify users Low Harmonic, Regenerative,
Common DC Bus
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PowerFlex® 755T Drives
Enhanced Motor Control

TotalFORCE® Technology
The next generation of FORCE motor control

Advanced power control capabilities

Differentiated motor control performance

Predictive analytics for maintenance

Patented Adaptive Control

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 PowerFlex® 755T Drives – TotalFORCE® Technology
Advanced Power Control Capabilities

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

 Requirements
 3-phase AC power
 LCL filter and Active converter
 Inverter

 Capabilities
 Regeneration
 Harmonic Mitigation
 Power Factor
 Voltage Boost

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 PowerFlex® 755T Drives – TotalFORCE® Technology
Advanced Power Control Capabilities – Regeneration

Regeneration leverages bi-directional flow of Braking Resistor

current through the active converter enabling

more efficient use of energy Motoring Motoring
Power Power

 Ideal for applications that have: AC Power Non-regenerative

Inverter Motor
 Overhauling loads
Converter
Line
Regenerative
 Frequent stops/starts Power

 Constant deceleration

Motoring Motoring
Power Power

AC Power Regenerative
Converter
Inverter Motor
Line
Regenerative Regenerative
Power Power

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 PowerFlex® 755T Drives – TotalFORCE® Technology
Differentiated Motor Control Performance

The Control and User Performance Architecture is a platform that leverages state-of-
the-art hardware technology integrated with modern design techniques
 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
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 Premier Integration – Analytics
PowerFlex® 750-Series Predictive Maintenance MAINTAIN

Maintenance  Predictive Maintenance monitors drive and system components

Reactive  All PowerFlex 750-Series drives
 Fans – heat sink, internal, cabinet
Preventative  Digital output relay contacts

Predictive  Motor and machine bearing and lubrication

 PowerFlex 755T drives

 DC bus capacitors
Cost  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
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Premier Integration – Analytics
Reduce 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
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 Premier Integration – Analytics
PowerFlex® 750 Predictive Maintenance Configuration
MAINTAIN

 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

Predictive Maintenance can be used in both integrated and standalone applications

to help reduce downtime
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 ®
PowerFlex 755T Product Details
Hardware Design

 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

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 ®
PowerFlex 755T Product Details
PowerFlex 755TL Low Harmonic Drive

 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)

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 ®
PowerFlex 755T Product Details
PowerFlex 755TR Regenerative Drive

 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

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 ®
PowerFlex 755T Product Details
PowerFlex 755TR Regenerative Drive
1. AC Pre-charge regulates the 4. Motor side inverter is a 230
input AC current from the mm wide module that controls
incoming power source, greatly the voltage and current of the
reducing stress on the power motor.
components during power up.
5. IP21/IP54 enclosures provide
2. LCL filter is a 230 mm wide a choice of packaging options to
module that provides low meet the environmental
harmonic capability and requirements of your
minimizes the current distortion application.
into the utility grid.
6. Control pod contains the
3. Line side converter is a 230 mm control platform that is
wide module. In the PowerFlex responsible for motor control,
755TL, it draws energy from the system control and
AC line without harmonic communications. Five option
distortion and converts it to DC slots allow you to add I/O,
power. safety and feedback.
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 ®
PowerFlex 755T Product Details
PowerFlex 755TM Drive System

 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

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PowerFlex 755TM Drive System
1. AC Pre-charge module regulates the 6. Control pod contains the control
input platform that is responsible for motor
AC current from the incoming power control, system control and
source, greatly reducing stress on the communications. Five option slots
power components during power-up. allow you to add I/O, safety and
2. LCL Filter is a 230 mm wide module feedback. There is one control pod
that provides low harmonic capability for each common bus inverter and
and minimizes the current distortion one for the regenerative bus supply.
into the utility grid. 7. DC Pre-charge regulates the input
3. Line side converter is a 230 mm DC current from the incoming power
wide module. In the PowerFlex source, greatly reducing stress on
755TM, it draws energy from the AC the power components during power-
line without harmonic distortion and up. It also provides a means of
converts it to DC power. It also isolating the inverter from the DC bus
provides a means of regeneration for service or maintenance.
back to the AC line. 8. Roll in/roll out design makes the
4. Motor side inverter is a 230 mm drive easy to install and service by
wide module that controls the voltage allowing complete removal of a
and current of the motor. module from cabinet, providing
generous room for wiring behind the
5. IP21/IP54 enclosures provide a drive.
choice of packaging options to meet
the environmental requirements of 9. Power wiring can stay connected
your application. while unit is rolled out.
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 ®
PowerFlex 755T Functions & Features
Common 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)

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PowerFlex Drives - Safety Solutions

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 Why Safety?
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

Rockwell Automation is committed to delivering world class safety products

& solutions
PUBLIC | Copyright ©2019 Rockwell Automation, Inc. 37
 Safe Torque Off
PowerFlex 755 AC Drives Safety Solutions Offerings
Hardwired Safety SIL3/Ple (20- Networked Safety SIL3/Ple (20-
750-S) 750-S3)
SensaGuard
GuardLogix Non-Contact
SensaGuard Controller Interlocks GuardLogix
PointGuard I/O
Non-Contact Controller
Interlocks

Stratix Switch

Stratix Switch

Guardmaster
Safety Relay Eliminate field wiring
and safety relays
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Safety Solutions via Hardware (IO & Relay)
Flexible Options for All Applications

Safe Torque Off

Safe Speed Monitor
PowerFlex 525 drive
PowerFlex 753 drive*
PowerFlex 527 drive
PowerFlex 755 drive*
PowerFlex 753 drive*
PowerFlex 755T drive*
PowerFlex 755 drive*
PowerFlex 755T drive*
* Via Option Card
PowerFlex 7000 drive*
Kinetix 5500
Kinetix 5700
ArmorStart ST

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 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

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Networked Safe Torque Off
Product Benefits
Networked Safety SIL3/PLe

Reduced hardware,
Field installable
wiring & labor costs

Reduced overall One node for safety

panel footprint & drive

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Scalable Software Safety Solutions
Control and Safety on the same wire
Networked Safe Networked Safety
Torque Off Functions
PowerFlex 527 drive Kinetix 5700 servo drive
Kinetix 5500 servo drive PowerFlex 755 drive S4*
Kinetix 5700 servo drive PowerFlex 755T drive S4*
PowerFlex 755T drive S3*
PowerFlex 755 drive S3*

* Via Option Card

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

 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  SLS Safely-Limited Speed

 SS1 Safe Stop 1  SDI Safe Direction
 SS2 Safe Stop 2*  SBC Safe Brake Control
 SOS Safe Operational Stop*  SLP Safely-Limited Position
*PF755T only

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Integrated Safety Functions
Option Module Example

PowerFlex 755 with

GuardLogix® Integrated
Networked Safe Monitor
Safety System Controller

PointGuard
I/OTM
20-750-S4
Integrated Safety Functions
Option Module

Stratix 5700TM Industrial

Ethernet switch

Feedback Options
(20-750-UFB-1 or
20-750-DENC-1)

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 PF 753/755 Firmware Version 14.002
Overview

 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

PUBLIC | Copyright ©2019 Rockwell Automation, Inc. 45

Thank you
www.rockwellautomation.com