New variable frequency drives from Rockwell can power motors up to 500 hp while retaining panel-mount capability. They are programmed with Studio 5000 and offer predictive maintenance with FactoryTalk.
Using variable frequency drives (VFDs) to control motor start-up and running speed has become an industry standard within the automation community, especially when dealing with large motor sizes. Motors this size will draw an enormous amount of current during the start-up process. By using a VFD such as a PowerFlex 755TS, this start-up current can be reduced.
A variety of different PowerFlex 755TS sizes. Image used courtesy of Rockwell
The PowerFlex 755TS lineup consists of many drives capable of driving motors from 1 hp to 500 hp while still having panel mounting functionally. All of the drives within the 755TS series support up to five expansion cards for I/O, communication, or auxiliary power supply. A corrosive gas protection option can be added to any of the 755TS drives which protects the drive when used in environments with corrosive gas.
Recently Rockwell Automation also announced the PowerFlex 755TS family will now support frame 7A sizes which are motors up to 500 hp.
Image of the PowerFlex 755TS Fram 7A. Image used courtesy of Rockwell
PowerFlex 755TS Frame 7A
The new PowerFlex drive from Rockwell Automation is a reduction in overall footprint size but not power. The 755TS low voltage model comes in a panel mount version instead of the typical floor-mounted variety and can drive motors up to 500 hp. Designed for system integrators in the oil and gas and power generation industries the 755TS is said to be easier to maintain and commission.
The 7A model has all of the same features as the other sizes within the 775TS catalog, including CIP safety communications, built-in dual gigabit ethernet ports, compatibility with Studio 5000 programming interface, and TotalFORCE technology.
A mixing tank would likely use a VFD for motor control. Image used courtesy of Unsplash
VFD Programming
Today, programming your PowerFlex VFD is even easier because you can use Studio 5000 software. Once connected, drive parameters can be set, and commands to start, stop, or command frequency can all be sent from within the PLC logic that is written with Studio 5000 software. The TotalForce technology gives the end user of the VFD more precise control and monitoring capability, which is made possible with its digital platform. Combined with FactoryTalk Guardian AI, a predictive maintenance software, maintenance staff can prepare for downtime and prevent unpredicted stoppages before they happen.
Processing plant using large pump motors. Image used courtesy of Unsplash
FactoryTalk Guardian AI
Predictive maintenance software monitors sensors, real-time values, and input from operators to determine which equipment will need to be maintained. The FactoryTalk Guardian software interfaces with Rockwell’s PowerFlex family of the VFDs to capture the warning signs of asset failure and hopefully prevent unexpected downtime of equipment.
Multiple assets can entered into the system and monitored at one time, your entire plant can be analysed from one installation of FactoryTalk Guardian. When FactoryTalk Guardian determines an anomaly within your assets, you get a notification about the cause of failure and the severity of the risk. FactoryTalk Guardian is designed to be installed on edge computing systems that often reside on the factory floor, and it is designed to interface with Rockwell Automation’s full portfolio of products.
