The Allen-Bradley PowerFlex Family of AC Drives

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1 PowerFlex Tomorrow s World-Class AC Drive Technology The Allen-Bradley PowerFlex Family of AC Drives Setting a new standard for powerful performance and flexible control to meet the global needs of virtually any industry, complete automation leader Rockwell Automation presents the Allen-Bradley PowerFlex family of AC drives. Ranging in kilowatts from 0.37 kw (0.5 hp) to 3,000 kw (4,000 hp), PowerFlex drives offer users world-class motor control solutions. The Allen-Bradley PowerFlex AC drives family includes three product lines: PowerFlex 70 AC Drive (0.37 to 15 kw; 0.5 to 20 hp) PowerFlex 700 AC Drive (0.37 to 30 kw; 0.5 to 40 hp - initial release) PowerFlex 7000 Medium Voltage (373 to 3,000 kw; 500 to 4,000 hp) PowerFlex drives share significant commonality across multiple platforms, including networks, operator interface, programming and hardware. This makes the drives easier to start up, operate and maintain, reducing total cost of ownership. Innovative Packaging & Global Power Ratings Compact PowerFlex drives meet world power ratings, packaging requirements and industrial standards straight out-of-the-box. PowerFlex drives can display programming and operator interface text in multiple languages, including Dutch, English, French, German, Italian, Portuguese and Spanish. The most recent advances in AC drive technology focus on size and performance improvements of the power switching devices known as isolated gated bipolar transistors, or IGBTs. Leveraging research at the Rockwell Science Center on IGBTs resulted in lower conduction losses, reducing the size of PowerFlex 70 and PowerFlex 700 drives while increasing reliability. The PowerFlex 7000 incorporates new power semiconductor technology called Symmetrical Gate Commutated Thyristor (SGCT). These SGCT components lower conduction and switching losses while increasing reliability. The Allen-Bradley PowerFlex family of AC drives includes three product lines: PowerFlex 70, PowerFlex 700, and the PowerFlex PowerFlex drives are designed to meet standards around the world.

2 Common Component Design Multilingual LCD Human Interface Module offered for both the PowerFlex 70 and PowerFlex line, 40-character LCD operator interface offered with the PowerFlex 7000 Medium Voltage drive. LED Human Interface Module offered for the PowerFlex 70. To optimize a process, operators need to be familiar with both individual drive performance and how multiple drives work together. Extensive interviews with global drive users confirmed that commonality across platforms from networks and hardware to communications and operator interface programming increases an operator s understanding of individual and linked drives and decreases training time. In response to this input, PowerFlex drives build upon a common programming core while incorporating an advanced, common operator interface to expand operator ease of use and simplify multiple drive integration. Drive users also requested simpler and faster startup methods. PowerFlex drives feature S.M.A.R.T. Start, a startup utility available in the PowerFlex 70 and 700 when using an LCD Human Interface Module (HIM). S.M.A.R.T. Start provides users with fast and easy set-up of the most commonly programmed parameters, allowing for set-up of the drive without in-depth knowledge of the parameter structure. In facilities requiring set up of single or multiple drives, S.M.A.R.T. Start will reduce startup time. The Set-up Wizard in the PowerFlex 7000 drive helps the user to set the required parameter menus by asking questions or prompting selections for desired operation. Error messages and comments appear, complete with help text, to keep the user on the right track. 2

3 PowerFlex 70 AC Drive Optimized Simplicity The Allen-Bradley PowerFlex 70 offers a compact package of power, control and operator interface designed to meet global OEM and end-user demands for space, simplicity and reliability. The PowerFlex 70 provides a broad spectrum of features to allow the user to easily configure the drive to meet most application needs to 7.5 kw 0.5 to 10 hp 240 volts PowerFlex 70 AC Drive 0.37 to 15 kw 0.5 to 20 hp 400 & 480 volts The PowerFlex 70 space-saving, panel mount design is available in power ratings from 0.37 to 15 kw (0.5 to 20 hp). The PowerFlex 70 features a choice of HIMs: A simple LED HIM featuring a seven-segment by six-digit display, offering a low-cost option with full functionality for programming, troubleshooting and operating the drive. An alphanumeric character LCD HIM available in four different keypad types providing full multilingual text for parameter grouping, parameter descriptions, programming, troubleshooting and startup. The PowerFlex 70 simplifies installation by providing clearly marked, conveniently placed terminal blocks, allowing direct access for power and control wiring. 3

4 PowerFlex 700 AC Drive Optimized Flexibility The innovative bookshelf design of the PowerFlex 700 optimizes panel space by allowing Zero Stacking or side-by-side mounting of the drives. The PowerFlex 700 offers a flexible package of power, control and operator interface designed to meet the demands for space, flexibility and reliability while providing a broad spectrum of features, allowing the user to easily configure the drive for most application needs. The PowerFlex 700 covers ratings from 0.37 kw to 30 kw (0.5 to 40 hp), 200 to 240, 400 to 480 & 600 volts (initial release). The PowerFlex 700 uses the same LCD HIMs as the PowerFlex 70 providing full multilingual text for parameter grouping, parameter descriptions, programming, troubleshooting and startup. PowerFlex 700 AC Drive 0.37 to 30 kw 0.5 to 40 hp 200 to 240, 400 to 480 & 600 volts (initial release) Multilingual LCD Human Interface Modules The PowerFlex 700 has many flexible options for control, communications and human interface modules. Cassette contains the main control board and drive I/O for all power ratings A variety of internal communication options 4

5 The innovative bookshelf design of the PowerFlex 700 optimizes panel space by allowing Zero Stacking, or side-by-side mounting of drives. The drive offers directable air flow, articulated cover hinges that allow complete access even in side-by-side mounting, and a removable cable entry plate that allows the entire drive to be removed without disturbing adjacent drives. All of these design features combine to offer the user great flexibility in panel layout and sizing. Logix PowerFlex 700S DriveLogix will combine the powerful performance and flexible control of PowerFlex AC drives with the highperformance Logix engine to produce a highly functional, costeffective drive and control solution. The PowerFlex 700 features a cassette that houses the main control board and other control cards. This cassette, separately removable from the power structure, is the same for all drive ratings and greatly simplifies training, installation and maintenance for the entire product line. Also resident in the cassette is the I/O board for the drive. By allowing the user to choose the required I/O, PowerFlex 700 drives can be tailored to a specific application. The standard I/O board contains 6 digital inputs, 2 relay outputs, 2 analog inputs and 1 analog output. I/O is also offered in 115 V AC or 24 V DC versions. PowerFlex 700S AC Drive For more challenging stand-alone applications, the PowerFlex family of drives will offer the PowerFlex 700S AC drive, a version of the PowerFlex 700. This high-performance drive will be configurable for Sensor or Sensorless Field Oriented Control, Permanent Magnet Brushless, or Volts per Hertz operation. Precise motor torque, speed and position control will be provided for the most demanding drive applications. The PowerFlex 700S AC drive will feature SynchLink, a highperformance, high-speed, drive-to-drive data link for transmitting synchronized drive and application data. SynchLink will also provide processor synchronization for multi-axes applications. PowerFlex 700S DriveLogix AC Drive The PowerFlex 700S DriveLogix AC drive will combine the performance and ease of use of the PowerFlex 700S with the common look and feel of the Logix family. With the Embedded Logix Engine, RSLogix5000 software, and the NetLinx integrated architecture, PowerFlex 700S DriveLogix will make the most of your engineering installation and training investments. From simple to sophisticated applications, and architectures with centralized or distributed requirements, the PowerFlex 700S DriveLogix AC drive will bring power and flexibility to your control solution. Watch for the launch of the PowerFlex 700S! 5

6 PowerFlex 7000 Medium Voltage AC Drive PowerFlex 7000 Medium Voltage Drive 373 to 3,000 kw 500 to 4000 hp 2400 to 6600 volts A PowerCage forms the heart of the PowerFlex 7000, containing the drive s main power components. The new modular design contributes to the drive s maintainability. The Powerflex 7000 Medium Voltage PWM AC drive increases performance and system efficiency by eliminating the need for an isolation transformer with the PWM rectifier and saves facility space with its decreased physical size. The unique design of the PowerFlex 7000 features a patented PowerCage that houses the main power components in a compact, modular package. The rugged characteristics and innovative arrangement of the SGCT power components result in a lower component count and an inherent improvement in reliability enabling a lower cost of ownership from initial purchase price to long-term maintenance costs. The PowerFlex 7000 is available in a 6-pulse, 18-pulse and PWM rectifier design to give the user the utmost flexibility in reducing line side harmonics. It also features sensorless direct vector control for better low-speed performance compared to volts-per-hertz drives, and the ability to control motor torque similar to DC drives. 6

7 A COMM COMM A HEALTH HEALTH COM ADAPTER 1794-ACN 24V COM ADAPTER 1794-ACN 24V 1793-OB4P 1793-OB4P Integrating PowerFlex Into your architecture The PowerFlex family of drives utilizes Rockwell Automation's NetLinx Open Network Architecture. This provides the common set of features and services for DeviceNet, ControlNet and EtherNet/IP networks resulting in lower total cost of ownership. Users can easily manage information from shop floor to top floor and seamlessly integrate their complete system as they control, configure and collect data. This optional built-in connectivity helps OEMs, end-users and systems integrators cost-effectively assemble highly integrated applications that link drives to the manufacturing process through Rockwell Automation NetLinx Open Architecture based networks including: DeviceNet ControlNet In addition to the NetLinx-based networks, the PowerFlex family of drives also supports: Universal Remote I/O RS485 DF1 Other open communications networks including Profibus and Interbus-S PowerFlex drives offer a variety of communications options. Virtually Trip-Free Performance PowerFlex drives undergo rigorous factory testing including extensive qualification tests, beta site testing, the exclusive Rockwell Automation Highly Accelerated Life Testing (HALT), printed circuit board verification, and finished drive audits. These tests, along with ongoing manufacturing process improvements and quality monitoring, result in superior drive quality and reliability for users. But, quality is more than just hardware. It takes intelligent software to keep the product continually operating. PowerFlex drives have software that continually monitors operating status to ensure process variations can be responded to without resulting in downtime. For example, the active thermal manager allows the drive to recognize excessive overload conditions and make internal adjustments that minimize conditions such as drive overheating. In addition, the bus regulation feature can manage line overvoltage or regenerative situations to prevent nuisance tripping that interferes with continuous process control. For added motor protection, PowerFlex drives include reflected wave reduction software to minimize damaging peak voltages caused by pulse width modulation (PWM) pulse reflection and electronic motor overload software to protect the motor from overload and overheating. All of these features combine to make PowerFlex drives nearly trip-free, maximizing user uptime and productivity. 7

8 The Allen-Bradley PowerFlex family of AC drives are world-class products that provide a single-source solution for virtually any drive application requirement ranging from 0.37 to 3,000 kw (0.5 to 4,000 hp). Significant commonality across multiple platforms including networks, operator interface, programming and hardware make PowerFlex drives easier to start up, operate and maintain. Multi-lingual programming, operator interface text and voltage-sensitive defaults will help save time and money during set-up, integration and maintenance of virtually any automation system. TM Rockwell Automation supports drive users whenever and wherever needed, providing drives specialists and manufacturing for unmatched service and support around the globe. In fact, one of every five Rockwell Automation employees is in the field with users everyday. Rockwell Automation also offers a full spectrum of value-added services and expertise to help simplify maintenance and enhance productivity. Rockwell Automation is committed to helping its customers meet ever-changing demands. PowerFlex drives illustrate our commitment to user productivity through timely delivery of world-class products and continued backward compatibility to minimize life-cycle costs. Count on Rockwell Automation to be your Complete Automation partner now and in the future. DriveLogix, PowerFlex, NetLinx, PowerCage, Zero Stacking, SynchLink, RSLogix5000, Complete Automation, and the Complete Automation graphic are trademarks of Rockwell Automation. DeviceNet is a trademark of the Open DeviceNet Vendor Assn. ControlNet is a trademark of ControlNet International. Publication PFLEX-BR001B-US-P, September Rockwell International Corporation. All Rights Reserved. Printed in USA.