Introducing the PowerFlex 755TS: The Next Generation of Allen-Bradley PowerFlex Drives

To those who are in the know, generational improvements are fascinating! Whether you are into phones, cameras, computer hardware, or, like us, automation equipment, every so often, the automation equipment that we know and love gets a refresh and is packed with new features that increase the quality of life while working on it. That’s why today we present to you a much-anticipated (albeit a bit late) introduction of Allen-Bradley’s new 755 TS line of VFDs! We will take it head-to-head against the previous generation 755 and showcase its new features.

The PowerFlex 755TS

The 755TS is an updated version of their 755 platform with new technology packed in and a more modern enclosure style to match. Its key features include:

• DeviceLogix: An embedded control technology that uses discrete inputs and drive status information to manipulate discrete outputs and drive control functions
• Predictive Maintenance: Leveraging TotalFORCE technology, the 755TS estimates and alerts you of your components’ longevity to streamline maintenance planning.
• Slot-Based Hardware Structure: This allows you to select safety communication, I/O, and feedback option modules for more customization.
• Safety Torque Off and Safe Speed Monitor: More intelligent control from the VFD to provide a choice for safety requirements for your specific application
• Load Observer: Maintains productivity with control that adapts to operating conditions
• Ride-Through: This is designed to keep the drive and motors running through brief power disturbances, such as sags or swells.
• TorqProve: Patented control coordinates motor torque and brake operation in hoist applications.
• More Power, Smaller Footprint: The 755TS provides more power in a smaller package to get the most out of your space as possible. It offers panel solutions up to 500 HP and cabinet solutions up to 6000 HP.

All About the TotalFORCE Technology

By now, this term has become synonymous with Allen-Bradley’s best drives, and for good reason. This technology has three main selling points: increasing plant productivity, minimizing downtime, and reducing energy costs. The 755TS just so happens to be the first six-pulse drive supporting this technology. While the older 755 does come with FORCE technology, it is not the same as TotalFORCE, as FORCE refers to basic torque control and regulation, as well as more advanced control algorithms for the time being.

How does it work?

This is achieved with real-time operational intelligence, along with automated application commissioning and optimization, all working behind the scenes to keep your operations running at optimal performance. This is Adaptive control, and it works by combining precise velocity, torque, and position control with its self-monitoring capabilities for unmatched motor control by automatically adjusting to the application load or mechanical changes it faces during operation so that it may improve electrical efficiency and mechanical reliability. Doing so relies on three other pieces of tech:

• Adaptive Tuning: It constantly retunes itself as the system changes by adjusting control loop gains and compensating for changes in mechanical load, temperature, system inertia, or wear over time.
• Load Observer: This function models and tracks the mechanical load on the motor in real-time. It estimates torque demand, friction, and inertia on the motor shaft even when direct sensors aren’t available. This allows for more accurate torque control, better regulation during load changes, and smoother transitions.
• Bus Observer: This monitors the DC bus voltage in the drive to predict and compensate for fluctuations in power quality.

Predictive Maintenance

Another beneficial feature of TotalFORCE is its ability to take real-time information and calculate the expected life of drive components based on your specific usage and environment. If it senses that something is about to fail, it will let you know ahead of time so that you can react accordingly to reduce any downtime. This includes sensing blown fuses, components approaching the end of their life, and increasing temperatures out of their normal range. Not only that, but the 755TS has a DC bus conditioner that helps protect power components, Voltage Boost to enable full voltage to the motor, and comes with the ability to switch between utility and generator power sources.

Crane, Hoists, and Lifting Compensations

When using the 755TS, the drive can make lifting loads much easier. Using TorqProve Control helps verify load control in lifting applications and compensates for sway by reducing the swinging of a moving load. Regeneration also enables the drive to put energy back on the incoming line to provide a braking solution that is far more efficient than resistive braking.

The Verdict?

TotalFORCE transforms your kind-of-smart motor controller into something much more. Not only would it save you money by helping to prevent downtime and optimize energy usage, but your technicians would also enjoy the wealth of features and quality-of-life upgrades that it brings to the table (or cabinet).

Energy Savings

Motor operation could account for about 50% of industrial energy use in an industrial automation plant, so upgrading to a 755TS is a smart move. After all, with all of its energy-saving features, the drive will pay for itself. The 755TS achieves this by using a few unique features, such as its Energy Pause, which disconnects its 3-phase power when it is idle to enter a low-energy state. When production kicks back on, the drive will ready itself and continue as it should.

The 755TS also utilizes an Economizer mode, which automatically adjusts the drive’s output voltage based on the application load when steady-state speed is achieved. When paired with regenerative capabilities to put energy into the incoming power supply, it can boast some impressive energy-saving stats.

Head-to-Head with the 755

Placing the modern 755TS side by side with the original 755 makes the evolution pretty clear. While the 755 earned its place as a flexible and reliable workhorse, the 755TS rethinks what a drive can do, not only from a control standpoint but also in how it supports the rest of your operation.

FORCE vs TotalFORCE

The most significant shift is how the drive handles motor control. The 755 uses FORCE technology for torque regulation and supports different control modes depending on the motor and application. It performs well in a range of situations, but it essentially expects the system around it to behave predictably. The 755TS, on the other hand, is designed to respond to the unexpected. Thanks to TotalFORCE, the 755TS continuously adapts to the load and adjusts control behavior in real time. If your mechanical system starts behaving differently, maybe due to temperature changes, shifting inertia, or just wear and tear, the drive picks up on it and adjusts accordingly. You don’t need to stop the process or fine-tune the settings manually; the drive tunes itself on the fly using Adaptive Tuning.

Another area where the 755TS pulls ahead is its awareness of what’s happening around it. The Load Observer in the TS models gives the drive eyes on the system, even without direct feedback devices. It estimates what kind of mechanical demand is being placed on the motor and adjusts torque accordingly. This means smoother lifts, steadier conveyors, and more consistent control, which is especially helpful in applications with fluctuating loads or frequent starts and stops. The original 755 can achieve some of this, but it typically requires external sensors or manual tuning to get there.

Power quality issues are another area where the two drives diverge. The 755 handles standard ride-through functions well enough, while the 755TS introduces the Bus Observer feature we explained earlier.

Safety is also handled with more flexibility on the 755TS. Both drives offer Safe Torque Off and Safe Speed Monitor, but the TS version is more versatile in how safety functions are integrated and how they respond to the machine state. Instead of being bolted on as a separate layer, safety features on the 755TS feel like they’re woven directly into the control fabric, giving machine builders more flexibility in how they configure protection levels without adding hardware or complexity.

Then there’s the matter of hardware architecture. The 755 was already well regarded for its modular design and easy-to-configure slots, but the 755TS takes that same concept and streamlines it further. Its updated layout allows for even more efficient use of cabinet space, better thermal management, and easier access to I/O, safety, and feedback cards when changes are needed. While the older 755 still holds its own in terms of footprint, the TS’s ability to pack more power into less space is a huge bonus for those tight on panel real estate.

Lastly, communication speed and drive intelligence take a notable leap. Where the 755 communicates at standard speeds, the 755TS includes gigabit networking out of the box, offering faster data handling and better responsiveness. This is especially useful when coordinating multiple drives or dealing with high-speed processes. Combined with the embedded logic capabilities in the TS, it’s much better equipped to make decisions locally and quickly, which helps reduce the load on the rest of the control system.

In short, the 755TS doesn’t just do what the 755 does a little better. It reimagines the role of the drive, making it more autonomous, more responsive, and more capable of adapting to the messy, real-world conditions that plants actually face. Where the 755 asks for a bit of guidance and setup, the TS leans in, listens, and learns. And for a piece of equipment that spends its life powering motion, that shift in intelligence can have ripple effects far beyond the cabinet door.

Final Thoughts

The future of automation is exciting! Allen-Bradley is absolutely smashing the game with its new lineup of PLC and VFD technology. The 755TS is a great example of what’s to come for industrial automation, with its wealth of new features in an even more compact package. While we didn’t exactly go over the numbers this time around, we are working on a 755TS selection guide, as well as other pieces, giving the spotlight to all things new and shiny from Allen-Bradley, so stay tuned for that. Though if you would like to take a look at the 755 series instead, we have an article here for you!

If you would like to transition to the new age of automation, we have a selection of PowerFlex 755TS models ready to bring your operation to the next level. Suppose this level of commitment is just out of reach, no sweat. We also provide services to fix your old drives or offer thousands of other VFDs that can also suit what you need. Give us a call today, and we will be more than happy to go over options with you! Thank you for reading.