Variable Frequency

Drives

DRV21201

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 Agenda and Objective

Agenda: Objective:
• Understand alternate methods • Learn the advantage of using
in motor starting, and solid state motor control.
advantages to solid state • Learn typical applications of
motor control using drives.
• Fundamental operation of a • Understand key features and
variable frequency drives. benefits of the PowerFlex
• PowerFlex Component Class drives and when to apply one
and Architecture Class drive over another.
families – Features & benefits
• Communication options and
Programming Software

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 What motor control is the right choice for the
application?
Short Short
Short CircuiProtection
CircuiProtection CircuiProtection
Device Device
Device

AC/DC/AC
Converter

M M M
DOL SMC Drive
Direct On-Line Solid State Motor Control Variable Speed Control
•Starter – NEMA/IEC •Voltage from the 3 phase power Solid State Motor control
•Voltage is applied to the coil of line is controlled through a •Voltage from the 3 phase power line
the contactor/starter device solid state device, such as a
is converted to DC voltage through a
(bulletin 500 or 100C). The coil AC to DC converter (diode converter).
transistor. These devices Solid State devices, referred to as
then, closes contacts to apply full (transistors) are switched (on/off), IGBT (insulted gate bi-polar
voltage (all three phases) to the which then applies voltage (3 transistors) are switched to create a 3
motor. The result: the motor will phase) to the motor in a controlled phase waveform to the motor. This
run at it’s nameplate rpm state. – allowing the motor to switching allows the drive to control
(ie.1800rpm). slowly ramp to full speed.
the frequency and voltage, allowing
you to control the motor speed with
infinite control (zero – full speed).
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 SMC’s vs. Drives - How do they differ?
When comparing or evaluating an application for what method of
starting should be used, remember that an SMC is used only for
starting and stopping. Also remember that because an SMC reduces
the voltage, torque is also reduced. If speed variation is required or
the application has some very high torque requirements, a drive is a
better solution.
SMC Drive
• Controls starting and stopping • Can vary the speed of motor at any time during the
• During reduced voltage starting, torque is reduced process for any duration
• Simple to adjust and setup • Continuous Control
• Cost • Can deliver high torque at any speed
– Below 15 HP – Similar to Drive • More complex to setup and install
– Above 15 HP - Lower Cost • Cost
– Very competitive below 5 HP
– Cost Increase significantly with HP

Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 4

 What are the advantages of using a solid state motor
controller?

• Minimize mechanical damage

–Provides a smooth acceleration and deceleration – no jerky motion
With full voltage start, very often there is a need to minimize mechanical shock to both the mechanical
equipment and the work in process. Frequent stopping and starting of a conveyor system places stress
on all it’s mechanical linkages.
• Application requires it - Soft starting or Soft stopping
–Speed changes on the fly – or changing continuously
–Critical stopping criteria: for repeatable and accurate “in position” applications
Loaded or unloaded starts and stops require different torque considerations, often requiring gradual
acceleration of a load that would otherwise be damaged by the mechanical shock of a full voltage across-
the-line start. Such applications require a soft-start, where the starting torque is gradually increased as the
load is brought up to speed.
• Limit line Power Disturbances
–Energy management. Utilities establish rules for starting motors on their lines, based on
reducing in-rush and its effects on the system. Heavy voltage dips, due to motor starting often
cause trouble in solid state equipment sensitive to current and voltage deviations. This
includes computers and on the floor programmable controllers. Moreover, the effect of
across-the-line starting of large motors often results in a light flicker and system disturbances
being reflected back through the utility line

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 What are the advantages of using a solid state motor
controller?

• Energy cost reduction

– Reduced energy usage on High Duty cycle applications.
– Reduced energy usage when applying dives on Centrifugal Pumps and Fan
applications.
• Intelligent Motor Control
– Local I/O required
– Diagnostics, Faults, Alarms
• Communications Status across the Network
– DeviceNet
– Ethernet
– ControlNet

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 Let’s first understand how a drive works?

– First, the Converter (usually a diode rectifier) converts three-phase AC power to DC power.
– Next, the DC Bus stores and filters the DC power in a large bank of capacitors.
– Last, the Inverter (usually a set of six IGBTs) switches or inverts the DC power in a Pulse
Width Modulated (PWM) AC waveform to the motor.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 A closer look at “Pulse Width Modulation”?

• The inverter produces an output of pulses at each motor phase

• The magnitude of the voltage equals +/- DC bus voltage.
• The drive varies the width of the pulses and gaps to control the RMS motor voltage
• This produces motor current that resembles the intended AC sine wave

DC Bus voltage (650VDC)

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 Pulse Width Modulation

• The drive varies the output frequency by varying the number and widths of the pulses
and gaps
• This makes the motor turn faster or slower

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 Typical applications for variable speed
control
• Food processing equipment
• High speed packaging
– food slicers, mixing equipment, pasta
applications
makers, etc.
• Air conditioning and ventilation • Dryers, ovens
systems
– exhaust fans, blowers
• Agitators, pumps
• Commercial machinery • Conveyors, de-palletizers, feed
– high speed drilling and cutting
aprons
equipment • Cable and wire followers
• Automatic or overhead door • Presses, paint booths
equipment • Lathes, planers
• Automatic car washes • Infeed chains
• Automated warehousing • Mixers
• Material winders
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 PowerFlex - Two Class Strategy

Architecture Class – optimized for Component Class – optimized for

application flexibility and control machine level and stand alone
system integration control
• Broad range of power and performance • Most economical Allen-Bradley offering
offerings • Simple set-up and operation
• Flexibility for simple to complex • Simple network communications
applications • External solutions for EMC, power
• Internal solutions for Electromagnetic quality, and control system noise
Compatibility (EMC), power quality, and
control system noise
• Force™ Technology Vector Control

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex Products Overview

The PowerFlex drive family offers the flexibility of both performance and functionality with
several drive models. Let’s take a closer look at the component class drives……
Performance / Functionality

PowerFlex 700S PowerFlex 700L

PowerFlex 700
PowerFlex 70
PowerFlex 700H
PowerFlex 40/
PowerFlex 40P
PowerFlex 4 PowerFlex 400
PowerFlex 4M

50 20 100 2500
0 0

Power Rating (HP @ 460V)

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 Component Class Drives – offer several
benefits
• 5 Component Drive
models available
• PowerFlex 4

Performance / Functionality
• PowerFlex 4M
• PowerFlex 40
• PowerFlex 40P
• PowerFlex 400

9Simple selection, set-up, &

operation PowerFlex 40P
9Industry-standard RS-485
communications PowerFlex 40
capabilities PowerFlex 400
PowerFlex 4
9Industry-standard power
PF4M
structure features &
installation options
5 10 20 50
10 400
0
Power Rating (HP @ 460V)

•Most economical Allen-Bradley offering in its power, performance &

feature segment
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 PowerFlex 4

Bulletin Number: 22A

Pertinent Documentation: 22A-UM001, 22A-QS001, 22-TD001, 22-PP001
Motor Control Algorithm:
– Volts per Hertz with slip compensation
(This is good enough for low performance applications like centrifugal fans and pumps)
Drive Ratings
– 115V, 1Ø, 0.2-1.1 kW (0.25-1.5 Hp)
– 230V, 1Ø, 0.2-2.2 kW (0.25-3 Hp)
– 230V, 3Ø, 0.2-3.7 kW (0.25-5 Hp)
– 460V, 3Ø, 0.37-3.7 kW (0.5-5 Hp)
Overload Rating
– 150% for 60 Seconds
– 200% for 3 Seconds
Enclosure Types and Mounting Options:
• Standard is IP20 DIN rail or panel mount
• Optional IP30 Kit (NEMA1)
• Optional IP20 FlangeMount
Integral Keypad provides out-of-the-box operation
Communication
– Integral RS485
– With external DSI communications kit: DeviceNet™, EtherNet/IP™, ControlNet™, Lonworks®, PROFIBUS DP,
BACnet® or Bluetooth®

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 4M (At a Glance)

• The PowerFlex 4M has the same capabilities as the

PowerFlex 4 plus additional features that include:
– Feed through wiring (power terminals on top and motor
terminals on bottom) allows for easy replacement of
fixed speed starters
– Additional HP ratings
• 200-240Volt up to10HP
• 400-480Volt up to 15HP
• Open Style IP20 enclosure only
(Not offered in NEMA 1 or Flange type)

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 4M (In Further Detail)

Bulletin Number: 22F

Pertinent Documentation: 22F-UM001, 22F-TD001, 22F-PP001
Motor Control Algorithm: Volts per Hertz with slip compensation
(This is good enough for low performance applications like centrifugal fans and
pumps)
Drive Ratings
– 100-120V, 1Ø, 0.2-1.1 kW (0.25-1.5 Hp)
– 200-240V, 1Ø, 0.2-2.2 kW (0.25-3.0 Hp)
– 200-240V, 3Ø, 0.2-7.5 kW (0.25-10 Hp)
– 380-480V, 3Ø, 0.37-11.0 kW (0.50-15 Hp)
Overload Rating
– 150% for 60 Seconds
– 200% for 3 Seconds
Packaging and Mounting
– DIN Rail Mounting
– Zero Stacking for Ambient Temperatures up to 40ºC
Communication
– Integral RS485
– With external DSI communications kit: DeviceNet™, EtherNet/IP™, ControlNet™,
Lonworks®, PROFIBUS DP, BACnet® or Bluetooth®
Features
– Feed through wiring (simple retrofitting of motor starters)
– Auto Restart and Flying Start provide recovery form fault conditions without user interfention

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 4 AC Drive – Typical Applications

• Ideal for applications requiring simple volts per hertz control such as:
– Fans
– Food processing equipment
– Machine tools
– Pumps
– Mixers
– Conveyor equipment
– Packaging machinery
– Wood working machinery
– Automatic and overhead door equipment.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 40

Bulletin Number: 22B

Pertinent Documentation: 22B-UM001, 22B-QS001, 22-TD001, 22-PP001
Motor Control Algorithms
– Volts per Hertz with slip compensation
(This is good enough for low performance applications like centrifugal fans and pumps)
– Sensorless Vector with slip compensation and Autotune
(This provides better low speed torque performance and response to step load changes for applications like conveyors,
mixers, saws and chippers)
Drive Ratings :
– 100-120V, 1Ø, 0.4-1.1 kW (0.5-1.5Hp)
– 200-240V, 1Ø, 0.4-2.2 kW (0.5-3Hp)
– 200-240V, 3Ø, 0.4-7.5 kW (0.5-10Hp)
– 380-480V, 3Ø, 0.4-11 kW (0.5-15Hp)
– 480-600V, 3Ø, 0.75-11 kW (1-15Hp)
Overload Rating
– 150% for 60 Seconds
– 200% for 3 Seconds
Enclosure Options
– DIN Rail Mounting on Frames A and B
– Zero Stacking for Ambient Temperatures up to 40ºC
– IP 20 / Open
– IP 30 / NEMA/UL Type 1
– Flange Mount
– NEMA/UL Type 4X/12, IP 66/54

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 40

Communication
– Integral RS485
– With internal communication adapters: DeviceNet™, EtherNet/IP™, ControlNet™, Lonworks®,
PROFIBUS DP, BACnet® or Bluetooth®
Additional Features
– PID Control
– StepLogic®
– Flying Start

This drive is like the PowerFlex 4 with the following additions:

• It offers sensorless vector motor control, which provides “good”
low speed torque performance for middle of the road applications
like conveyors
• It offers a higher power range
• It offers an internal place for communications modules
• PID control allows control of process variables (e.g. flow,
pressure, tension) within the drive
• StepLogic is a allows the drive to cycle through eight steps or
states in a profile
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 Configurable I/O can activate timers & logic
functions within the drive

• Timer and counter functions Application

ApplicationBenefits
Benefits
– activate via a digital input command •• Eliminate
Eliminatediscrete
discretewiring
wiringtotoaa
microcontroller
microcontrollerbybyperforming
performingsimple
simple
– drive performs timer or counter function and logic functions within the drive.
logic functions within the drive.
activates a programmable output based on
user-defined time or count value •• Free-up
Free-upcontroller
controllerI/O
I/Ofor
forother
other
process functions.
process functions.
• Basic Logic Functions •• Eliminate
Eliminatethe
theneed
needfor
forstand
standalone
alone
– relay or opto outputs controlled by status of timing relays or counters
timing relays or counters
digital inputs programmed as “Logic Inputs” •• ideal
idealfor
forbatch
batchprocessing
processingand
andparts
parts
– output changes state when AND, OR and counting applications
counting applications
Exclusive Link logic condition is true

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 StepLogic Functionality

• Logic controlled steps using

preset speed settings
• Each step can be programmed to:
20s

– Step, based on digital input(s) 60Hz

command (drive can perform

Step Step
Step 4 7 End
40Hz
1 Program
Step

basic AND, OR and NOT logic) 20Hz 0

0Hz

– Step, based on a specified time -20Hz

Step
5

– Control speed, direction and -40Hz

accel/decel rate 3-Wire

Start

– Control the status of an output LogicPLC

In 1
Input 1
PLC
Logic In 2

– Make deterministic jumps

Input 2
PLC
Stp Logic Out
Output

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 40 AC Drive – Typical Applications

• Ideal for applications in the 1/2 - 15 Hp range requiring simple V/Hz

control such as:
• Fans
• Fans
• Food processing equipment
• Machine tools
• Pumps
• Mixers
• Conveyor equipment
• Packaging machinery
• Wood working machinery
• Automatic and overhead door equipment.
• Or for applications requiring low speed torque (sensorless vector)
demands such as mixers, machine tool equipment and those requiring
network connectivity

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 40P
• The PowerFlex 40P has the same capabilities and ratings as the
PowerFlex 40, plus:
– Optional Encoder/Pulse Train Feedback
• Closed loop for improved speed control or position control
– Optional Drive Guard Safe-off
• Prevents a drive from delivering rotational energy to motors
• Meets EN954-1, category 3 (safe-off and protection against restart)
– Position Control Mode
• Ability to control the position of the motor, not just speed
– ½ DC Bus Operation and Improved Ride Through
• Continuous output under brown out conditions
• Inherent breaking and ride through with the use of drives/loads
in application)
– Fiber Features
• Traverse and P-Jump
• Ideal for applications in fiber& textiles industry such as:
Drafting Machines, Ring Spinning Machines, Roving
Machines, Carding Machines, Draw/Twist machines, fiber
winder control, synthetic fiber spinning machines
• However, It does not have a full keypad
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 PowerFlex 400 (At a Glance)

Optimized for Commercial Fan and Stand-Alone

Pump Applications
• 208/240 and 480V AC Offering
• Integral RS485 Communications
• Application Specific Features
• Wide Power Range
• Variable Torque Ratings Packaged
• LCD Keypad

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 400 (In Further Detail)

Bulletin Number: 22C

Pertinent Documentation: 22C-UM001, 22C-QS001,
22C-TD001, 22C-PP001
Motor Control Algorithm:
– Volts per Hertz with slip compensation
(This is good enough for low performance applications
like centrifugal fans and pumps)
Ratings
– 3 to 50HP @ 208/240V AC
– 3 to 350HP @ 480V AC
Overload Rating
– 110% for 60 Seconds
Enclosure
– IP20 / UL Open
• C Frame units standard
– IP30 / NEMA 1 / UL Type 1
• C Frame units with optional kit
• D, E and F frame units standard
Environment
– IP20 rated for 50°C
– IP30 rated for 45°C

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 400
Application Specific Features
• Sleep Function
– used to reduce energy consumption
• Internal PID Controller
– saves complicated programs
• Skip Frequencies
– avoids resonant frequencies in mechanical systems
• Selectable Fan/pump Curves
– allows more flexible control
• Purge Input
– overrides building automation controller stop command
• Automatic Restart
– provides restart feature
• Flying Start
– picks up spinning motor
• Auxiliary Motor Control
– provide pump sequence control
• Damper Input
– allows interlock with damper control

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 400
Package Styles

Main Input 3 Contactor Full Feature 3 Contactor Basic

Disconnect Bypass with Disconnect Bypass with Disconnect

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 Component Class Communications Adapters

• Various Protocols
– 22-COMM-D DeviceNet
– 22-COMM-C ControlNet
– 22-COMM-E EtherNet IP
– 22-COMM-P Profibus DP
– 22-COMM-L LonWorks®
– 22-COMM-B BACnet ®
• 22-XCOMM-DC-BASE allows
mounting outside of drive
• Multi-Drive mode available allows
up to five drives to share one
network node
• PowerFlex 40, 40P and 400 drives can house
communication adapters
• PowerFlex 4 and 4M drives can connect to
communications adapters via a 22-XCOMM-DC-BASE
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 Next, let’s introduce the Architecture class
of PowerFlex drives.
“Architecture” Class - Optimized for application
flexibility and control system integration
• Broad range of power and performance offerings “7-Class”
• Flexibility for simple to complex applications Products
• High through-put, tightly integrated communication &
architecture connectivity
– Premier integration to Logix, NetLinx & View
• Power structure robustness to address harmonics, motor
effects and control system noise
– “Installation & Retrofit-friendly”
• Package designs to maximize control panel space

“Component” Class – Optimized for machine-level

and stand-alone control
“4-Class” • Most economical Allen-Bradley offering in its power,
performance & feature segment
Products
• Simple selection, set-up, & operation
• Industry-standard RS-485 communications capabilities
• Industry-standard power structure features & installation
options
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 PowerFlex Products

PowerFlex 700S PowerFlex 700L

Performance / Functionality

PowerFlex 700

PowerFlex 70
PowerFlex 700H

50 200 1000 2500

Power Rating (HP @ 460V)

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 PowerFlex 70 (At a Glance)

• 200 to 690 VAC, 3ph input

• Human Interface Module (HIM)
– Easy to use with large LCD display
– Assisted Startup
– Copy Cat
– Removable
• V/Hz, Sensorless Vector and Vector Control
with FORCE™ Technology
• EMC compliance ‘out of the box’
• Variety of Dedicated Enclosure Styles

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 70 (In Further Detail)
Bulletin Number: 20A
Pertinent Documentation: 20A-UM001, 20A-TD001, 20A-PP001
Motor Control Algorithms:
– Volts per Hertz with slip compensation (This is good enough for low performance applications like centrifugal fans and
pumps)
– Sensorless Vector with slip compensation and Autotune (This provides better low speed torque performance and
response to step load changes for applications like conveyors, mixers, saws and chippers)
– Vector Control with FORCE™ Technology (This provides the best low speed torque regulation and speed control for the
most demanding applications)

Drive Ratings
– 200-240V, Normal Duty 0.37-18.5 kW (0.5-25 hp) , Heavy Duty 0.25-15 kW (0.33-20 hp)
– 400-480V, Normal Duty 0.37-37 kW (0.5-50 hp) , Heavy Duty 0.25-30 kW (0.33-40 hp)
– 500-600V, Normal Duty 0.37-37 kW (0.5-50 hp) , Heavy Duty 0.25-30 kW (0.33-40 hp)

Overload Rating
– Normal Duty Application
• 110% of motor rated current for 60 seconds
• 150% of motor rated current for 3 seconds
– Heavy Duty Application
• 150% of motor rated current for 60 seconds
• 200% of motor rated current for 3 seconds

Internal Dynamic Braking IGBT: All Drives

Internal EMC Filtering: Available in Most Drives

(see documentation for exceptions)

Communication: Works with all DPI Communications Adapters

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 FORCE™ Technology for High Performance
Motor Control

• True vector control (separate control of motor torque and magnetizing currents)
• Best low speed torque (for applications such as lifts, winders)
• Best speed regulation (for high performance applications)
• Best position control
• Best shock response (maintains speed regulation regardless of load changes)
• Pure torque control capability (for applications like center-driven winders and multiple
drive load sharing)

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 70 AC Drive packaging options

NEMA 1 (50°C) Flange (50°C) NEMA 4X (40°C) NEMA 12 (40°C)

Also IP20 Front = NEMA1 / IP20 Also NEMA 12 & IP66 Also IP56
Backside = NEMA 4X / IP66
(indoor only)
Backside = Indoor & Outdoor

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 70 AC Drive – Application
Features

• Extremely Fast Bus Regulation and

Current Limit for trip-less operation of
dynamic loads
• Reflected Wave Reduction helps
protect motors from the effects of long
motor cables
• PID and Sleep / Wake Control can
eliminate the need for a stand-alone
controller
• Droop Control for load sharing
applications
• Fiber Features (P Jump, Trave7rse,
Sync Speed Change)

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700 (At a Glance)

• Outstanding Performance
– Three control modes for any application requirement
• V/Hz
• Sensorless Vector – with or without encoder feedback
• Vector Control with FORCE™ Technology – with or without encoder feedback
– Position regulator for simple position indexing / speed profiling applications
– Flexibility for simple to very complex applications.
• TorqProve™ for lifting applications
• Positioning/Speed Profiling
• Adjustable Voltage for non-motor applications
• Oil Well macros for Pump Jacks and
Progressive Cavity Pumps (PCPs)
• Easy to use
– Full Numeric HIM with LCD display
– Assisted Start enables programming without using a manual
– Pull-apart I/O terminal blocks
– Control cassette common across all ratings
• Saves Space
– Internal brake transistors and communication options, integral EMC
filters and common mode cores all save panel space and wiring time
– Compact, bookshelf design allows Zero Stacking™

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700 (In Further Detail)

Bulletin Number: 20B

Pertinent Documentation: 20B-UM001, 20B-TD001, 20B-PP001
Motor Control Algorithms:
– Volts per Hertz with slip compensation (This is good enough for low performance applications like centrifugal fans and pumps)
– Sensorless Vector with slip compensation and Autotune (This provides better low speed torque performance and response to step load
changes for applications like conveyors, mixers, saws and chippers)
– Vector Control with FORCE™ Technology(This provides the best low speed torque regulation and speed/position control for the most
demanding applications)

Drive Ratings
– 200-240V, Normal Duty 0.37-75 kW (0.5-100 hp) , Heavy Duty 0.25-55 kW (0.33-75 hp)
– 400-480V, Normal Duty 0.37-132 kW (0.5-200 hp) , Heavy Duty 0.25-110 kW (0.33-150 hp)
– 600-690V, Normal Duty 0.75-132 kW (1.0-150 hp) , Heavy Duty 0.55-110 kW (0.75-125 hp)

Overload Rating
– Normal Duty Application
• 110% of motor rated current for 60 seconds
• 150% of motor rated current for 3 seconds
– Heavy Duty Application
• 150% of motor rated current for 60 seconds
• 200% of motor rated current for 3 seconds

Internal Dynamic Braking IGBT: Available in All Drives

(see documentation for exceptions)

Internal EMC Filtering: All Drives

Communication: Works with most DPI Communications Adapters

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700 – Application Guide

• The PowerFlex 700 Drive is perfect for almost any application including:
– Fans & Pumps
– Extruders (Torque performance)
– Stamping Presses (great performance with cyclical high inertia loads)
– Cranes & Hoists (TorqProve)
– Entertainment – amusement park attractions
– Material handling
• Conveyors (Load sharing)
• Vertical lifts (TorqProve and Positioning)
• Palletizers (Performance, TorqProve and Positioning)
– Centrifuges
– Mixers (eccentric loads)
– Winders
– Rock crushers (high impact eccentric loads)
– Oil Well Pumps (pump jacks & PCP)
– Adjustable Voltage
• Vibration welding equipment for OEMs
• Power Supplies for power generation company

From
Fromsimple
simplefans
fanstotocomplex
complexwinders,
winders,the
thePowerFlex
PowerFlex700
700Drive
Drive
isisperfect
perfectfor
foralmost
almostany
anyapplication!
application!
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 PowerFlex 700S (At a Glance)

High Performance AC for very complex or very high performance

applications
• Wide range of power ratings
– .5 – 1250 hp
– 240 – 690V
• Selectable Motor Control Algorithms: Vector Control with FORCE™
Technology – with or without an encoder, Permanent Magnet Motor,
and V/Hz control
• Inertia Adaptation - Can increase speed regulator bandwidth x4
• Integral Position Loop
– Point-to-Point, Direct, and Interpolated (Course to Fine) positioning,
homing
• User Functions (with or without DriveLogix™)
– Bit Swaps, Peak Detects, Position Watch, Switch blocks, Real – DINT
conversion, Scale blocks, Logic blocks, Compare blocks, MOP, Basic
Indexer, Timers blocks, Add/Subtract blocks, Multiply/Divide blocks
• Feedback Loss Switchover “On the Fly” (in Speed Mode)
• Advanced Diagnostics
– Integral 4 Channel Trending with Event Triggering, Multiple Test Points

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700S (At a Glance)

• Assisted Startup Routine

• Multiple Feedback Options
– 2nd Encoder, 2nd Encoder with DriveGuard® Safe-off, Resolver,
Stegmann and Heidenhain
High Resolution Feedback, Stahltronis and Temposonics SSI Linear
Feedback
• High Speed Data Fiber Link Option – SynchLink™
• Embedded Logix Controller Option - DriveLogix5730
– Programming Memory:
– 1.5 Mbytes of user program
– CompactFlash for Non-Volatile program storage
– RSLogix5000 which also includes Motion Instruction Support
– Up to 16 Local Compact I/O Modules (2 banks)
– Embedded EtherNet/IP™ Communication option
– NetLinx Daughter cards Communication options

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700S (In Further Detail)
Bulletin Number: 20D
Pertinent Documentation: 20D-UM0016, 20D-TD002, 20D-PP0014
Motor Control Algorithms:
– Volts per Hertz 1(This is good enough for low performance applications like centrifugal fans and pumps)
– Vector Control with FORCE™ Technology(This provides the best low speed torque regulation and speed/position control for the most
demanding applications)
– Field Oriented Control with Temperature Adaption (This is a highly specialized control mode)
– Permanent Magnet Motor Control (This allows the drive to control a permanent magnet motor)

Drive Ratings
– 208V, Normal Duty 0.75 - 66 kW , Heavy Duty 0.37 - 55 kW
– 240V, Normal Duty 1.0 - 100 hp , Heavy Duty 0.75 - 75 hp
– 380, Normal Duty 0.75 - 800 kW , Heavy Duty 0.55 - 710 kW
– 480V, Normal Duty 1.0 - 1250 hp, Heavy Duty 0.75 - 1000 hp
– 600V, Normal Duty 1.0 - 1300 hp, Heavy Duty 0.5 -1100 hp
– 690V, Normal Duty 75 - 1100 kW , Heavy Duty 55 - 1000 kW

Overload Rating
– Normal Duty Application
• 110% of motor rated current for 60 seconds
• 150% of motor rated current for 3 seconds
– Heavy Duty Application
• 150% of motor rated current for 60 seconds
• 200% of motor rated current for 3 seconds

Internal Dynamic Braking IGBT: Available in All Drives up to Frame 9

(see documentation for exceptions)

Internal EMC Filtering: All Drives up to Frame 9, Frames 9 and Higher have
AC Line Reactors
Communication: Works with most DPI Communications Adapters

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700S AC Drive
Application Guide
• Target customers requiring precise speed, torque, or position control.
• An integrated Logix/PowerFlex solution with a fully-programmable drive and reduced
hardware cost for applications requiring a controller
– standalone applications and small systems.
• The following is a list of applications that are well-suited for the PowerFlex 700S drive:
– transfer systems - winding/unwinding - belt reels
– feeders - positioning - rolling and shaping
– test stands - cut-to-length - hoist
– extruders - material handling - electronic camming
– web handling - electronic gearing - load sharing
• Migration path for 1336 Impact and 1336 Force products

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700H (At a Glance)

• Global voltage ratings: 200 to 2200 HP at 500V and 160 to 2000 kW at 690V
• Easy-to-remove control module is common among all PowerFlex 700H power ratings
• Easy to use with large LCD display and Assisted Startup
• Flexibility for simple to complex applications
• Sensorless Vector with Slip Compensation and V/Hz
• Superior connectivity to Logix, NetLinx & View
• Internal EMC filtering and built in AC line reactor
• Standard floor standing cabinet Frames 10 and higher
• Internal brake transistors (Frame 9)

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700H (In Further Detail)

Bulletin Number: 20C

Pertinent Documentation: 20C-PM001, 20C-TD001, 20C-PP001
Motor Control Algorithms:
– Volts per Hertz with slip compensation (This is good enough for low performance applications like centrifugal
fans and pumps)
– Sensorless Vector with slip compensation and Autotune (This provides better low speed torque performance
and response to step load changes for applications like conveyors, mixers, saws and chippers)
Drive Ratings
– 400-480V, Normal Duty 132 - 560 kW (200 - 900 hp) , Heavy Duty 110 - 500 kW (150 - 800 hp)
– 600-690V, Normal Duty 160 - 800 kW (150 - 900 hp) , Heavy Duty 132 - 630 kW (150 - 700 hp)

Overload Rating
– Normal Duty Application
• 110% of motor rated current for 60 seconds
• 150% of motor rated current for 3 seconds
– Heavy Duty Application
• 150% of motor rated current for 60 seconds
• 200% of motor rated current for 3 seconds

Communication: Works with all DPI Communications Adapters

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700H Drive – Application Guide

• The PowerFlex 700H drive is perfect for many applications including:

– Fans & Pumps
– Simple Extruders
– Stamping Presses (great performance with
cyclical high inertia loads)
– Conveyors
– Centrifuges
– Mixers (eccentric loads)
– Rock crushers (high impact eccentric loads)

• Successes for the PowerFlex 700H

drive include:
– Fans
• Power plant two cooling towers of fans.
• Eight twenty-eight foot fans per tower each requiring 250 HP

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700L (At a Glance)

• The PowerFlex 700L AC Drive is an extension of the

PowerFlex drive family that incorporates the following:

– Liquid-cooled power structure

(high power density and smaller cabinet)
– Multiple Voltage Classes
• 380-480V
• 600-690V
– Power ratings from 300 to 1150HP
– Active Front End
• Regeneration for applications with overhauling
loads like test stands and ski lifts
• Reduced power harmonics
– Dual control capabilities
• PF700 Vector Control
• PF700S Phase II Control

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700L (In Further Detail)
Bulletin Number: 20L
Pertinent Documentation: 20D-UM0001, 20D-TD002, 20D-PP0001
Motor Control Algorithms:
– Volts per Hertz 1(This is good enough for low performance applications like centrifugal fans and pumps)
– Vector Control with FORCE™ Technology(This provides the best low speed torque regulation and speed/position control for the most
demanding applications)
– Field Oriented Control with Temperature Adaption (This is a highly specialized control mode)
– Permanent Magnet Motor Control (This allows the drive to control a permanent magnet motor)

Drive Ratings
– 208V, Normal Duty 0.75 - 66 kW , Heavy Duty 0.37 - 55 kW
– 240V, Normal Duty 1.0 - 100 hp , Heavy Duty 0.75 - 75 hp
– 380, Normal Duty 0.75 - 800 kW , Heavy Duty 0.55 - 710 kW
– 480V, Normal Duty 1.0 - 1250 hp, Heavy Duty 0.75 - 1000 hp
– 600V, Normal Duty 1.0 - 1300 hp, Heavy Duty 0.5 -1100 hp
– 690V, Normal Duty 75 - 1100 kW , Heavy Duty 55 - 1000 kW

Overload Rating
– Normal Duty Application
• 110% of motor rated current for 60 seconds
• 150% of motor rated current for 3 seconds
– Heavy Duty Application
• 150% of motor rated current for 60 seconds
• 200% of motor rated current for 3 seconds

Internal Dynamic Braking IGBT: Available in All Drives up to Frame 9

(see documentation for exceptions)

Internal EMC Filtering: All Drives up to Frame 9, Frames 9 and Higher have
AC Line Reactors
Communication: Works with most DPI Communications Adapters

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex 700L Key Markets & Applications

• Ski lifts
• Automotive
– Test stands • Conveyor manufacturers
– Large presses • Oil well drilling
• Plastics & rubber • Mining
– Extruders – Pumps
– Mixers – Fans
– Banburys – Traction
• Food products • Lumber
– Extruders – Log lathes
– Mixers – Saw carriages
• Centrifuges • HVAC OEMs
• Pumps and pumping • Thermal oxidizers
• Cement kilns • Eddy current absorbers

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex Architecture Class
Communications Adapters
• Communication Adapters fit inside the
front cover of Architecture Class drives
• Communication Adapters can be
mounted externally
(in a DPI External Comms Kit)
• Communications Adapters compatible
with most Architecture Class drives
(Some 16-bit networks are not compatible with
some 32-bit drives)
– 20-COMM-L is not compatible with the PowerFlex
700 Series B and 700S
– 20-COMM-H is compatible with all in Modbus mode,
but not compatible with the PowerFlex 700 Series B
and 700S in N2 and P1 modes
• Datalinks allow transfer of up to eight
parameters of data into drive from
network and eight parameters out of
drive to network

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 Architecture Class Communications Adapters

• Rockwell Automation offers Architecture Class Communications adapters for the

following communications protocols:

20-COMM-E 20-COMM-C 20-COMM-Q 20-COMM-D 20-COMM-R 20-COMM-S

EtherNet/IP ControlNet ControlNet DeviceNet Remote I/O RS-485 DF1

20-COMM-P 20-COMM-I 20-COMM-H 20-COMM-L 20-COMM-B

Profibus Interbus RS485 HVAC LonWorks BACnet MS/TP

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

PowerFlex Architecture Class Drive
Programming Software

DriveExplorer
• An intuitive, Windows Explorer-like software package for
basic online programming of Allen-Bradley drive products
• Multiple versions:
– DriveExplorer Full
– DriveExplorer Lite – Freeware
– Pocket DriveExplorer – PDAs running Windows Mobile 2003 SE or
Windows Mobile 5.0
DriveTools SP
• A family of software planned and designed to accommodate
demanding user requirements:
– DriveExecutive - Online/offline drive configuration tool using RSLinx
– DriveObserver - Samples and plots parameter values

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

PowerFlex Architecture Class Drive
DriveExplorer Versions
Full Version Lite Version
Point to Point Connections Yes Yes
Online View and Edit Parameters Yes Yes
Save, Upload, & Download Parameters Yes Yes
Print Parameters Yes Yes
Parameter & Online Help Yes Yes
Wizards Yes Yes
Flash Updates Yes Yes
Upload / Download All Yes No
Serial to Network Routing Yes No
Ethernet Direct Connection Yes No
Control Bar Yes No
Custom Parameter Views Yes No
Parameter Link Operations Yes No
Compare Parameters Yes No
Fault, Alarm and Event Help Yes No

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex Architecture Class Drive
DriveTools SP
• DriveExecutive
− This is a full version with all the features of DriveExecutive Lite plus
some additional features designed for convenience to facilitate
faster and easier drive set up and maintenance.
• DriveExecutive Lite
− This is a special version with features that offer basic functionality
for use with networks and controllers. Currently bundled with
RSLogix 5000 and RSNetworx MD for DeviceNet
• DriveObserver
• Can be used to monitor drives, adapters, and HIMs.
• Can communicate with multiple drives.
• Designed to run alongside DriveExecutive.

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 Component and Architecture Differentiators

Feature Component Architecture

Detachable HIM „ „
LCD HIM „ „
Vector Control „ „
Encoder Feedback „ „
CIPMotion / CIPSnyc „ „
High Speed Communications Interface „ „
Core Network Support „ „
Enhanced Safety „ „
Safe-Off „ „
Security Aware „ „
Security Enabled „ „
Premier Integration „ „
Key differences:
• “High performance”/better regulation – vector control and encoder feedback
• Network connectivity – comms interface
• Detachable HIM – copycat function, shared HIMs (don’t need one for every drive)

„ Standard „ Optional „ Available on some models „ Not Available

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
 PowerFlex Drives (Summary)

• Broad product offering:

– Variety of motor control technologies (V/Hz,Sensorless Vector, Vector Control with
Force TechnologyTM)
– Best motor control performance in their respective classes
– Broad selection of delivery mechanisms
• Space savings:
– Zero stacking designs @ 50 Celsius Degrees
– Less external components required (Filters,Brake,etc)
– Variety of mounting options: DIN rail, Bus bar, Flange, Plate mount, IP21, IP65.
• Fast system start-up:
– SMART Start and Assisted Startup routines in all class 7 Drives
– Top ten most used parameters on all class 4

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

 PowerFlex Drives (Summary)

• Seamless control system integration to maximize uptime

– Best-in-class integration with Logix
– Open network architecture
– Investment protection
• Set-up time and training cost reduction:
– Consistent Programming structure
– Common PC Tools
– Common operator interface ‘look and feel’
• Risk reduction
– Increased information and network connectivity
– Increased Safety for Operator and Process via Drive Guard options

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.