Upgrading from the PowerFlex 700 to the 750-Series? What You Need to Know

If your facility is still running on Rockwell’s PowerFlex 700 drives, you’re not alone. These drives were a workhorse for a long time, but as of November 30, 2023, the PowerFlex 700 series has officially been discontinued. That means no more new units, limited support, and a growing risk to your uptime.

Whether you’re proactively modernizing or facing a drive failure that forces your hand, the PowerFlex 750-Series (including the 753 and 755) is the most logical next step. But it’s not just a swap, it’s a strategic upgrade. And like any upgrade, it comes with new capabilities, different requirements, and important considerations.

Let’s break down what the migration looks like, how the 750-Series stacks up, and what you need to know to make an informed decision.

Why the PowerFlex 700 Is Being Discontinued

Rockwell’s decision to discontinue the PowerFlex 700 comes down to aging technology and component availability. As key components have become obsolete, Rockwell has phased out the product line, with all sales and most services ending in 2023.

For customers still using the 700, the implications are real:

• No new units available: Once your stock runs out, that’s it.
• Repair and replacement delays: Fewer parts, longer lead times.
• Increased risk of downtime: A single failure could put your line out of commission with no easy fix.

That’s why now is the right time to start planning your transition.

Why the PowerFlex 750-Series Is the Right Fit

The PowerFlex 750-Series isn’t just a replacement. It’s a significant step forward in terms of flexibility, power, and control. It comes in two models:

• PowerFlex 753: Great for standard applications with up to 3 option slots.
• PowerFlex 755: Designed for advanced control, with 5 option slots and built-in safety features.

Here’s what makes the 750-Series the logical upgrade:

Modular Design

Both the 753 and 755 feature modular, scalable hardware that gives you more flexibility to tailor the drive to your specific application. With additional option slots and configuration options, you’re no longer locked into a one-size-fits-all setup.

Built-In Ethernet/IP and Network Options

Unlike the PowerFlex 700, which required add-on communication modules for Ethernet/IP or other protocols, the 750-Series comes with embedded networking capabilities, simplifying installation and reducing total cost of ownership.

Advanced Control Capabilities

This is where the 750-Series really shines. You get access to enhanced motor control methods, including:

• Sensorless Vector Control (SVC)
• Flux Vector Control
• Torque Proving
• Safe Torque Off (STO)

These upgrades enable better performance, improved energy efficiency, and more precise motor handling.

The Not-So-Plug-and-Play Truth About Migration

One thing we don’t want to gloss over, something we see competitors frequently omit, is that this migration is not a simple “set it and forget it” swap.

While both drives use the same Rockwell Studio 5000 or Connected Components Workbench software, programming the PowerFlex 750 is not a one-to-one match with the 700.

More Parameters, More Granular Control

The PowerFlex 750-Series offers significantly more parameter settings than the 700. That’s a good thing in terms of capability: you get more fine-tuned control over motor behavior, safety features, and network configurations.

But it also means that when you're migrating an application:

• You cannot copy parameters over directly.
• You’ll need to configure and test manually.
• Your commissioning time will increase, especially if you’re not familiar with the new options.

For facilities with tight production schedules or limited engineering bandwidth, this is a critical consideration. The good news? Once configured, the 750’s advanced capabilities can reduce future maintenance headaches and improve system resilience.

Key Differences You Should Be Aware Of

As you evaluate the shift from PowerFlex 700 to the 750-Series, it's important to understand how these drives differ, not just in features but in day-to-day function and integration.

Support Status

While the PowerFlex 700 has been discontinued, repair services are still available, for now. That said, lead times are increasing, and costs are going up as parts become scarcer. If you're relying on repairs to keep aging drives afloat, it’s a good idea to have a migration plan ready in case a critical unit fails unexpectedly.

Network Capabilities

One of the most visible changes in the 750-Series is how networking is handled. The PowerFlex 753 does not come with built-in Ethernet/IP by default, instead requiring a plug-in communication module. The 755, on the other hand, offers Ethernet/IP as a standard feature. For facilities looking to future-proof their infrastructure with smarter, connected drives, the 755 may offer fewer barriers to integration.

Safety Features

Both the 753 and 755 come with built-in Safe Torque Off (STO), allowing for basic safety compliance. However, if you're looking for advanced safety features, such as Safe Speed Monitoring or Safe Stop 1, you'll only find them on the 755, and even then, only by using optional safety expansion cards. If machine safety is a priority in your operation, this distinction matters.

Programming Differences

As mentioned earlier, this isn't a plug-and-play migration. The 750-Series introduces more parameters and greater configuration depth. The upside? You get far more control over how your motor operates. The tradeoff? You'll need to reconfigure everything manually, with careful attention to how your system logic translates between generations.

Physical and Electrical Considerations

Mounting dimensions, wiring layouts, and cooling requirements can differ between models. Some 750-Series frames may require modifications to your existing panel or cabinet. Additionally, compatibility with legacy 20-COMM modules is mixed; some work, others need adapters or updated firmware.

Considerations During Installation

Physical Dimensions

Depending on the frame size of your existing 700, you might run into fitment issues. The 750-Series drives have different mounting requirements, which may require:

• Rewiring or conduit adjustments
• Mechanical modifications to panels
• Consideration of cooling and airflow differences

We recommend using Rockwell’s migration dimension guides or partnering with your automation distributor (like us at HESCO) to assess your enclosure layout ahead of time.

Communication Modules

Some legacy 20-COMM modules used with the 700 are compatible with the 750-Series, but not all. You may need a carrier adapter or updated firmware depending on your existing setup.

What You Gain by Upgrading

Despite the programming learning curve, there are compelling reasons to move to the 750-Series sooner rather than later.

Reduced Downtime Risk

With active support, available inventory, and updated components, the 750-Series positions you to maintain uptime and keep production on track.

Smarter Integration

Modern networks require smarter devices. With built-in Ethernet/IP, scalable IO, and support for safety over Ethernet/IP, the 750 drives make it easier to integrate with your control systems.

Greater Control = Better Performance

With enhanced torque control, safety features, and high-performance motor handling, the 750 lets you fine-tune your automation environment in ways the 700 simply couldn’t.

Future-Proofing

You’re not just solving today’s problem. You’re setting your facility up for years of flexibility, safety, and efficiency gains.

When Should You Upgrade?

Every facility is different, but we generally recommend considering an upgrade if:

• You’re experiencing increased downtime or repair delays.
• Spare parts are getting hard to find.
• You’re adding new lines or expanding capacity.
• You want to integrate safety features or advanced motor control.

If you’re planning a scheduled shutdown or system update, that’s the perfect time to roll a migration into your broader modernization strategy.

What’s the Best Way to Approach It?

Here’s how we suggest getting started:

1. Inventory your existing drives: What models, frame sizes, and configurations are in use?
2. Review your application needs: Do you require advanced torque control? Is space a constraint? Is STO necessary?
3. Talk to a migration partner: We can help assess your existing setup and recommend the right 750 model and accessories.
4. Plan your commissioning: Factor in the time and expertise needed for configuration and testing.

At HESCO, we’re happy to walk you through it step-by-step, whether you’re swapping one drive or upgrading an entire facility. You can also find Rockwell's official migration paperwork at the link here.

Final Thoughts: A Smart Move, If You Plan It Right

The PowerFlex 700 served its purpose well, but it’s time to move on. The 750-Series brings enhanced capabilities and future-ready features that today’s facilities need. Just remember: this isn’t a simple drop-in replacement.

Know what’s different. Prepare for the programming lift. And partner with a team that understands how to guide you through the change smoothly.

Need help figuring out where to begin? Contact us today for a consultation. We’ll help you evaluate your options and develop a migration plan that minimizes downtime and maximizes ROI.