700S High Performance Drive

Huang Yongjin
Power Control Solution Architect

Email:yjhuang@ra.rockwell.com
Mobile:139 8000 9701
Copyright © 2008 Rockwell Automation, Inc. All rights reserved.

PowerFlex 700S
1. PowerFlex 700S Phase II Overview
2. Load Sharing
3. Installation
4. Q&A
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 2

PowerFlex 700S
1. PowerFlex 700S Phase II Overview
2. DriveLogix
3. SynchLink
4. Safe-Off

PowerFlex Drives
PowerFlex ???
= Powerful Performance + Flexible Control
PowerFlex Drives

PowerFlex Family of Drives Offering
Scaleable Motor Control –

From Simple to Complex
• 4-Class drives for simple, cost-effective motor control
for machine-level and stand-alone applications
• 7-Class drives offer a broader feature set and meet
higher performance application requirements
Premier Integration
Open Network • Integrated drive profiles &
RSLogix 5000 reduces
Architecture configuration time by up to 70%
• Open network architecture allows • Single software environment –
you to control, configure and ease of use
collect data
• Automatic generation of
• Wide Variety of Network Options: descriptive tags
Serial, EtherNet/IP, ControlNet
and DeviceNet • Global objects & faceplates –
simplifies use
• Wide-range of 3rd party network
and device integration options. • CIP Motion Support—configure,
program, and commission in
RSLogix 5000 using motion
profiles and instruction sets
Sustainable solutions
• Improve motor control performance
• Reduce energy consumption
• Global standards & voltage ratings
• Safe-Torque off (SIL3/Cat 3)
• Safe Speed Control (SIL3/Cat 4)

PowerFlex Family of Drives
• Power ratings from 0.2kW (0.25 Hp) single phase to 25MW (34,000 Hp) at medium voltage
• Seamless control system integration – maximize uptime
• Decrease development time by as much as 70% with Premier Integration —RSLogix 5000 Software with
PowerFlex drives add-on-profiles
• Power ratings from 0.2kW (0.25 Hp) single phase to 25MW (34,000 Hp) at medium voltage
• Seamless control system integration – maximize uptime
• Decrease development time by as much as 70% with Premier Integration —RSLogix 5000 Software with
PowerFlex drives add-on-profiles
• Increase productivity and flexibility with
integrated safe speed control technology
and safe torque off options
• Flexible control – simplifies operation,
reduces training & costs
– Common operator interface &
integration capabilities
– Consistent programming structure
– Consistent software tools
– Variety of packaging designs
0.2 kW (0.25 Hp) to 25.4 MW (34,000 Hp)

北美市场低压变频器厂家市场占有率
$ 0 .0 $ 5 0 .0 $ 1 0 0 .0 $ 1 5 0 .0 $ 2 0 0 .0 $ 2 5 0 .0
R o c k w e ll A u t o m a t io n - - A B
Y a s ka w a
A BB
S c h n e id e r
S ie m e n s
Danf os s
M it s u b is h i
TB W o o d s
R o c k w e ll A u t o m a t io n - - R E
Em e r s o n / C o n t r o l T e c h n iq u e s
• Rockwell Automation markets electric motor
L e n z e / A C T e c h n o lo g y
drives under two brands
T o s h ib a • Allen-Bradley
S a f t r o n ic s
• Reliance Electric
B a ld o r
• RA is the clear drive leader in North America
Ea t o n - C u t le r H a m m e r
G E- F u ji • Number 2 or 3 in the world

G e n e r a l Ele c t r ic
Source: ARC 2001 Global High Horsepower Markets for AC Drives
V acon ARC 2001 Global Low Horsepower Markets for AC Drives
Marketing Data from RA Drives Mktg Team
A S I R o b ic o n

市场: 低压变频器的市场份额

Control Magazine 2008 Readers’ Choice Awards
Top Honors
Software, Alarm Management Software, Human-Machine Interface Software, Loop Tuning
1. Rockwell Automation -- 24%* 1. Rockwell Automation -- 31%* 1. Rockwell Automation -- 27%*
2. Emerson Process Management -- 18% 2. Invensys Wonderware – 25% 2. Emerson Process
3. Siemens – 8% 3. GE Fanuc – 16% Management – 22%
TiPs – 8% 4. Emerson Process 3. Expertune – 17%
GE Fanuc – 7% Management – 8% 4. ControlSoft – 8%
Invensys Wonderware -- 7% FactoryTalk View Software from 5. Honeywell – 5%
7. Honeywell – 5% Rockwell Automation* RSLogix 5000 Programming Software
Iconics – 5% from Rockwell Automation*
Matrikon -- 5%
FactoryTalk Alarms and Events from
Rockwell Automation*
Software, Neural Network Software, PLC Programming Software, Simulation

1. Rockwell Automation/ 1. Rockwell Automation – 75%* 1. Rockwell Automation/
Pavilion – 44%* 2. AutomationDirect – 5% Pavilion -- 30%*
2. Emerson Process GE Fanuc – 5% 2. Mynah Technologies -- 15%
Management – 33% Schneider Electric – 5% 3. AspenTech -- 7%
Pavilion Technologies, a Rockwell RSLogix 5000 Programming Services National Instruments – 5%
Automation Company* from Rockwell Automation* Pavilion Technologies, a Rockwell
Automation company*
Variable Speed Drive

1. Rockwell Automation -- 52%*
2. ABB -- 10%
3. Baldor/Reliance -- 6%
Siemens – 6%
Eaton Cutler-Hammer – 5%
Allen-Bradley PowerFlex 700 AC Drive
from Rockwell Automation*

PowerFlex 700S
Performance and Power Range
PowerFlex 700S Highest Performance

PowerFlex 700L
Performance / Functionality
PowerFlex 700
Widest Power Range:
PowerFlex 70
1.1 A to 1500A!
PowerFlex
0.5 hp to 1600 hp! 700H
5 10 20 50 200 2000
Power Rating (HP @ 460V)

700S
Performance
• Selectable Motor Control Algorithms

– Vector Control with Force Technology™ – with or without an
encoder
• Voltage Adaption
– Permanent Magnet Motor
– V/Hz control
• Speed, Torque or Position Control
• Point to Point, Direct or Interpolated (Course to Fine)
positioning, Logix based motion with DriveLogix
• Inertia Adaption - Can increase speed regulator BW x4
• Feedback Options

PowerFlex 700S
Overview – Specifications and Features
• Drive Ratings (normal duty) • Features
– 200-240V, 0.75…66 kW • 1…100 Hp • 4.2…260 A – Motor Overload Retention
– 400-480V, 0.75…800 kW • 1…1250 Hp • 2.1…1250 A – DriveGuard® Safe-off
– Assisted Start-up Routine
– 500-600V, 75…1500 kW • 1…1600 Hp • 1.7…1500 A – Advanced Diagnostics
– 690V, 75…1500 kW • 1…1600 Hp • 1.7…1500 A – Analog Loss Detection
• Motor Control – Feedback Loss Switchover (in speed
– Vector Control with FORCE™ Technology mode)
– Slip Compensation – Stegmann Interface
– Encoder Speed Control – Heidenhain™ Interface
– Encoderless Speed Control – Resolver Interface
– Torque Regulation – Stahltronic and Temposonics® SSI
– V/Hz Motor Control Interface
– Permanent Magnet Motor Control – Integral Position Loop
• Ambient Temperature Limit for Enclosures – SynchLink™ (high speed data link)
– IP20, NEMA/UL Type Open: 0 to 50°C (32 to 122°F) – DriveLogix™ Option
– Inertia Adaptation
– IP21, NEMA/UL Type 1: 0 to 40°C (32 to 104°F) – User Function Blocks
• Enclosure Styles (Wall mount) – Common Bus Capability
– IP21 / NEMA/UL Type 1 – Frame 9 – Adv. Drive Overload Protection
• Enclosure Styles (Floorstanding) – Bus Regulation
– Rittal Style “A’ – Frames 10-14
• IP21 / NEMA/UL Type 1
– MCC Style “B” – Frames 10-12 (400,480, and 600V)
• IP21 / NEMA/UL Type 1

PowerFlex 700S
Overview – Packaging
• IP20 Wall Mount – Frame 1-9

• Rittal Cabinet IP21 – NEMA 1
• Motor Control Center (MCC)
IP21 – NEMA 1
• IP00 – NEMA Open

PowerFlex 700S
Ratings and Dimensions
PowerFlex 700S PowerFlex 700S PowerFlex 700S

Frame 1 Frame 2 Frame 3
Normal Duty Normal Duty Normal Duty
Ratings: Ratings: Ratings:

200-240V, 0.75-5.5 kW (1-7.5Hp) 200-240V, 7.5 kW (10Hp) 200-240V, 11-15 kW (15-20Hp)
400-480V, 0.75-11 kW (1-15Hp) 400-480V, 15-18.5 kW (20-25Hp) 400-480V, 22-37 kW (30-50Hp)
600V, 0.75-11 kW (1-15Hp) 600V, 15-18.5 kW (20-25Hp) 600V, 22-37 kW (30-50Hp)
Dimensions: Dimensions: Dimensions:

Height = 389mm (15.31”) Height = 389mm (15.31”) Height = 564mm (20.20”)
Width = 200mm (7.87”) Width = 285mm (11.22”) Width = 285mm (11.22”)
Depth = 202.7mm (7.98”) Depth = 202.7mm (7.98”) Depth = 202.7mm (7.98”)

PowerFlex 700S

Ratings: Ratings: Ratings:

200-240V, 18.5-22 kW (25-3Hp) 200-240V, 30 kW (40-50Hp) 200-240V, 45-66 kW (60-100Hp)
400-480V, 45 kW (60Hp) 400-480V, 55 kW (75-100Hp) 400-480V, 90-132 kW (125-200Hp)
600V, 45 kW (60Hp) 600-690V, 75-90 kW (75-100Hp) 600-690V, 110-132 kW (125-150Hp)
Dimensions Dimensions: Dimensions:

Height = 758.9mm (29.88”) Height = 644.5mm (25.37”) Height = 850mm (33.46”)
Width = 285.9mm (11.26”) Width = 369.4mm (14.54”) Width = 466.7mm (18.37”)
Depth = 202.7mm (7.98”) Depth = 275.4mm (10.84”) Depth = 275.5mm (10.85”)

PowerFlex 700S

Ratings Ratings
Ratings
400V: 200-250 kW, (385-500A) 400V: 315-400 kW, (590-730A)
400V: 132-160 kW, (261-300A)
480V: 350-450Hp, (385-500A) 480V: 500-600Hp, (590-730A)
480V: 200-250Hp, (261-300A)
600V: 250-450Hp, (250-450A) 600V: 450-600Hp, (460-590A)
600V: 150-200Hp, (170-208A)
690V: 250-400 kW, (250-450A) 690V: 450-560 kW, (460-590A)
690V: 160-200 kW, (170-208A)
Dimensions Dimensions: Dimensions:

Width = 480mm (18.9”) Width = 600mm (23.62”) Width = 797mm (31.38”)
Depth = 362mm (14.25”) Depth = 600mm (23.62) Depth = 600mm (23.62”)

PowerFlex 700S

Ratings Ratings Ratings

400V: 450-560 kW, (820-1030A) 400V: 630-800 kW, (1150-1450A) 600V: 1600Hp, (1500A)
480V: 700-900Hp, (820-1030A) 690V: 1500 kW, (1500A)
480V: 1000-1250Hp, (1150-1450A)
600V: 700-900Hp, (650-820A)
600V: 1000-1300Hp, (920-1180A)
690V: 630-800 kW, (650-820A)
690V: 900-1100 kW, (920-1180A)
Dimensions: Dimensions: Dimensions:

Width = 1196.05mm (47.09”) Width = 1412mm (56”) Width = 2800mm (110”)
Depth = 600mm (23.62”) Depth = 619.2mm (24.4”) Depth = 600mm (23.62”)

PowerFlex 700S
Phase II Overview

What You Will Learn
After completing this lesson you will be able to identify the PowerFlex 700S
Phase II drive and its and associated components by completing the following
tasks:
• Describe the Purpose and features of the PowerFlex 700S Phase II drive
• Identify the PowerFlex 700S Phase II drive and its components
• List the power connections to the drive
• Describe the network and control connections to the drive
• From a list match the operation of the drive power section to its function

Before You Begin
The PowerFlex 700S Phase II is a high performance variable frequency drive

(VFD) it can be optionally combined with a ControlLogix processor and
memory. This arrangement provides the variable speed and controllability of
the drive combined with the processing power of ControlLogix. The drive also
has special communication and encoder capabilities.

Before You Begin
The drive package is very powerful for precise multiple position control and
indexing applications.
Typical components in drive applications include:

• PowerFlex 700S Phase II drive with or without ControlLogix processor
• Motor with high resolution encoder
• Drive enclosure and control system

700S Phase II Drive Configurations
The PowerFlex 700S Phase II is available in two basic configurations:

• 700S Phase II
• 700S Phase II with DriveLogix

PowerFlex 700S Phase II Components
The PowerFlex 700S Phase II drive consists of the following major

components:
• Drive cover
• Communications adapter
• HIM (Human Interface Module)
• Drive main control board
• Encoder feedback board (Optional High resolution )
• DriveLogix embedded Logix engine (Optional)
• I/O and status LEDs

Drive Cover
The PowerFlex 700S Phase II drive cover by using a screwdriver to lift the red
locking tab:

Drive Cover
The drive cover hinges allow

the cover to swing away from
the drive chassis.
The cover houses the

optional DPI communications
adapter
20COMM-R

Communications Adapters
The PowerFlex communication adapters allows the drive to communicate with

its controlling systems via :
• DeviceNet
• Remote I/O
• ControlNet
• EtherNet/IP
• Profibus-DP
• Modus TCP/IP
• Modus RTU

Communications Adapters
DIP and/or rotary switches should

be set correctly. Incorrect settings
will prevent communication
between the controlling system and
the drive preventing machine
operation.

Human Interface Module (HIM)
The HIM is located on the front cover of the drive and can be removed by
pressing on the tab on top of the drive and lifting the HIM out of its cradle.

HIM Options
The options for the HIM include:

• LCD full numeric keypad
• Operating and programming only
• Programming only
• Analog speed control

HIM Options
The LCD HIM can be used for:

• Configuring
parameters
• Controlling the drive
• Saving parameters
• Displaying drive
information

Main Control Board
The main control board provides the following:

• Control Loops
• High speed I/O
• Interconnections to feedback options and DriveLogix
• SynchLink
• Connections for discrete a Main drive processors
• Drive parameter memory
• Analog inputs and outputs

Main Control Board
The following components DriveLogix Section
are part of the main control

board:
SynchLink
Connector
Encoder 1
Connector
Expanded I/O High-Speed

Connector Communications Option

Main Control Board
The Expanded Cassette includes the following components:

• NetLinx daughter card
Compact I/O
• Compact I/O connection Connection
• Feedback option
• Second encoder connection Compact Flash
• Compact Flash
NetLinx Daughter
Card
Feedback Option
Second Encoder Connection

Main Control Board Connectors (TB1)
The following table shows the Main Control Board connector layout for TB1.

Main Control Board Connectors (TB2)
The following tables show the Main Control Board connector layout for TB2.

Main Control Board I/O Configuration
Settings
DIP switches are used

to configure selected
I/O settings on the main
control board:

Main Control Board I/O Configuration
Settings
The following table can assist in switch configuration:

Main Control Board SynchLink
SynchLink provides high

speed synchronization and
communication between
multiple PowerFlex 700
drives. SynchLink
connections are shown
below:

Hazard of permanent eye damage

exists when using optical
transmission equipment. This
product emits intense light and
invisible radiation. Do not look into
module ports or fiber optic cable
connectors.

SynchLink fiber optics Provides:
Processor to Processor Synchronization

• Internal Processors Synchronized
• Drive to Drive Synchronization
High Speed Data Transfer

• Direct/Buffered Data Configurations
• 50 µSec Direct Data Transfer
• 500 µSec Buffered Data Transfer

Topologies
• Star - updates up to 256 slave drives at maximum data rate
• Daisy Chain - passes data peer to peer at maximum data rate, multi-drive
configurations (up to 10 drives) receive data at multiples of the maximum
data rate
• Ring - a variation of the Daisy Chain, closing the “ring” from the last node
back to the master

PowerFlex 700S Phase II Power
Connections
1 = Power Terminal Block

2 = SHLD (Shield) Terminal
3 = AUX Terminal Block

PowerFlex 700S Phase II Power
Connections
Terminal Block Designations
Terminal Description Notes
BR1 DC Brake (+ ) Dynamic Brake Resistor Connection (+ )
BR2 DC Brake (–) Dynamic Brake Resistor Connection (–)
DC+ DC Bus (+ ) DC Input Power or Dynamic Brake Chopper
DC– DC Bus (–) DC Input Power or Dynamic Brake Chopper
PE PE Ground
Motor Ground
U U (T1) To motor
V V (T2) To motor
W W (T3) To motor
R R (L1) AC Line Input Power
S S (L2) AC Line Input Power
T T (L3) AC Line Input Power
BR1
BR2
DC+
DC–
PE
U (T1)
V (T2)
W (T3)
R (L1)
S (L2)
T (L3)

PowerFlex 700S Phase II
Power Connection Recommendations
The following illustration shows the recommended power and ground

connections

PowerFlex Power Structure

PowerFlex Power Structure-Converter
Converts incoming 3 ph AC into DC bus plus and minus.

• Diode Rectifier
• Separate pre-charge function required.
• This is included in the Power Structure as a relay and resistor.

PowerFlex Power Structure - Pre-Charge
The pre-charge circuit is designed to limit inrush current during start-up. A

current limiting resistor is place in series with the capacitor bank limiting current
to safe level. When the DC bus reaches approximately 80% of its nominal
voltage value the pre-charge resistor is switched out allowing full current
operation.

PowerFlex Power Structure – DC Bus
The DC bus components filter, remove noise and smooth the rectified 3 phase
AC
The main components are:

• Filter capacitors
• High frequency noise capacitors
• DB bus chokes

PowerFlex Power Structure – DC Bus

PowerFlex Power Structure - Inverter
Converts the DC bus plus and minus into a sine coded pulse width modulated
waveform (PWM) that the motor sees as AC.
The inverter section consists of insulated gate bi-polar transistors (IGBT) that
perform as high speed low loss switches.

PowerFlex Power Structure - Inverter

Power Structure – Current Sensing
Three current sensors monitor 3 ph current and provide the following:

• Current Limit
• Instantaneous Over Current Trip
• Inverter Temperature monitoring
• Motor Control

Power Structure – Current Sensing

Catalog Number

PowerFlex 700S
1. Performance and Power Range
2. DriveLogix
3. SynchLink
4. Safe-Off

PowerFlex 700S
DriveLogix
• The DriveLogix option is a real Logix
controller embedded on the main control
board of a PowerFlex 700S
• You program it with RSLogix 5000
(just like other Logix controllers)
• It can reside on a network
• It can scan local I/O
• It has a RUN/REM/PROG switch
• It supports Logix Motion Commands
• It has a high-speed connection to its host
drive via a “virtual backplane”
(better than other Logix controllers)
• Saves space and money with no extra power
supply or chassis (better than other Logix
controllers)`

DriveLogix5730 – Integrated Motion
– Supports generic axis data type

– “Servo” axis is used to control the local PowerFlex 700S drive
– “Feedback only” axis is used with any PowerFlex 700S feedback option
− Incremental encoder, resolver and high resolution Stegmann encoder
− Speed and position data received from a remote PowerFlex 700S over
SynchLink
– 25 motion instructions supported including home, jog, move, gear, cam, registration,
and watch
– Control and Status functions
− Drive Enable
− Servo Active
− Shutdown, Fault Reset
− Linear and Rotary

– Single Axis System Controller

− Good choice for modular and 1 - 2 axes applications
− Compact I/O expansion provides user scalable capabilities
− Connectivity allows operator interface and plant-wide integration
– Synchronization capabilities
− Hardwired feedback devices
− Speed and position data via SynchLink
– High power, single axis controller
− 1 – 1250Hp
– Complements Kinetix® Integrated Motion with common tools and instructions
− Standardized control and programming environment
− Maintains the RSLogix 5000 look and feel throughout the user application

– Integrated control and drive simplifies control strategy

• Provides single point of contact for programming and drive configuration
– Compatible motors
• Allen-Bradley® MPL motors (Stegmann or Resolver)
• Allen-Bradley 1326 motors (Stegmann or Transmitter type Resolver)
• Induction motors
• Some 3rd party permanent magnet motors (Mequon testing required)
– Performance
• 4-millisecond planner update rate is the fastest achievable execution rate
today. Fastest position loop update in the drive is 1 msec
– Versatile and compact
• Wide range of power and connectivity options allowing you to integrate into
a variety of applications, architectures and power platforms
– Easy to configure, commission and integrate
• Seamless integration into Allen-Bradley and third-party systems

DriveLogix5730 – Performance
• Performance comparisons for ladder program execution

– The performance tests were conducted with the same base line program in all
platforms
– The DriveLogix 5730 is based on the CompactLogix processor
Maximum Average
SLC™ 5/04 or 5/05 25ms 19ms
FlexLogix 8.9ms 5.0ms
DriveLogix 5730 CompactLogix L35E 5.4ms 3.1ms
ControlLogix® L55 5.4ms 3.7ms
ControlLogix L63 3.3ms 2.1ms
*Lower times are better

PowerFlex 700S
2. DriveLogix
3. SynchLink
4. Safe-Off

PowerFlex 700S
SynchLink
• SynchLink is a high-speed (data transferred every 50 microseconds) , synchronous,
drive-to-drive data link for transmitting synchronized drive and application data
• SynchLink uses fiber-optic cable (so it is immune to electromagnetic interference)
• SynchLink is ideal for transferring:
– Torque command (in a load sharing application)
– Position command (in an electronic line shaft or positioning application)
• Useful for: Electronic Line Shaft, Electronic Gear Ratio, Load Sharing

PowerFlex 700S
SynchLink Example - Electronic Line Shaft

PowerFlex 700S
2. DriveLogix
3. SynchLink
4. Safe-Off

PowerFlex 700S
Safe-Off
• Will not send energy to motor when Safe-Off input is low.

• Operator Safety
• Machine and Factory Productivity
• EN-954-1 Category 3
• TUV Functional Safety Report
• Duality (Redundancy), Diversity, Diagnostics

PowerFlex 700S
Control Hardware Loc.

PowerFlex 700S
Options Overview
Options available in the Slim or Expanded cassette
– SynchLink
– DriveLogix 5730
• Embedded EtherNet/IP
Options that require the Expanded cassette
– Feedback options
• 2nd Encoder, Stegmann, Heidenhain, Resolver, MDI
• Heidenhain EnDat through Global Drive Systems
– Logix Expansion board
• NetLinx daughter cards communications
(1788-xxxx)
• CompactFlash
• Compact I/O
Use the Expanded so you can add options later

PowerFlex 700S
Target Applications and Industries
• Applications that Require High Performance

– Low speed torque
– Tight torque or speed or position control
• Applications that Require Esoteric Feedback Capability
– Stegmann or Heidenhain or linear or Resolver
– Feedback loss switch over
• Applications that Require Permanent Magnet Motor Control
• Applications that Require High Speed Synchronization
• Applications that Require Logix or Motion Commands
• Applications that Require Safe-Off

PowerFlex 700S
Target Applications and Industries
• Metals, Paper, Converting…

– Web handling
– Winding/un-winding
– Extruders
– Flying Shear
• Automotive
– Test Stands
– Transfer Systems
– Feeders (Press, cut-off…)
• Printing
– Electronic Gearing
– Cut to Length
– Unwind

PowerFlex 700S related manual
• User Manual 20D-UM006

• Installation Instruction PFlex-IN006
• Reference Manual PFlex-RM003
• Quick Start 20D-QS004
• More manual can download at
www.ab.com

PowerFlex 700S
1. PowerFlex 700S introduction
2. Load Sharing
3. Installation
4. Q&A

Load Sharing with AC Drives

Load Sharing
• In the world of DRIVES Load Sharing:

– Involves multiple drives/motors powering the same process
– Is having each drive contribute a fair share of torque to do work proportional to
its own capacity
– Is NOT multiple motors controlled by one drive powering the same process
– Is NOT having each drive/motor combination operate entirely independent of
each other.

Load Sharing
• Using
– Droop Follower
– Torque Follower (master / slave)
– Speed Trim Follower (Cascade)

Droop Follower
• Enhances the slip characteristics of an induction

motor but will not assure load sharing.
• Prevents contention between independent speed
regulator drives.
• As torque current increases –
output frequency decreases.
• No interconnection required –
drives operate independent
of each other.

Droop Follower

Droop Block Diagram

Droop Follower Applications
• HVAC and Pump Stations

• Common media to process
• Multiple independent motors

• Uneven load of material can cause one motor to pull harder than the
others.
• Droop on each drive will allow load sharing with some change in speed.
• Leaving one drive without droop will provide better speed regulation but
worse load sharing.

• Self Propelled Rail Car

– One drive wheel with motor on each
side.
– During a curve, outside wheels move
faster and farther than the inside
wheels.
– Higher proportion of load alternates
from side to side.

• Intermittent Load Coupling

• Load sharing required when coupled.
• When uncoupled Drive rollers must not run away.

Droop Follower
Advantages Disadvantages
• Simple. • Poor speed regulation.
• No extra wiring. • Limited speed range difference.
• High Performance drives not • Sharing of load is not precise.
required.
• Does not result in runaway
condition when load is
uncoupled.

Load Sharing
• Using
– Droop Follower

Torque Follower
• Precise master slave load sharing.

• Precise speed regulation.
• To operate over a wide speed range.
• Multiple drives to act
as ONE larger drive.

Torque Follower Block Diagram

Torque Follower Applications



• Intermittent Load Coupling

• Load sharing required when coupled.
• When uncoupled roller must not run away - use min torque/speed
comparator feature.

Torque Follower
• Precise load sharing to act as one • Available only on FVC drives –
drive. PF700S-PF700VC – PF70EC -
• No speed range limit. 1336 Impact.
• Do not have to give up speed • Requires interconnected signal
regulation. wiring.
• Min/Max torque reference • Load loss can cause torque
compare feature eliminates run follower drives to run away.
away

Load Sharing
• Using
– Droop Follower

Speed Trim Follower
• Continuous automatic load sharing compensation

on elastic and pull only applications.
• No manual compensation for “initial loading” or
“strip out” activities.
• Precise overall speed
regulation.
• To operate over an
entire speed range.

Speed Trim Follower Block Diagram

Speed Trim Follower Applications
• Chain Conveyor
– Large speed range may exist.
– Overall Speed regulation is critical.
– Proper load share prevents excess equipment wear.
– Mechanical coupling between motors is pull only

• Head drive sets the pace and rotates both tracks

• Each helper drive independently assists with one track
• Load sharing with a speed trim configuration, allows for independent
helper drive reaction to unique loading

• Continuous automatic load sharing • Available only on higher
compensation. performance drives
• No manual compensation for “initial
loading” or “strip out” functions. • Requires interconnected signal
• No speed range limit. wiring.
• Do not have to give up speed
regulation.
• Trim feature built into the drive.

Summary
Application Characteristic Load Sharing Control Technique
Droop Torque Speed Trim

Follower Follower
No direct mechanical load coupling X
Elastic or rubber band effect, involving stretch, X X

expansion and contraction of media mechanically
coupled (belt, monorail, chain conveyors etc.)
Parallel fans moving gaseous media from same plenum X
Parallel pumping of liquids X
Mechanically and rigidly coupled equipment with multi- X

motors;
coupled inline drive shafts
rack and pinion
engaging the same axle or shaft
engaging a bull or ring gear
nip rollers
Serpentine conveyor belt around close proximity drives X
Any rigid mechanical coupling of multiple motors X

teamed up as one large motor.
web lines with multi-stage tension regulation X

General Guidelines
• Use Droop When:

– Speed range is less than 10 hertz.
– Speed regulation is not critical.
– Load sharing of 35% - 65% or worse is ok.
– Mechanical coupling is soft or elastic.
– No more than 2 drives.

General Guidelines
• Use Torque Follower When:

– Large speed range can exist.
– Speed regulation is critical.
– Precise Load share.
– Need to act as one drive.
– Mechanical coupling between motors is stiff or ridged.

General Guidelines
• Use Speed Trim Follower When:

– Large speed range can exist.
– Overall Speed regulation is critical.
– Load share is necessary to prevent excess equipment wear.
– Mechanical coupling between motors is elastic or can only be pulled not pushed.

PowerFlex 700S
1. PowerFlex 700S introduction
2. Load Sharing
3. Installation
4. Q&A

AC Drive and Motor Installation Practices
Line Transients
A little protection
and good
technique
ACME INCORPORATED go a long way to
insure a good
drive installation
Common Mode
&
Capacitive Coupling
Tell me again
why I’m using ? Harmonics
drives?
Reflected Wave
Grounding
&
Bonding

Recommended System Grounding Scheme

Why Should I use a drive ?
• To improve process control though speed and torque control

• To improve system efficiencies
• To extend life of equipment by reducing mechanical stress

Installation Concerns for AC Drives
• Reflective Wave
• Common Mode Noise
• Capacitve Coupling
• Grounding and Panel Layout
• Power Quality

IGBT Advantages
• Higher Switching (Carrier) Frequencies than Bipolar Transistors

– Lower Motor Noise
– Lower Motor Heating
– Reduced Under-lap Time for Better Stability
• Drive Size Reduction
• High Input Impedance
– Reduces Base Driver Power Consumption
– Reduces Base Driver Board Size

IGBT vs. Bipolar Transistor Current
7.5HP MOTOR
1336 @ 60HZ NO LOAD

SWITCHING FREQUENCY
Bi-Polar 1.26KHZ
1336 PLUS @ 60HZ

NO LOAD SWITCHING
IGBT FREQUENCY 9KHZ

The Reflected Wave Phenomenon
• First identified in 1900 with power distribution lines

• Also known as Standing Wave or
Transmission Line Effect
• Well documented in digital communications
• Coming to the forefront in IGBT based drives
• Can cause voltage peaks at the motor
• Presents the possibility for insulation breakdown

The Physics of it All
• The cable between the drive and motor represents a substantial

impedance to the PWM voltage pulses of the drive
• Cable impedance is proportional to length
Inductance / unit length
Z0= Capacitance / unit length
• If the cable surge impedance does not match

the motor surge impedance----
– Voltage reflection WILL occur !!

Transmission Line Effect
INVERTER CABLE MOTOR

SOURCE LOW Z CAPACITOR Zo BETWEEN 50 - 200 OHMS FOR ZLOAD (60Hz) >> Zo
3 PHASE CABLE
+ Zo 1K - 2K OHMS - SEPARATED PHASES X1 X2

R1
LINE A
CSG Xm R4 S
LINE B
Per Phase Motor
1
- Zo = L/C v=
L*C
Possible 2x To 4x
Bus Voltage Ring Up
PROBLEM:
* Motor Insulation Capability - Now The Voltage Across The First Few Turns
Of The Coil Group Can Be > 1350 Volts, Rather
Than The Typical Across-The-Line Voltage Of
10-30 Volts
* Cable Insulation Capability - Need Higher Rating Voltage - Long Life
* Increased Motor dv/dt Noise Current Oscillating In The 1 -3MHz Range

Typical PWM VLL Output Pulse at the Motor
Terminal
+2
+1
-1

What will the amplitude be?
• The velocity of the reflection

(Dependent on cable capacitance & inductance)
PLUS
• The rise time of the switching device

determine the cable distance at which the
reflected wave will reach maximum amplitude
The
amplitude can be 2 - 3 times the DC Bus voltage
( 675VDC X 2 = 1350 Volts typical )

Predicted Motor Overvoltage for IGBT’s, BJT’s &
GTO’s
2.2
Semiconductor Risetime
2 50 ns
Motor Overvoltage / Vdc
100 ns IGBT
1.8
200 ns
1.6
400 ns
1.4 600 ns
BJT
1 us
1.2
2 us
1
4 us GTO
1 10 100 1000 10000
Cable Distance [ft]

Insulation breakdown
• 60 - 80 % of the reflected wave is distributed across the first coil

group of the motor
• Can punch through these microscopic holes
• Insulation breakdown can be caused by
– Repetitive Partial discharges
• Voltage exceeds breakdown Voltage of air
• Degradation is relatively slow
– Corona
• Voltage ionizes the surrounding air
• Arcs across the windings
• Insulation failure is immediate
– Voltage exceeds magnet wire insulation

480v Reflected Wave Stress - Long Cable
2000
480 Volt System V LL /V DC = 3 Per Unit
1800
Peak Line-Line Motor Voltage (V PK)
1600 1600 Volts

Corona Susceptible Areas
1400
1200
1000 1000 Volts
800
600
400
200
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
Time ( m s)
• NEMA MG1 Part 31 1600V Motor is Inadequate

• Reduction of 1000 Vpk Motor Insulation Life Accelerated

Motor Failure Mechanism High Volt/Mil Stress in Coil
500
T1 ORN
T3 ORN 400
T5 ORN Line End Coil V
o 300
T7 ORN
l
T9 ORN t 200
T11 ORN a
g 100
T13 ORN
e
T1 BLU 0
T3 BLU
-100
T5 BLU
T7 BLU -200
T9 BLU Second Coil 0 0.5 1 1.5 2 2.5 3 3.5 4
T11 BLU Time (uS)
T13 BLU
Coils 3-12
T0
12 coils
• Peak Inter-turn Voltage is a Function of the Transmission
12 coils Line affect of the motor and the number of Turns of the
T2 T3 coil group

Effect of Corona
• White Residue
• Phase to Phase W/O Separator
• Turn to Turn
• Drive Typically OL Trip

Where is the highest risk?
• The smaller the Drive / Motor, the greater the risk
• Lower HP drives typically have fastest rise times
• Smaller, low cost motors typically have

– Less insulation - Voids are probable
– No phase paper - End Turns
– No slot paper
– Usually machine wound - Nicks

What can you do about it?
• Specify and buy inverter duty insulated motors
• Keep motor lead lengths as short as possible
• Install a motor “protection” device where needed

All motors are not the same!
• Typical low cost motor safe value is 960V if

rise time ³ .1 µS
• “Inverter Duty Rated” usually specs a better
THERMAL rating, not insulation breakdown
• NEMA MG1 - para 31.40.4.2 specifics a maximum peak voltage and
rise time that inverter duty motors must meet.
• Motor manufacturers must redesign to
increase their insulation
• A-B offer .5-600 HP motors that meets the new NEMA MG1
• Better motors allow longer distances with no
degradation or breakdown

Protect the Motor
• Output Reactor between drive & motor

– Slopes off the waveform (lengthens rise time)
– Reduces destructive force for same amplitude
– Allows longer lead lengths
– Does create Voltage drop
• May cause reduction in torque
• Output Filters
– 1204-RWR2
• LR filter
– KLC filters

The Terminator
• Highly Cost Effective

• Smaller
• No Voltage Drop
• Works @ any cable distance
• Maintains current waveform
• 2 - 3 choices fit all applications
• Most effective solution
• Solves multi-motor installations concerns
• Works on all A-B IGBT & BJT drives

Solutions
AC Drive
Allen-Bradley
1329 Inverter Duty Motor
AC
Motor
AC Drive
1204-RWR2
Reactor
KLC filter
@drive or Non Inverter Duty Motor
AC
Motor
Terminator
1204-TFA1
1204-TFB2
@Motor

Results
Plot 2
Before and after the addition of a 1204-RWR2 & 3.0mhy output reactor
1305 3HP 460V 60HZ No-load
300ft shielded cable
After addition of
1321 output reactor
1140Vpk @ Motor
14ms/rise time Before addition of
1204-RWR2
1180Vpk @ Motor
660Vpk @ Inverter
After addition of
1204-RWR2
720Vpk @ Motor
660Vpk @ Inverter

Cable Issues Require Attention
• Capacitive Coupling
• Cable charging current

Problems Identified With Common Mode
Noise
• Non operational
– Control Interface(4-20ma, 0-10V)
• PLC communication errors
– RIO
– DH+
– SCANport
– KT/Control View
• Radiated noise
• Conducted Noise
– Ultra Sonic Sensors
– Temperature Sensors
– Bar Code
– Vision System

Existing Condition: dv/dt “Noise” Current
Triangular 3 Phase
Power Cable
L LINK Cable Without Shield
C MOD PHASE A
C MOD
ISG1 CSG MOTOR
CHASSIS GND
GROUND
ALL CURRENTS IG MUST ISG WIRE
RETURN HERE OR HERE
I SG2
I G RETURN
Problem: Customer Ground Noise

* Return Path in Ground Thru Stray Capacitive Divider
(i.e.. Unknown Paths)
* I GND Can Find Its Way Into CNC, PLC, And Computer Grounds
* Conducted Ground Current  Customer EMI Noise Problem

Fundamental Problem
70 ns
Inverter V
LL
output
voltage
Common
Mode
Current
dv
6 MHz I C
I PEAK
dt

Philosophy Of Common Mode Noise
Abatement
• 1. Grounding practices
• Eliminate ground loops (Single Point Grounding)
• Panel Layout
• 2. Attenuate noise source (drive)
• Add Common mode chokes to drives output
• Add common mode chokes to Blue Hose
• 3. Shield noise away from sensitive equipment
• Use 4 conductor shielded cable (required for CE)
• Use 4 conductor in conduit
• 4. Capture and return noise to source (drive)
• EMI/RFI filter (required for CE)
• Add common mode caps

Single Point Grounding/ Panel Layout
Neutral
For PLC grounding
Equipment recommendation
Ground refer to Publication
PLC 1770-4.1
TE-ZERO VOLT
POTENTIAL BUS (Isolated from panel)
1336 Plus
1305
Motor
Logic
Logic
PE PE
PE GROUND BUS Motor
Usually bonded
to nearest
Building ground
Figure 1: Grounding requirements vary depending on the type of drive implemented, drives with true earth
(TE) terminals must have a zero volt potential bus, separate from potential earth (PE) ground bus. users
now have two choices. They can either tie the buses together at one point in the control cabinet or bring
them back separately to the building ground grid (tied within 10ft of each other).

Single Point Grounding/ Panel Layout
Neutral
For PLC grounding
Equipment recommendation
Ground refer to Publication
PLC 1770-4.1
TE-ZERO VOLT
POTENTIAL BUS (Isolated from panel)
1336 Impact 1336 Plus
Motor
Logic Logic
PE TE PE
PE GROUND BUS Motor
Usually bonded
to nearest
Building ground
Figure 1: Grounding requirements vary depending on the type of drive implemented, drives with true earth
(TE) terminals must have a zero volt potential bus, separate from potential earth (PE) ground bus. users now
have two choices. They can either tie the buses together at one point in the control cabinet or bring them back
separately to the building ground grid (tied within 10ft of each other).

System Grounding Scheme
1336 Plus 1336 Plus 1336 Impact 1336 Force
1305 1305
Logic Logic
Logic Logic
PE PE PE
PE Logic Logic
PE TE PE TE
PE Bus PE Bus PE Bus
TE Bus
Common Mode Voltage V 1-2
Common Mode Current I I ao

ao
Ground Potential #1 Ground Potential #2

Improper Cabinet Grounding w/Drives & Susceptible
Equipment
Conduit or Conduit or
Armor Bond Output Conduit / Armor Armor Bond Output Conduit / Armor
M1, M2, M3, PE L1, L2, L3
U VW PE R S T
Noise Current Drive 1 Drive 2
Return Path
Cabinet Back Plane
PLC PE PE
Drive 3 Drive 4
PE PE
PE Copper Bus
To System Ground

Proper Cabinet Grounding w/Drives & Susceptible
Equipment
Common Mode
Current on Armor
PE PE All Drives
Output Conduit or Armor
Input Conduit / Armor
Bond to Cabinet
L1, L2, L3, GND
U VW R S T
Drive 1 Drive 2
Cabinet Back Plane
Current on Green Wire

Common Mode
PLC PE PE
Drive 3 Drive 4
PE PE
PE Copper Bus
Optional PE to Structure
Steel if Required

X = Io RETURN
X X X
X
X X
SHIELD X
X
a b X
X
. = Io SOURCE
X X
X X COAXIAL LOW INDUCTANCE STRUCTURE
X X
X FOR ZERO SEQUENCE CURRENT
Shield Noise X
X c g X
X X
X X SHIELD PREDOMINATES 95% Io
Iao
AC MOTOR
DRIVE <<
Ibo
<<
C STATOR/GROUND
SLOT
CAPACITANCE
Ico
<<
Io RETURN FRAME
60 Hz SAFETY GROUND 5%
COAX SHIELD 95% LOCAL

TO SYSTEM CODE
GROUND GROUNDING
1 TO 5 OHM GROUND GRID RESISTANCE 5% WIRE

Effect of Cable Construction A
 Cable Construction Can Affect Current Balance In V/Hz Drives

• Greater Than 125HP
A B C A B C
TRAY TRAY
ARMOR
ARMOR PVC
PVC PVC
STRANDED
A A A A NEUTRAL
B C B C B C B C
CONTINUOS WELDED INTERLOCKED TRAY CABLE EUROPEAN

ALUMINUM ARMOR ARMORED UTILITY
STANDARD

Capture and Return Noise
to Source
COMMON MODE CAPS

LLINK ATTENUATES NOISE WITH SHIELD CAPTURES NOISE
COMMON MODE CHOKE RETURNING TO DRIVE
+
LEM
+
MOTOR
+ LEM
LLINK
GND
CHASSIS

Technical Solutions
* Reduce Carrier Frequency * Common Mode +/- Caps

* Common Mode Output Core * Common Mode Core (RIO / DH+)
* Shielded Output Cable & 4 Wire Input Cable * Output Line Reactor
* RFI Filter
MOTOR
CONDUIT / RFI FILTER FRAME
4 WIRE CABLE 1336 PLUS COMMON OUTPUT
MODE REACTOR SHIELDED
DRIVE CORE CABLE
L1
A
B MOTOR
WINDINGS
L2 C
PE / GND GROUND
PE SHIELD
L3 + DC
PE GROUND
- DC PER LOCAL
NEC CODE
RIO / DH+
+/- COMMON
MODE CAPS
COMMON PE
MODE
CORE
ROD TO COMPUTER
GROUND AT TE GROUND

Capacitive Coupling
• Cable charging current issues

– Requires a fixed amount of current
– May exceed small drive rating
• Simple solutions
– Limit motor lead length for small drives
– Reduce drive carrier (PWM) frequency

What is Capactive Coupling?
• In any given motor cable there will be a certain amount of distributed

stray capacitance.
• Every time the drives’ DC bus voltage switches at the carrier (or
PWM) frequency it causes current to conduct through this
capacitance.
• These capacitive current spikes then get reflected back to the drive
and measured by it’s current feedback circuitry.
• THIS IS ALSO REFERRED TO AS “CABLE CHARGING

CURRENT”.

Cable Charging Current
• This phenomenon exists for all drives
• 460 volt drives will exhibit this phenomenon to a greater degree then will
230 volt drives.
• One of the ways to mitigate this effect is by reducing the carrier (or PWM)
frequency to 2 KHz.
• Another mitigation technique is adding a 3 phase inductor on the output.

Installation Conclusion
• Thank you.
• Questions?

700S High Performance Drive

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700S High Performance Drive

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Huang Yongjin

Power Control Solution Architect

Copyright © 2008 Rockwell Automation, Inc. All rights reserved.

1. PowerFlex 700S Phase II Overview

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 2

1. PowerFlex 700S Phase II Overview

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 3

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 4

Scaleable Motor Control –

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0.2 kW (0.25 Hp) to 25.4 MW (34,000 Hp)

G E- F u ji • Number 2 or 3 in the world

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 7

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 8

Software, Neural Network Software, PLC Programming Software, Simulation

Variable Speed Drive

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 9

PowerFlex 700S Highest Performance

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 10

• Selectable Motor Control Algorithms

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• IP20 Wall Mount – Frame 1-9

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PowerFlex 700S PowerFlex 700S PowerFlex 700S

Ratings: Ratings: Ratings:

Dimensions: Dimensions: Dimensions:

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 14

PowerFlex 700S PowerFlex 700S PowerFlex 700S

Ratings: Ratings: Ratings:

Dimensions Dimensions: Dimensions:

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 15

PowerFlex 700S PowerFlex 700S PowerFlex 700S

Dimensions Dimensions: Dimensions:

Height = 1150mm (45.28”) Height = 2275mm (89.6”) Height = 2275mm (89.6”)

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 16

PowerFlex 700S PowerFlex 700S PowerFlex 700S

Ratings Ratings Ratings

Dimensions: Dimensions: Dimensions:

Height = 2275mm (89.6”) Height = 2275mm (89.6”) Height = 2275mm (89.6”)

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 17

Copyright © 2008 Rockwell Automation, Inc. All rights reserved.

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 19

The PowerFlex 700S Phase II is a high performance variable frequency drive

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Typical components in drive applications include:

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The PowerFlex 700S Phase II is available in two basic configurations:

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The PowerFlex 700S Phase II drive consists of the following major

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The drive cover hinges allow

The cover houses the

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The PowerFlex communication adapters allows the drive to communicate with

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DIP and/or rotary switches should

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The options for the HIM include:

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The LCD HIM can be used for:

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