PowerFlex 755T Drive Solutions New Solutions for Low Harmonic, Regenerative & Common Bus Applications

Tomorrow s PowerFlex 755T drives expand our portfolio for greater flexibility connectivity productivity and to compete for applications that were previously out of reach Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 3

Introduction Scalable Solutions PowerFlex 753 PowerFlex 755 PowerFlex 755TL PowerFlex 755TR PowerFlex 755TM 0.75 to 270 kw 0.75 to 1500 kw 160 to 1400 kw 160 to 2000 kw Speed and Torque Control Speed, Torque, Position Control Speed, Torque, Position Control Speed, Torque, Position Control Speed, Torque, Position Control 6-Pulse Drive 6-Pulse Drive Low Harmonic Regeneration and Low Harmonic Common Bus Drive System Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 4

PowerFlex 755T Drive Solutions The next step in Powerful Performance. Flexible Control. New drives offer more precise and responsive motor control with TotalFORCE control technology Cost effective solutions for regeneration, low harmonics and flexible drive system configurations Designed with more self aware capabilities to help keep your productions up and running Reduced footprint and save time and costs associated with installation and maintenance Seamlessly integrate into Logix control system with Premier Integration Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 6

PowerFlex 755T Drive Solutions PowerFlex 750-Series Foundation Commonality with PowerFlex 755 drives Designed for ease of installation and maintenance Premier Integration with Studio 5000 Logix Designer PowerFlex 750-Series control pod architecture Safety, feedback, communications and I/O options Programming tools Predictive diagnostics Added features Regenerative and harmonic reduction capability Line disturbance ride through and power factor correction TotalFORCE Technology Built-in dual port EtherNet/IP Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 7

PowerFlex 755T Drive Solutions Hardware Design Designed for efficient installation and maintenance while optimizing the floor space required Modular design with roll in/out units Wire unit once power wiring stays connected while unit is rolled out Highly serviceable with access to service areas and eased removal of parts Enclosure types to meet environmental requirements: IP21 (Type 1) and IP54 (Type 12) Common spares through out PowerFlex 755T drives helps reduce spare part inventory Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 8

PowerFlex 755T Drive Solutions Premier Integration Experience Studio 5000 is the single software tool to configure devices for a Logix architecture Premier Integration gives you: 1. Single software tool for controller and drive setup 2. Faster configuration with full access to device data 3. Interface to streamline device configuration and programming a. Device parameters, control tags, device properties b. Elimination of mismatch errors 4. Automatic Device Configuration Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 9

PowerFlex 755T Drive Solutions Safety Safety options help protect personnel and assets while enabling increased application uptime Safe Torque Off removes rotational power to the motor without shutting down the drive. SIL 3/PLe CAT 3 Safe Speed Monitor allows access to parts of the application while there is limited motion. SIL 3/Ple CAT 4 Helps with faster start ups and reduces wear on motor assets Reduce wiring and installation space with safety options installed directly into the drive Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 10

PowerFlex 755T Drive Solutions Communications Industrial networks enable real time visibility to optimize production, maintenance, and safety Standard built-in dual port for EtherNet/IP Supports linear, star and ring topologies with support for DLR Options for additional industrial networks DeviceNet (20-750-DNET) ControlNet (20-750-CNETC) ProfiNet (20-750-PNET, 20-750-PNET2P) ProfiBus (20-750-PBUS) BacNET/IP (20-750-BNETIP) Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 11

PowerFlex 755T Drive Solutions Simplified Programming Dynamic Human Interface Module (HIM) LCD Scrolling Text Multiple Languages Connected Components Workbench Software Free software Studio 5000 Logix Designer Application Premier Integration Automatic Device Configuration (ADC) Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 12

PowerFlex 755T Drive Solutions Predictive Maintenance Improve productivity with built-in predictive maintenance capabilities to monitor drive and associated motors before an unplanned event occurs Predict remaining life span of fan/blower, bus & LCL capacitors, IGBTs and relay contacts Measuring and monitor the run time hours for machine or motor bearings Thermal manager provides dynamic control of your power components for increased thermal life Blown fuse indication and feedback Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 13

PowerFlex 755T Drive Solutions TotalFORCE Technology FORCE Technology (Current PF753 & PF755) Patented motor control since the early 90 s Concurrent & independent control of Flux and Torque Motor agnostic control for maximum flexibility TotalFORCE Technology (PowerFlex 755T) Next Generation of FORCE Technology High bandwidth motor control World-class torque smoothness / accuracy Load Observer and Adaptive Tuning Patented common mode noise reduction algorithms Enhanced energy efficient control capabilities Simplified startup and user experience Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 14

PowerFlex 755T Drive Solutions Low Harmonics Built-in harmonic mitigation helps reduce costs associated with hardware, energy and maintenance. Mitigate harmonics with active front end technology combined with active converter and LCL filter Eliminate need for external multi-phase transformers and associated costs and floor space Combination of lower harmonics and power factor correction reduce the need to oversize electrical power equipment Maintains power factor near 1.0 Meets IEEE 519 (< 5% total harmonic distortion) 145 150 162 175 187 195 0.0 Lx1.I = 0.0 100 0 0 00.0-10 00.0-20 145 150 162 175 187 195 755TL 755TR 755TM Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 15

PowerFlex 755T Drive Solutions Regeneration Provides more energy efficient solution than resistive braking Reduce energy expenses and return energy back to incoming power supply Reduce the need for braking resistors and associated equipment save on acquisition, installation and maintenance costs Active front end technology with regeneration lower harmonics and provides means for regeneration 755TR 755TM Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 16

PowerFlex 755T Drive Solutions Common Bus Drive System Enable coordination of multiple motors based on two main building blocks: regenerative common bus supplies and common bus inverters Optimize the sizing of the bus supply to strictly match the energy consumption requirement of the application Flexibility to combine inverters and bus supplies into different arrangements and ratings to create a high power dense system with a small footprint Use one interface to configure and program the converter and inverter Optimize floor space, installation and hardware with drives connected via common bus Reduce costs associated with additional hardware, wiring, installation when using common bus system Gain energy efficiencies with coordinated motors that share energy between regenerating and motoring loads Scalable system use PowerFlex 753 & PowerFlex 755 drives in our common bus system 755TM Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 17

PowerFlex 755T Drive Solutions Footprint World-class footprint to minimize floor space requirements Eliminate the space needed for additional hardware along with associated costs with acquisition, installation, wiring and maintenance Eliminate external filter and transformers to reduce harmonics Eliminate the need for resistive braking for regeneration Optimize your drive system with high a high power density system and small footprint Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 18

PowerFlex 755TL AC Drive PowerFlex 755TL Low Harmonic Drive 160-1250 kw / 250-1800 Hp Designed to mitigate harmonics using active front end technology and internal harmonic filter Complete solution that includes: line side converter and harmonic filter and inverter Delivered complete with a non-regenerative AFE converter Mitigates harmonics to meet IEEE 519 (< 5% total harmonic distortion) Maintains power factor near 1.0 to minimize energy expenses Reduce adverse effects of harmonic distortion on adjacent electrical equipment and control system instrumentation Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 19

PowerFlex 755TL AC Drive Ratings and Dimensions Frame 8 Frame 9 Frame 10 400V (kw) 480V (Hp) 600V (Hp) 690V (kw) Frame Height mm (in.) Width mm (in.) Top Entry Bay Width mm (in.) Top Exit Bay Width mm (in.) Depth mm (in.) 160 400 250 650 250 550 200 500 8 2150 (84.5) 1200 (47.2) NA 400 (15.7) 650 (25.5) 500 800 700 1100 600 1000 560 900 9 2150 (84.5) 2000 (78.7) NA. 400 (15.7) 650 (25.5) 900 1250 1250 1800 1100 1500 1000 1400 10 2150 (84.5) 3200 (126.0) 400 (15.7) 400 (15.7) 650 (25.5) Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 20

PowerFlex 755TL AC Drive Summary Power Ratings 400/480V: 160 to 1250 kw / 250 to 1800 Hp 600/690V: 250 to 1500 Hp / 200 to 1400 kw Motor Control Performance TotalFORCE technology includes flux vector, sensorless vector, V/Hz and Economizer Control Modes Speed, torque and position support Communications Built-in EtherNet/IP dual port Safety Option Safe Torque-Off SIL3/PLe, Cat 3 Safe Speed Monitor SIL3/PLe, Cat 4 Enclosures IP21 IP54 Efficiency 94% at rated amps Global Standards UL, cul, CE,, CAN/CSA, DNV, ABS, Lloyd s Register, IEC 60721-3-3, ISA 71.04-1985, ATEX, Semi-F47, AC156, Regulartory Compliance Mark, EAC Mark, UkrSepro Mark, KC Mark, CE Mark, ODVA EtherNet/IP Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 21

PowerFlex 755TL AC Drive 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. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 22

PowerFlex 755TR AC Drive PowerFlex 755TR Regenerative Drive 160-2000 kw / 250-3000 Hp Provides regeneration and low harmonics with an active front end technology Complete solution that includes: line side converter with regeneration, harmonic filter and inverter Recover dissipated energy and re-use that energy for other applications Eliminate braking resistors and costs associated with installation, cooling, and maintenance Built-in regeneration helps reduce energy consumption by returning energy back to the incoming power supply Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 23

PowerFlex 755TR AC Drive Ratings and Dimensions Frame 8 Frame 9 Frame 10 Frame 11 400V (kw) 480V (Hp) 600V (Hp) 690V (kw) Frame Height mm (in.) Width mm (in.) Top Entry Bay Width mm (in.) Top Exit Bay Width mm (in.) Depth mm (in.) 160 400 250 650 250 550 200 500 8 2150 (84.5) 1200 (47.2) NA 2. 400 (15.7) 650 (25.5) 500 800 700 1100 600 1000 560 900 9 2150 (84.5) 2000 (78.7) NA 2. 400 (15.7) 650 (25.5) 900 1250 1250 1800 1100 1500 1000 1400 10 2150 (84.5) 3200 (126.0) 400 (15.7) 400 (15.7) 650 (25.5) 1650 2400 2000 1800 11 2150 (84.5) 3800 (149.6) 800 (31.5) 800 (31.5) 650 (25.5) 2000 3000 2500 2300 12 2150 (84.5) 4600 (181.1) 800 (31.5) 800 (31.5) 650 (25.5) Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 24

PowerFlex 755TR AC Drive Summary Power Ratings 400/480V: 160 to 2000 kw / 250 to 3000 Hp 600/690V: 250 to 2500 Hp / 200 to 2300 kw Motor Control Performance TotalFORCE technology includes flux vector, sensorless vector, V/Hz and Economizer Control Modes Speed, torque and position support Communications Built-in EtherNet/IP dual port Safety Option Safe Torque-Off SIL3/PLe, Cat 3 Safe Speed Monitor SIL3/PLe, Cat 4 Enclosures IP21 IP54 Efficiency 94% at rated amps Global Standards UL, cul, CE,, CAN/CSA, DNV, ABS, Lloyd s Register, IEC 60721-3-3, ISA 71.04-1985, ATEX, Semi-F47, AC156, Regulartory Compliance Mark, EAC Mark, UkrSepro Mark, KC Mark, CE Mark, ODVA EtherNet/IP Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 25

PowerFlex 755TR AC Drive 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 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. 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. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 26

PowerFlex 755TM Drive Systems PowerFlex 755TM Drive System 160-2000 kw / 250-3000 Hp World-class coordinated multi-motor, common bus systems Best-in-class system footprint, usability, and motor control performance Common Bus Inverters One common bus inverter (up to 3000 Hp) for each motor in system Common bus inverters share a single common DC bus Patented common mode noise reduction algorithms Common DC Bus Supplies Sized to provide input power for entire common bus system Single point of connection and protection for incoming AC power Support for current PF750-Series DC-input drives and PF755TM Common Bus Inverters Optimize the sizing of the bus supply so that energy consumption remains strictly matched with the requirements of the application Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 28

PowerFlex 755TM Bus Supplies Ratings and Dimensions Frame 8 Frame 9 Frame 10 Frame 11 400V (kw) 480V (Hp) 600V (Hp) 690V (kw) Frame Height mm (in.) Width mm (in.) Top Entry Bay Width mm (in.) Depth mm (in.) 160 400 250 650 250 550 200 500 8 2150 (84.5) 1000 (39.4) NA 650 (25.5) 500 800 700 1100 600 1000 560 900 9 2150 (84.5) 1400 (55.1) NA. 650 (25.5) 900 1250 1250 1800 1100 1500 1000 1400 10 2150 (84.5) 2400 (94.5) 400 (15.7) 650 (25.5) 1650 2400 2000 1800 11 2150 (84.5) 2600 (102.4) 800 (31.5) 650 (25.5) 2000 3000 2500 2300 12 2150 (84.5) 3200 (126.0) 800 (31.5) 650 (25.5) Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 29

PowerFlex 755TM Common Bus Inverters Ratings and Dimensions Frame 8 Frame 9 Frame 10 Frame 11 400V (kw) 480V (Hp) 600V (Hp) 690V (kw) Frame Height mm (in.) Width mm (in.) Top Exit Bay Width mm (in.) Control Bay Width (for 2 Inverters) mm (in.) Depth mm (in.) 160 400 250 650 250 550 200 500 8 2150 (84.5) 400 (15.7) 400 (15.7) 300 (11.8) 650 (25.5) 500 800 700 1100 600 1000 560 900 9 2150 (84.5) 600 (23.6) 400 (15.7) 300 (11.8) 650 (25.5) 900 1250 1250 1800 1100 1500 1000 1400 10 2150 (84.5) 800 (31.5) 400 (15.7) 300 (11.8) 650 (25.5) 1650 2400 2000 1800 11 2150 (84.5) 1200 (47.2) 800 (31.5) 300 (11.8) 650 (25.5) 2000 3000 2500 2300 12 2150 (84.5) 1400 (55.1) 800 (31.5) 300 (11.8) 650 (25.5) Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 30

PowerFlex 755TM Drive System Summary Power Ratings Common Bus Inverters 400/480V: 160 to 2000 kw / 250 to 3000 Hp 600/690V: 250 to 2500 Hp / 200 to 2300 kw Regenerative Bus Supplies 400/480V: 160 to 2000 kw / 250 to 3000 Hp 600/690V: 250 to 2500 Hp / 200 to 2300 kw Motor Control Performance TotalFORCE technology includes flux vector, sensorless vector, V/Hz and Economizer Control Modes Speed, torque and position support Communications Built-in EtherNet/IP dual port Safety Option Enclosures Safe Torque-Off SIL3/PLe, Cat 3 Safe Speed Monitor SIL3/PLe, Cat 4 IP21 IP54 Efficiency Bus Supplies: 96% at rated amps Common Bus Inverters 96% at rated amps Global Standards UL, cul, CE,, CAN/CSA, DNV, ABS, Lloyd s Register, IEC 60721-3-3, ISA 71.04-1985, ATEX, Semi-F47, AC156, Regulartory Compliance Mark, EAC Mark, UkrSepro Mark, KC Mark, CE Mark, ODVA EtherNet/IP Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 31

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. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 32

PowerFlex 755TM Drive System Example configuration of a coordinated system PF755TM Regenerative Bus Supply PF755TM Inverter with Control Bay PF755TM Inverter Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 33

PowerFlex 755T Drive Solutions TotalFORCE Technology PowerFlex 755TL, PowerFlex 755TR & PowerFlex 755TM High Bandwidth Motor Control Low tracking error High disturbance rejection High Performance Torque Accuracy Responsive to torque disturbances Smoothness throughout operating range TotalFORCE Motor Control Applications Rotary Knives Storage and Retrieval Machining Positioning Winders / Unwinders Test Stands Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 34

PowerFlex 755T Functions & Features Implementation Plan Function/Feature Release 1 Release 2 Release 3 Induction Motor Control X PM Motor Control X Adjustable Voltage Control X Stop and Start Functions X Position Reference and Regulator Options X Speed Reference and Regulator Options X Torque Reference and Regulator Options X TorqProve X Smooth Transitions * X * New feature in TotalForce platform Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 35

PowerFlex 755T Functions & Features Implementation Plan Function/Feature Release 1 Release 2 Release 3 Load Observer * X Adaptive Tuning * X Feedback Options X Security * X Diagnostics and Protection X Predictive Maintenance * X Integrated (CIP) Motion X Emergency Override * X DeviceLogix X * New feature in TotalForce platform New Universal Feedback Board at CR2 or later Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 36

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) Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 37

PowerFlex 750-Series Drives Scalable Solutions PowerFlex 753 PowerFlex 755 PowerFlex 755TL PowerFlex 755TR PowerFlex 755TM 1 to 400 Hp/ 0.75 to 270 kw 1 to 2000 Hp/ 0.75 to 1500 kw 250 to 1800 Hp/ 160 to 1400 kw 250 to 3000 Hp/ 160 to 2300 kw 250 to 3000 Hp/ 160 to 2300 kw Speed & Torque Control Speed, Torque & Position Control Speed, Torque & Position Control Speed, Torque & Position Control Speed, Torque & Position Control 6-pulse Drive 6-pulse Drive Low Harmonic Regeneration & Low Harmonic Common Bus Drive System Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 38

PowerFlex 755T Drive Solutions Premier Integration with Studio 5000 Logix Designer and a Logix controllers Embedded dual-port EtherNet/IP Faster troubleshooting, maximize uptime Advanced Predictive Maintenance for IGBT, bus capacitors, LCL capacitors & blower Advanced Diagnostics provides status on blown fuses and surge suppressors Easier serviceability, minimize downtime Tool-free maintenance for roll-out unit fans Fewer hardware connections on roll-out modules Can roll out units via cart or ramp allowing for greater mounting flexibility Automatic Device Configuration reduces downtime if drive needs to be replaced Application flexibility with standard ratings and configurable options Wide range of operating temperatures World class power density 5 option slots for safety, communications, I/O & feedback Optional integrated DV/DT filter and EMI options Optional wiring options for cable entry and exit Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 39