Rockwell Automation AutoMax™ Distributed Power System

Rockwell Automation AutoMax ™  Distributed Power System

AutoMax Distributed Control System and Programming Software V3.5 is an industrial automation solution launched by Rockwell Automation. Its core includes Distributed Power System (DPS) and AutoMax Programming Executive V3.5 programming software, supporting multiple types of AC/DC drivers (such as SA500/SA3000/SD3000, etc.). Distributed control is achieved through hardware architecture of UDC module+PMI interface and fiber optic communication (10Mbit/s). The programming software supports three languages: BASIC/Control Block/Adder Logic, with offline configuration, online monitoring, multiple security mechanisms (key switch+password+access level), and is suitable for industrial motor speed regulation, process control and other scenarios. Electrical safety standards and operating procedures must be strictly followed.

Overall system architecture

Core positioning and components

System positioning: Industrial grade distributed control system, integrating hardware drivers and software programming to achieve multi device collaborative control

Core components: divided into two parts: hardware (DPS distributed power system) and software (AutoMax Programming Executive V3.5). Hardware is responsible for power conversion and signal transmission, while software is responsible for configuration, programming, and monitoring

Compatibility feature: Supports mixing with AutoMate, Shark and other series modules, and can upgrade existing third-party drives

Hardware core parameters | Hardware modules | Key specifications | Core functions|

|UDC module | 10 units/rack, dual port memory, 2 fiber optic interfaces | Drive control, PMI communication, dual task independent operation (Drive A/B)|

|PMI interface | 4 slots (medium power)/8 slots (high power) rack | Signal processing, I/O expansion, and UDC fiber optic communication|

|Drive | DC: SD3000 (3-1000HP), SF3000 (1000-5000HP); AC：SA500（14-48A）、SA3000（70-1457A）； Medium voltage: 1500-5500HP | Motor speed regulation, power output, fault self diagnosis|

|Communication link | Fiber optic: 10Mbit/s, maximum 750m; RS-232; PC Link module | Anti EMI interference, long-distance transmission, multi device synchronization|

Distributed Power System (DPS)

Hardware architecture hierarchy

Control layer: AutoMax processor+UDC module, responsible for instruction issuance and status feedback

Interface layer: PMI module, implementing signal conversion between UDC and driver (Resolver feedback, I/O extension)

Power layer: Various AC/DC drivers provide motor operation power and support N+1 redundant parallel connection

Communication layer: Fiber optic link (Manchester encoding) to avoid electromagnetic interference and ensure stable data transmission

Driver classification and characteristics | Driver type | Power range | Core configuration | Applicable scenarios|

|DC (SD3000/SF3000) | 3-5000HP | 4-channel PMI rack, SCR rectifier, regenerative/non regenerative mode | DC motor speed regulation, heavy-duty starting|

|AC (SA500) | 14-48A (corresponding to power 1-15HP) | Built in PMI, IGBT inverter, DC bus power supply | Small fan and pump equipment|

|AC (SA3000) | 70-1457A (corresponding power 30-600HP) | 4/8 slot PMI rack, vector control, parallel expansion | industrial production line, large fan|

|Medium voltage (1567 PowerMax) | 1500-5500HP | Liquid cooled rectifier/inverter, 8-slot PMI rack, 3-level topology | Medium voltage motor drive, heavy industry|

Key hardware functions

Fiber optic communication: 10Mbit/s transmission between UDC and PMI, supporting 750m long distance deployment, and resistant to EMI interference

Redundant design: Drivers support N+1 parallel connection, UDC module dual task independent operation, improving system reliability

Self diagnosis: PMI monitors voltage, temperature, and I/O status in real-time, triggering LED alarms and relay actions in case of faults

Core functions of programming software V3.5

Offline configuration function

System configuration: Create system/partition/rack hierarchy, support importing ASD/V2 version configuration files

Hardware configuration: Add UDC/PMI/driver module, configure driver parameters (motor nameplate, torque boost, etc.)

Variable configuration: Map I/O variables, public memory variables, network variables, support local/network name linking

Task development: Create BASIC/Control Block/Adder Logic tasks that support compilation and cross referencing generation

Online operation function

Connection management: supports serial port (9600-19200bps), PC Link module, network connection, and can set AUTO-RUN

Task control: single task/full task start stop, load/delete, supports remote reset and fault clearing

Monitoring and debugging: Real time viewing of variable/I/O status, forcing variables (up to 16), online editing of ladder diagram sequences

Fault handling: Store 10 error logs, support fault code query, manual/automatic reset

Programming and Task Characteristics

Language support:

BASIC: General programming, numerical processing, supports array and string operations

Control Block: Control loop programming (PID, integrator, etc.), UDC task specific

Ladder Logic: Sequential logic programming, graphical editing, supports counters/timers

Task limit: Up to 32 tasks per rack, UDC module up to 2 tasks (Drive A/B)

Compile validation: syntax check, object file generation, error log output, supports debugging and optimization

Security mechanisms and regulations

Triple security guarantee

Key switches: PROTOCT (monitoring only), SETUP (monitoring+tuning), GRAM (full permission)

Password protection: default password "AUTOMAX", supports modification, expires after 2 minutes of timeout

Access level: None (monitoring only) → Data (modifying variables) → Task (task control) → Rack (full control), up to 4 users can access simultaneously

Electrical and operational safety

Electrical safety: protection against electric shock and arc flash, wait for 5 minutes for capacitor discharge after power failure

Mechanical safety: protection of rotating parts, zero speed warning, motor steering verification

Operation specifications: parameter locking, emergency stop configuration, task critical marking (only STOP-ALL can be stopped)

Application scenarios and compatibility

Typical Applications

Industrial production: production line motor speed regulation, fan/pump control, machine tool auxiliary drive

Mobile scenarios: ships, RVs, off grid solar systems

Special scenarios: medium voltage motor drive (1567 PowerMax), heavy industrial process control

Compatibility Description

Hardware compatibility: Supports AutoMax 6010/7010 processors, UDC modules (57552/57652), and various third-party I/O modules

Software compatibility: backward compatible with V2 version configuration files, supports ASD V8 system import, compatible with Windows 3.1+, MS-DOS 5.0+