Medium Voltage AC Drives Selection Guide PowerFlex 7000 Direct-to-Drive Technology Air-Cooled Liquid-Cooled

Transcription

1 Medium Voltage AC Drives Selection Guide PowerFlex 7000 Direct-to-Drive Technology Air-Cooled Liquid-Cooled

2 POWERFLEX 7000 MEDIUM VOLTAGE AC DRIVES Improve efficiency and maximize profitability with a single solution for all your motor control applications from 200 hp to 34,000 hp (150 kw to 25,400 kw). The Allen-Bradley PowerFlex 7000 medium voltage drive enables soft-starting and variable-speed control of processes with high power demands, to reduce energy costs, maintenance and motor wear. The advanced power semiconductor technology reduces component count to the lowest of any medium voltage drive available, translating to increased savings and reliability, less downtime and fewer spare parts. These drives use intelligent motor control strategies to further your investment, using communication software and programmability to monitor and control your processes. Our entire product line delivers virtually perfect current and voltage waveforms to allow the use of standard or existing motors and motor cables. All PowerFlex 7000 medium voltage drives adhere to the applicable standards from NEC, IEC, NEMA, UL and CSA. Maximum uptime, ease-of-use and lowest total cost of ownership is what the PowerFlex 7000 delivers. Direct-to-Drive Technology Reduce the cost, size and weight of your medium voltage drive system with the Allen-Bradley PowerFlex 7000 with Direct-to-Drive technology. This is the first and only technology that allows you to directly connect a medium voltage drive to utility power without the requirement of an isolation transformer. Isolation transformers with multiple secondary windings are required for traditional AC drives to address line-side harmonic concerns and common mode voltage. However, typical isolation transformers are large, heavy, costly, complex and inefficient. Direct-to-Drive technology combines an Active Front End (AFE) rectifier to dramatically lower line-side harmonics and a patented DC link inductor to address common mode voltage at its source. By addressing harmonics and common mode voltage, the isolation transformer becomes redundant. This reduces system complexity to maximize uptime and increases system efficiency to lower operational costs. Exceptional output voltage and current waveforms, true of our entire product line, make this ideal for retrofit applications and allow the use of standard motors for new applications. Air-Cooled, PowerFlex 7000 Enhance motor control and increase energy efficiency on motor applications from 200 hp to 5500 hp (150kW to 4100kW) with the Allen-Bradley PowerFlex 7000 air-cooled medium voltage AC variable frequency drives. Three configurations (Direct-to-Drive, AFE and 18-pulse) allow optimal flexibility for a variety of installations. 2

3 Liquid-Cooled PowerFlex 7000 Users with higher horsepower needs can reduce energy use and improve process control on motors from 3000 to 8500 hp (2240 to 6340 kw), at 4160 to 6900V nominal supply voltage ratings. Increase reliability with the closed-loop liquid-cooling system with liquid-toair or liquid-to-liquid style heat exchangers options and an integral pump cabinet. The patented PowerCage modules let you replace power devices in less than ten minutes. Installation costs are reduced by using a central cabling cabinet for the complete drive package. Extended Horsepower PowerFlex 7000 Available up to 34,000 hp (25,400 kw), these high horsepower air-cooled and liquid-cooled drive modules have the proven technology and benefits of PowerFlex 7000 medium voltage drives. PowerFlex 7000 extended horsepower drive systems are effective solutions for hot back-up and redundancy, LCI retrofits, and horsepower upgrades. Allen-Bradley Medium Voltage Motor Controllers Customize total system control for your specific application with the wide range of Allen-Bradley medium voltage starters. Drive output/bypass starters, drive input starters, full-voltage starters, reduced voltage starters and solid-state reduced-voltage starters, two-speed starters, and synchronous starters. All controllers provide monitoring and diagnostic options for faster, more accurate troubleshooting, maintenance planning, asset management and reduced downtime. 3

4 DIRECT-TO-DRIVE TECHNOLOGY Reduce Capital, Installation and Operating Costs Direct-to-Drive technology can: Reduce capital costs: No isolation transformer purchase required. Reduce installation costs: No need for an isolation transformer protection relay, a dv/dt filter, sine filter, motor terminator or special line-side or motor-side power cables. Reduce shipping costs: A smaller, lighter drive system is easier to handle and less costly to ship. Reduce operating costs: Higher system efficiency and inherent regenerative capability that can return power to the utility. Reduce maintenance costs: Low parts count and many components are common between the rectifier and inverter. Reduce Size and Weight of Drive System Reduced drive system size and weight are a strategic advantage for industries world-wide, where the use of transformers and control room space is challenging and expensive, such as on offshore oil and gas platforms. PowerFlex 7000 with Direct-to-Drive technology systems are: Typically smaller and lighter than drive technologies using isolation transformers. Perfect for retrofit, process improvement or energy-savings projects with existing motors, switches and control rooms. Intelligent Motor Control All PowerFlex 7000 drives provide Intelligent Motor Control capabilities such as: Communications Software Operator interface software monitors a variety of drive parameters and trends real-time information to help predict and prevent downtime. Power Regeneration Inherent regeneration provides both the most efficient motor stopping method and the ability to regenerate power back to the distribution system. Synchronous Bypass Synchronous transfer and bypass capabilities optimize the efficient control of motors by allowing one drive to control a multi-motor system. While the drive controls one motor, critical process information from each motor is monitored independently. 4

5 Innovative Design Historically, medium voltage motor AC drives (2.4 kv to 6.9 kv), use power topologies that generate common-mode voltage, which can cause premature failure of the motor winding insulation. Multi-pulse isolation transformers are typically used to address this common-mode voltage stress and also to mitigate harmonics. The innovative PowerFlex 7000 with Direct-to- Drive technology connects the power supply directly to the medium voltage drive without an isolation transformer. Leading edge technology combines three innovations to achieve transformerless Direct-to-Drive technology: the Symmetrical Gate Commutated Thyristor (SGCT) in both the inverter and rectifier allow operation of high switching frequency to minimize switching losses; the active front end (AFE) rectifier used at the input stage; and the common mode choke to block common mode voltage. Total Harmonic Distortion (THD) of the input current is within IEEE and most global harmonic guidelines in virtually every system. Current and voltage waveforms are near sinusoidal, minimizing voltage stress on the motor winding, even if connected through long cables. The Active Front End (AFE) Rectifier To reduce harmonics, the active front end uses active switching and Selective Harmonic Elimination (SHE) and provides near-unity power factor. Common Mode Voltage Protection The integrated common mode choke provides a very high impedance to the common mode current and mitigates motor neutral-to-ground voltage. The Symmetrical Gate Commutated Thyristor (SGCT) The Symmetrical Gate Commutated Thyristor (SGCT) is an integration of the power semiconductor and its gate drive to achieve superior pulse-width modulation switching patterns that significantly reduce line current harmonics and minimize snubber requirements and switching losses mm (90 inches) 3000 kg (6600 Ibs) 3100 mm (122 inches) 2640 kg (5800 Ibs) Dimension comparison between and 18-Pulse drive with isolation transformer (left) and a PowerFlex 7000 drive with Direct-to-Drive technology (right) 2400 mm (94.5 inches) 2950 kg (6500 Ibs) 5

6 AIR-COOLED COMPACT PACKAGING PowerFlex 7000 Air-Cooled Drives Increase energy efficiency on motor applications from 200 hp to 5500 hp (150 kw to 4100 kw) and supply voltages from 2400 to Enhance motor control and increase system reliability with the low component count, design simplicity and 6500 V Symmetrical Gate Commutated Thyristor (SGCT) power semiconductor switches that help reduce downtime and spare parts stock. Maintenance is simple and quick with the patented PowerCage inverter and rectifier modules that allow SGCT replacement in under ten minutes. Configuration #1 - Direct-to-Drive Technology Direct-to-Drive technology directly connects to the utility power without an isolation transformer. On new or existing motors, Direct-to-Drive technology eliminates unnecessary motor filtering and common mode voltage and saves control room space with a drive system smaller and lighter than a drive that requires a transformer. Installation costs are minimized by eliminating the need for a transformer protection relay, a dv/dt filter, sine filter or motor terminator and special cables. Available with or without an integral input starter. Configuration #2 - AFE Rectifier The AFE rectifier is available with an integral isolation transformer (up to 160A in most voltages) or configured for connection to a separately mounted isolation transformer (all sizes). This allows for considerable size reduction and the capability of stepping down from higher distribution voltages. Configuration #3-18 Pulse Rectifier The 18 Pulse rectifier uses an externally mounted isolation transformer. This allows for considerable size reduction and the capability of stepping down from higher distribution voltages. Indoor dry type, outdoor oil-filled or cast coil transformers can be used. 6

7 LIQUID-COOLED HIGH HORSEPOWER PowerFlex 7000 Liquid-Cooled Drives Reduce energy use on motors from 3000 to 8500 hp (2240 to 6340 kw), at 4160 to 6900V nominal supply voltage ratings. Liquid-cooling results in a more efficient transfer of heat than air-cooling, with approximately 90% of the heat removed from the control room via a heat exchanger, so control room air-conditioning costs are drastically reduced. The closed-loop liquid-cooling system with liquid-to-air or liquid-to-liquid style heat exchangers and an integral pump cabinet with redundant pump capability increases reliability. Maintenance is simple with the patented PowerCage converter modules that let you replace power devices in less than ten minutes. You can also reduce installation costs by using a central cabling cabinet for the complete drive package. Liquid-cooled drives are also more tolerant of higher elevations and higher ambient temperatures in the control room. 7

8 EXTENDED HORSEPOWER To accommodate higher horsepower applications up to 34,000 hp (25,400 kw), Rockwell Automation has designed a modular drive system that allows you to add drives until the drive power matches the application requirements. This system allows continued operation even with a component failure, is suitable for hot back-up applications and has an option for control redundancy. A hub module and ControlLogix processors are used to coordinate the modular drive system operation. The higher horsepower configurations offer these features and benefits: Compatible with 3-phase or 6-phase motors. Continues to function at reduced capacity in the event of a component failure. Suitable for hot back-up applications. PanelView Plus system control touch screen with color interface. Integral motor protection scheme. On-board graphical diagnostic trending. Up to four drive modules can be used together in one system. 8

9 OPERATOR INTERFACE EASY-TO-USE INTERFACE TERMINAL Available in a variety of languages, everything about the PowerFlex 7000 operator interface terminal is user friendly right from the greeting on the opening screen. The terminal is designed for the greatest ease of use for start-up, monitoring and troubleshooting. The set-up wizard helps the user to set the required parameter menus by asking questions or prompting selections for desired operation. Warnings and comments appear complete with help text to keep the user on the right track. The set-up wizard combined with the autotuning feature allows the drive to be tuned to the motor and load quickly and accurately, resulting in fast start-ups, smooth operation and less down time. Large Text and Graphic Display Area The operator interface terminal features a 16- line, 40-character, LCD display that makes text and graphics easy to read. Bar chart meters are configurable for common process variables including speed, voltage and load. The membrane keypad includes function keys, cursor selection keys, and number keys for menu navigation, item selection and data entry. The standard operator device cluster includes, start, stop, and emergency stop pushbuttons, local/remote selector switch and local speed potentiometer. Drive Identity Module Pre-loads Order Data A drive identity module, unique to every PowerFlex 7000 drive, captures order data from our automated business systems. The order data provides information to the drive firmware about specific drive hardware and application details. This results in less set-up time at the end site, saving you time and money. 9

10 SGCT POWER SEMICONDUCTOR The PowerFlex 7000 uses 6.5kV rated Symmetrical Gate Commutated Thyristors (SGCT) and has the fewest number of inverter switching devices of any MV drive topology. The power structure is fuseless, inherently regenerative, and utilizes a current limiting DC link inductor. The result is a simple, rugged product with very low component count, and optimum reliability. The unique characteristics of the SGCT and the PowerFlex 7000 drive topology make it possible to cost-effectively apply this versatile component into both the PWM inverter and PWM active front end rectifier. Low Parts Count The PowerFlex 7000 requires only six inverter SGCTs (at 2300V) while other drives using IGBTs or IGCTs require from 18 to 36 power semiconductor switches. The superior characteristics of the SGCT combined with the fewest number of components makes the PowerFlex 7000 drive inherently more reliable. SGCT - The Ideal Power Semiconductor Switch for MV Drives The Symmetrical Gate Commutated Thyristor (SGCT) with integrated gate drive, high switching frequency, and double-sided cooling is an ideal power semiconductor switch for MV drive applications. Its compact and efficient inverter design results from a Pulse Width Modulation (PWM) switching pattern for the SGCTs and is optimized for the lowest possible conduction and switching losses. The SGCT has a non-rupture, non-arc failure mode, meaning the fault is contained within the device. This ensures minimum mean-time-to-repair (MTTR). Other MV drives using IGBTs, can have rupture/arc failure modes that can lead to significant (MTTR) to rebuild the drive. Rupture, arc Rupture, arc 10

11 POWERCAGE AIR & LIQUID-COOLED DESIGNS Innovative PowerCage Reduce mean-time-to-repair (MTTR) time with fast and simple power semiconductor device change-out. The patented PowerCage converter modules in every PowerFlex 7000 drive house the SGCT power semiconductors in a compact, modular package that has fewer components and faster semiconductor device change-out than any other MV drive. The PowerFlex 7000 air-cooled design PowerCage: Uses an advanced heatsink design that works with a high pressure air flow pattern to ensure highly effective heat transfer and reduction of thermal stress. Allows power device change-out in less than ten minutes. The PowerFlex 7000 liquid-cooled design PowerCage: Has an innovative chill block used to transfer the heat. Allows power device change-out in less than ten minutes. No need to drain the cooling system to change a device. Air-Cooled Liquid-Cooled 11

12 POWER QUALITY LOWER LINE HARMONICS Line Current Line Voltage (V L-L ) Most MV drives on the market today reduce line-side harmonics by increasing the rectifier pulse number through parallel rectifier bridges and phase-shifting transformers. These drives have a higher component count, higher complexity and higher number of connections. The PowerFlex 7000 drive offers several solutions for lower line harmonics. The Direct-to-Drive feature mitigates line current harmonics to levels compliant to IEEE , EN and G5/4. Active Front End (AFE) Rectifier The AFE rectifier meets IEEE and most global standard Harmonic Guidelines in the vast majority of cases, provides near unity power factor, and optimizes drive performance. This power quality solution is also available with an isolation transformer when stepping down from a higher distribution voltage, resulting in maximum flexibility. l8-pulse Rectifier meets IEEE Harmonic Guidelines in the majority of cases at the primary of the drive isolation transformer. Compatible with Standard Motors Motor-friendly waveforms have been the trademark of Allen-Bradley MV drives since their introduction in All PowerFlex 7000 MV drive configurations have near sinusoidal output current and voltage waveforms at all speeds and loads, are compatible with standard induction or synchronous motors without derating and do not require an inverter duty motor. 12

13 No Additional Heating or Voltage Stress to Motor Insulation Compared to Fixed Speed Operation The PWM switching pattern in the PowerFlex 7000 reduces the harmonics going to the motor, especially at lower operating frequencies. The PWM pattern works in combination with a small integral capacitor to reduce the large order harmonics at higher frequencies. The result is no additional motor heating or voltage stress to motor insulation compared to fixed speed operation. Virtually Unlimited Motor Cable Distance While some variable frequency drives have limitations in motor cable distance due to high switching frequencies or capacitive coupling, the cable distance with the PowerFlex 7000 is virtually unlimited. This technology is capable of controlling motors as far away as 15 kilometers (9.2 miles) from the drive. Quiet, Smooth Motor Operation For a quieter, safer work environment, the PowerFlex 7000 medium voltage drive operates the motor with less audible noise than across-the-line, due to the quality of voltage and current waveforms, optimal voltage balancing and reduced speed. The Direct-to-Drive feature mitigates common mode voltage and does not produce dv/dt or reflected wave voltage stress on motors. Motor Voltage (V L-L ) Motor Current 13

14 TAKE A TEST DRIVE PERFORMANCE TESTING MV DRIVES In-house Testing Saves You Time and Money to ensure your medium voltage drive lives up to your expectations before delivery. On-site testing can be impractical due to typically short start-up time and unforeseen issues that can cause unnecessary and costly downtime. The drive system functions flawlessly upon start-up, thus maximizing your initial production. Our in-house test facility tests your drive at the full capacity it will use in the field, and ensures the entire system functions and produces the power needed. This reduces start-up time (and therefore reduced overall project lead-time), efficiency-testing for energy savings, customer witness testing, overload and system testing, and diagnostics for field issues. Cambridge Test Facility The multi-million dollar Rockwell Automation medium voltage drive test facility, in Cambridge, Ontario, Canada enables full load testing of medium voltage drives up to 7000 hp. The facility also has a motor base to mount a customer motor for combined testing with the PowerFlex 7000 drive and has the infrastructure to test large transformers with the drive system. The dynamometer (the motor and drive arrangement used for load testing) consists of two 2,500 hp (1,865 kw) induction motors (3,810/6600 volts) and one 5,500 hp (4,103 kw) induction motor at 2,400/4,160 volts. The dynamometer is capable of simulating two different load types: constant torque found in conveyor and reciprocating compressor applications, and variable torque found in pump, fan and centrifugal compressor applications. Several dry-type transformers power the test area and produce voltage from 1,000V to 13.8 kv in 6- pulse and 18-pulse configurations. A second 8,600 kva transformer powers the high-horsepower test bay. Features 10,325 ft 2 (959 m 2 ) medium voltage test facility. 10 test bays. 3 regenerative drives plus 2 customer demonstration drives. 9 MV motors totaling 16,650 hp (12.4 MW). 7 transformers totaling 23,860 kva. Capabilities Tests 6-pulse, 18-pulse or AFE rectifier. Can simulate 2 load profiles. 100 hp to 7,000 hp (76 kw to 5,222 kw) drives at voltages from 1,000 to 6,900 V. Benefits Reduced start-up time. Efficiency testing for energy savings. Customer witness testing and training. Overload, system and performance testing. CAMBRIDGE TEST FACILITY 14

15 High Horsepower Testing at Rated Load The dynamometer (the motor and drive arrangement used for load testing) demonstrates high horsepower liquid-cooled drives at rated load and horsepower to better serve markets such as the petrochemical or mining industries, or the synchronous motor retrofit market. By simulating anomalies that occur in the field, the test facility is able to find solutions quickly, without interrupting your process. Customer Training Learn how to program, operate and service your PowerFlex 7000 drives during scheduled shut-downs by attending customer drive schools in the medium voltage test facility. The four-day training, provided by qualified Rockwell Automation Product Support Engineers, gives hands-on experience with actual operating drives. This training is invaluable in keeping personnel trained on the product, and up-to-date on proper safety and lockout procedures. Regional MV Drive Manufacturing/Testing Facilities To better support our global customers, Rockwell Automation has two additional manufacturing centers: 1Harbin, China to support customers in the Asia-Pacific region. 2Katowice, Poland to support customers in the European, Middle East and African regions. Both facilities have extensive testing capabilities. 15

16 INTELLIGENT MOTOR CONTROL MEETING TOMORROW S MANUFACTURING NEEDS...TODAY We understand that you need to control performance, reduce downtime, improve safety, increase productivity, and perform diagnostics. That s why we ve combined leading-edge motor control and protection devices with the advanced networking and diagnostic capabilities of Rockwell Automation s Integrated Architecture to provide you with Intelligent Motor Control. PROTECTION Thanks to integrated I/O and advanced diagnostic and protection capabilities, all Intelligent Motor Control products constantly monitor the motor operation to help you follow performance trends and take remedial action before potential failures occur. Reduce unwanted downtime while increasing overall production efficiency. 16

17 COMMUNICATIONS Because you have a wide range of application needs, Intelligent Motor Control offers a variety of motor control technologies. Simplified control technologies are designed to suit your needs... DeviceLogix component technology increases the control possibilities with function block diagrams that operate at the device level. DriveLogix offers embedded Logix control for application programmability and control of auxiliary functions in one package. MV FVNR Controller Integrated Architecture enables you to reduce your total cost of ownership by using a single control infrastructure for the entire range of factory automation applications, large or small. MV SMC Flex Controller MV ArcShield Controller SCALABLE FUNCTIONALITY PowerFlex 7000 MV AC Drive Reuse engineering designs and practices to reduce development time and cost. Quickly respond to customer or market demands. Reduce maintenance costs and downtime. Easily access plant and production data from business systems for better management decision-making. COMMUNICATIONS The key to intelligence in motor control... Utilize open networked architecture to enhance motor protection, share diagnostic information and speed troubleshooting for a more productive, "intelligent" process. From simple I/O to complex power monitoring tasks, DeviceNet lets you cost effectively integrate many low-level manufacturing functions. NetLinx open network technology provides seamless communications throughout your enterprise (DeviceNet, ControlNet, and EtherNet/IP). Flexibility and commonality of communications across the product offering makes Intelligent Motor Control easy to use. 17

18 PACKAGING CAPABILITIES Deal directly with one vendor for a complete power control house custom-engineered for your needs. We partner with a variety of manufacturers to custom design, fabricate, pre-wire and test the power control house to accommodate our PowerFlex 7000 medium voltage drives, low voltage and medium voltage motor control centers, indoor and outdoor transformers, indoor and outdoor switchgear, and other auxiliary equipment. Our control houses also include the heating, ventilation, and air conditioning (HVAC) system, and lighting, and is shipped in one piece with lifting lugs for trouble-free crane handling. SYNCHRONOUS TRANSFER Reduce capital costs and energy use with one VFD to start and synchronize multiple motors using synchronous bypass transfer capabilities. Transfers a load from one variable frequency bus to a fixed frequency bus by matching the voltage waveform frequency, amplitude and phase relation between the two sources. Prevents voltage drop, vibration problems and process disturbances. Reduces full-load current and optimizes processes. Complete system including MV output/ bypass modules and control, are all manufactured by Rockwell Automation. 18

19 Bulletin 7000 Medium Voltage Drives Specifications Description of Features Designed to Maximize Uptime, be Easy to Use, and Lower Total Cost of Ownership Totally isolated and separated low voltage and medium voltage compartments Fiber optic isolation for firing of rectifier and inverter devices Mechanical and electrical interlocks between the drive and input disconnecting means Double offset ventilation pattern on the drive doors to ensure operator safety Emergency stop control capability, complete with safety relay 6500 Volt rated power semiconductor devices (SGCTs) results in low component count, fewer connections, and simple power structure SGCT has very low FIT (failures in time) rate of 100 per billion hrs of operation Derating of electrical components for reduced voltage and thermal stress Remote dial-in access via modem > 99.9% availability Patented PowerCage module allows for device replacement in less than 5 minutes for either air-cooled or liquid-cooled versions without any special tools User-friendly operator interface terminal with interactive set-up wizard results in fast start-ups, smooth operation, and less down time Cable connection cubicle provides easy access to line and load cable termination points. Both top and bottom cable direction is accommodated PC tools (DriveTools, DriveExplorer) assist with programming, monitoring and troubleshooting Premier Integration provides integrated drive configuration capability with RSLogix 5000 to reduce set-up time by as much as 70% Drive identity module allows pre-programming of customer specific drive and application parameters for faster start-ups Operator interface mounted on the low voltage door, complete with large 16-line 40-character LCD display and setup wizard, for easy viewing Standard operator device cluster including provisions for start, stop, emergency stop pushbuttons, local / remote selector switch, and speed potentiometer Bar type digital metering for output amps, volts, speed, and load displayed on operator interface Integral DC link reactor eliminates need for semiconductor fuses Fully digital control with digital signal processors (DSP) and field programmable gate arrays (FPGA) for advanced fault handling, gating and diagnostics, and drive synchronization control Sensorless vector control. Full vector control with tachometer feedback is optional Trend buffers for 16 variables (one shot or multi-shot) Sixteen (16) digital inputs and sixteen (16) digital outputs on external I/O board On-board programming (update firmware via laptop) Four (4) test modes including low voltage gating check Near sinusoidal current and voltage waveforms to motor allow use of virtually any existing or new motor AFE or 18-Pulse Rectifier options for maximum flexibility in reducing line side harmonics Electronic drive and motor overload protection eliminate the need for a separate protection relay 5 cycle ride-through (extended ride through with optional UPS) ensure drive control during a power dip Inherently regenerative for better process control (motor braking) and energy saving (can operate continuously in regeneration mode) Visit our Web site: 19

20 Bulletin 7000 Medium Voltage Drive Specifications General Design Specifications POWER Description Air-Cooled Liquid-Cooled Power Rating kw (200 to 5500 hp) kw ( hp) Motor Type Induction or Synchronous Input Voltage Rating 2400V, 3300V, 4160V, 6600V 4160V, 6600V, 6900V Input Voltage Tolerance ± 10% of Nominal Line Voltage Voltage Sag -30% Control Power Loss Ride-Through Input Protection 5 cycles (Standard); >5 cycles (optional UPS) Surge Arrester AFE Rectifier / Metal Oxide Varistor (MOV) 18P Input Frequency 50/60 Hz, ± 5% Input Short-Circuit Current Withstand Short-Circuit Fault Rating Basic Impulse Level (based on Altitude of 1000 m (3300 ft.)) Power Bus Design Ground Bus Customer Control Wireway Input Power Circuit Protection (optional) Input Impedance Device Output Voltage Control Power For 2300V, 3300V, and 6900V offering, contact factory. 5 cycle V (25 ka RMS SYM) 50 kv 45 kv Copper Tin plated Copper Tin plated 6 x 51 mm (¼ x 2 inches) Separate and Isolated Vacuum Contactor with Fused Isolating Switch or Circuit Breaker Isolation Transformer or AC Line Reactor V, V, V, V, V, V V, V, V 220/240V or 110/120V, V, 3 phase, 50/60 Hz 1 phase, 50/60 Hz (20 Amp) 20 Visit our Web site:

21 Bulletin 7000 Medium Voltage Drive Specifications DESIGN Inverter Design Inverter Switch Inverter Switch Failure Mode Description Air-Cooled Liquid-Cooled Inverter Switch Failure Rate (FIT) Inverter/Rectifier Switch Cooling Inverter Switching Frequency PWM Symmetrical Gate Commutated Thyristor (SGCT) Non-rupture, Non-arc 100 per 1 Billion Hours Operation Double-sided, Low Thermal Stress Hz No. of Inverter SGCTs (per phase) 2 at 2400V, 4 at 3300/4160V, 6 at 6600V 4 at 4160V, 6 at 6600/6900V SGCT Peak Inverse Voltage (PIV) Rating Rectifier Designs Typical Line Harmonic Content Typical Power Factor Rectifier Switch Rectifier Switch Failure Mode Rectifier Switch Failure Rate (FIT) No. of Rectifier Devices (per phase) SCR Peak Inverse Voltage Rating (per device) Fiber Optic Interface Design Standards AFE: 2 at 2400V, 4 at 3300/4160V, 6 at 6600V 18-pulse: 6 for all voltages 6500V per device Active Front End (AFE) Rectifier or 18-pulse <5% Current THD (AFE Rectifier) Selectable up to unity (AFE Rectifier) SGCT (AFE Rectifier), SCR (18-pulse Rectifier) Non-rupture, Non-arc 50 (SCR), 100 (SGCT) per 1 Billion Hours Operation 18-pulse: 4500V at 2400V, 3300V, 4160V 6500V at 6600V AFE: 4 at 4160V, 6 at 6600V 18-pulse: 6 for all voltages 18-pulse: 4500V at 4160V 6500V at 6600V Rectifier Inverter Cabinet (Warning/Trip) CSA, UL, IEC, NEMA, ANSI, IEEE COOLING Description Air-Cooled Liquid-Cooled Cooling Forced Air Liquid Coolant Iron and chlorine-free ethylene glycol mixed with deionized water Coolant Conductivity Detection 1-2 micro-siemens per cm/alarm/trip Heat Exchangers Liquid-to-Air; Liquid-to-Liquid Visit our Web site: 21

22 Bulletin 7000 Medium Voltage Drive Specifications PERFORMANCE Output Waveform to Motor Medium Voltage Isolation Modulation Techniques Control Method Tuning Method Speed Regulator Bandwidth Torque Response Bandwidth Service Duty Rating (Overload Rating) Description Air-Cooled Liquid-Cooled Sinusoidal Current/Voltage Fiber Optic SHE (Selective Harmonic Elimination); PWM (Pulse Width Modulation) Digital Sensorless Direct Vector, Full Vector Control with Tach Feedback (Optional) Normal Duty (variable torque): 110% Overload for 1 minute every 10 minutes Heavy Duty (constant torque): 150% Overload for 1 minute every 10 minutes Auto Tuning via Setup Wizard Radians/Second Radians/Second Normal Duty (variable torque): 110% Overload for 1 minute every 10 minutes Heavy Duty (constant torque): Contact Factory Speed Regulation 0.1% without Tachometer Feedback % with Tachometer Feedback Acceleration/Deceleration Range Independent Accel/Decel 1200 sec. Acceleration/Deceleration Ramp Rates 4 x Independent Accel/Decel S Ramp Rate 2 x Independent Accel/Decel 1200 sec. Critical Speed Avoidance 3 x Independent with Adjustable Bandwidth Stall Protection Delay / Speed Load Loss Detection Adjustable level, delay, speed set points Control Mode Speed or Torque Current Limit Adjustable in Motoring and Regenerating Output Frequency Range 0.2 Hz to 85 Hz Typical VFD Efficiency >98.0% (18-pulse) >97.5% (AFE Rectifier) Input Power Factor AFE Rectifier: 0.98 min., % load 18-pulse Rectifier with PFCC: 0.95 min., % load Harmonic Guidelines IEEE Compliant VFD Noise Level <85 db(a) per OSHA Standard 3074 Regenerative Braking Capability Inherent No additional Hardware or Software required Flying Start Capability Yes Able to Start into and Control a Spinning Load in Forward or Reverse Direction LANGUAGES Description Air-Cooled Liquid-Cooled Operator Interface 40-character, 16-line formatted text; 0.1 Hz Display Speed Resolution Languages English, Spanish, Portuguese, Chinese (Mandarin), French, Italian, German 22 Visit our Web site:

23 Bulletin 7000 Medium Voltage Controller Specifications I/O and COMMUNICATION External I/O External Input Ratings External Output Ratings Description Air-Cooled Liquid-Cooled 16 Digital Inputs, 16 Digital Outputs Hz AC or DC, V 1 ma Hz AC or DC, V 1 Amp Analog Inputs (3) Isolated, (1) Non-isolated, 4-20 ma, 0-10V Analog Outputs (1) Isolated, (8) Non-isolated, 4-20 ma, 0-10V Analog Resolution Communication Interface Communications Protocol (Optional) Scan Time Analog Input 12-bit (4-20 ma) Internal Parameter 32-bit resolution Serial Communication 16-bit resolution (0.1 Hz) (Digital Speed Reference) DPI RI/O DeviceNet, ControlNet, Ethernet, Profibus, Modbus, Modbus Plus, Interbus, Lonworks, Can Open, RS485 HVAC, RS485 DF1, RS232 DF1, RS232 C Internal DPI 5 ms Drive Configurations Dimension Comparison Visit our Web site: 23

24 Bulletin 7000 Medium Voltage Drive Configurations Drive Overview PowerFlex 7000 A Frame Air cooling Low end power range, kw ( hp) 2400 to 6600V nominal supply voltage ratings Compact packaging for smallest footprint requirements Three input configurations for optimum installation flexibility: 1) Direct-to-Drive 2) AFE Rectifier (connection to separate isolation transformer) 3) AFE Rectifier (complete with integral isolation transformer) Normal duty service rating (for variable torque loads, 110% overload for 1 minute every 10 minutes) Heavy duty service rating (for constant torque loads, 150% overload for 1 minute every 10 minutes) Active Front End rectifier for low line harmonics, high power factor and commonality of parts Three (3) Cables in / Three (3) cables out for lower installation costs PowerFlex 7000 B Frame Air cooling Low and Medium power range, kw ( hp) 2400 to 6600V nominal supply voltage ratings Normal duty service rating (for variable torque loads, 110% overload for 1 minute every 10 minutes) Heavy duty service rating (for constant torque loads, 150% overload for 1 minute every 10 minutes) Three input configurations for optimum installation flexibility: 1) Direct-to-Drive 2) AFE Rectifier (for connection to separate transformer) 3) 18-pulse rectifier for low line harmonics and connection to a high voltage distribution system Three (3) Cables in / Three (3) cables out (AFE rectifier) Nine (9) Cables in / Three (3) cables out (18-pulse rectifier) PowerFlex 7000L C Frame Closed loop liquid cooling system with liquid-to-air or liquid-toliquid style heat exchangers High end power range, kw ( hp) 4160 to 6600V nominal supply voltage ratings Small integrated package for high end power range Normal duty service rating (for variable torque loads, 110% overload for 1 minute every 10 minutes) Heavy duty service rating (for constant torque loads, 150% overload for 1 minute every 10 minutes) Three input configurations for optimum installation flexibility: 1) Direct-to-Drive 2) AFE Rectifier (for connection to separate transformer) 3) 18-pulse rectifier for low line harmonics and connection to a high voltage distribution system Three (3) Cables in / Three (3) cables out (AFE rectifier) Nine (9) Cables in / Three (3) cables out (18-pulse rectifier) 24 Visit our Web site:

25 Bulletin 7000 Medium Voltage Drive Configurations Drive Configurations PowerFlex 7000 A Frame Drive Configuration #1 Direct-to-Drive (AFE with DTD DC Link) Elimination of isolation transformer results in lower losses and saved space An integrated system solution for fewer connections and reduced installation costs New or existing motors Small system footprint 3 cables in / 3 cables out, on entire system for easy installation Low line harmonics & high power factor (typical current THD < 5%, PF > 0.98 with AFE rectifier) Fan control power and control circuit power supplied internally Input starter optional Directto-Drive (Optional Input Starter) Configuration #2 AFE Rectifier (Separate isolation transformer) Optimum installation flexibility with connection to indoor or outdoor isolation transformers Compact packaging for smallest footprint requirements New or existing motors 3 cables in / 3 cables out, for easy installation Low line harmonics & high power factor (typical current THD < 5%, PF > 0.98) Fan control power supplied internally (1-Phase control circuit power supplied by customer, 120V / 60 Hz, 110V / 50 Hz, 20 amp) AFE Rectifier Configuration #3 AFE Rectifier (Integral isolation transformer) An integrated system solution for fewer connections and reduced installation costs Small system footprint New or existing motors 3 cables in / 3 cables out for easy installation Integral cooling fans for VFD & transformer Low line harmonics & high power factor (typical current THD < 5%, PF > 0.98) Fan control power supplied internally (1-Phase control circuit power supplied by customer, 120V / 60 Hz, 110V / 50 Hz, 20 amp) Integral Isolation Transformer Visit our Web site: 25

26 Bulletin 7000 Medium Voltage Drive Configurations Drive Configurations PowerFlex 7000 B Frame Drive Configuration #1 Direct-to-Drive (AFE with DTD DC link) Elimination of isolation transformer results in lower losses and saved space An integrated system solution for fewer connections and reduced installation costs New or existing motors Small system footprint 3 cables in / 3 cables out, on entire system for easy installation Integral cooling fan for VFD Low line harmonics & high power factor (typical current THD < 5%, PF > 0.98 with AFE rectifier) Configuration #2 AFE Rectifier (Separate isolation transformer) Optimum installation flexibility with connection to indoor or outdoor isolation transformers Compact packaging for smallest footprint requirements New or existing motors 3 cables in / 3 cables out, for easy installation Low line harmonics & high power factor (typical current THD < 5%, PF > 0.98) Configuration #3 18-pulse Rectifier Optimum installation flexibility with connection to indoor or outdoor isolation transformers New or existing motors Small system footprint 9 cables in / 3 cables out on entire system for easy installation Low line harmonics (typical current THD < 5%) 26 Visit our Web site:

27 Bulletin 7000 Medium Voltage Drive Configurations Drive Configurations PowerFlex 7000 C Frame Drive Configuration #1 Direct-to-Drive (AFE with DTD DC link) Elimination of isolation transformer results in lower losses and saved space An integrated system solution for fewer connections and reduced installation costs New or existing motors Small system footprint 3 cables in / 3 cables out, on entire system for easy installation Low line harmonics & high power factor (typical current THD < 5%, PF > 0.98 with AFE rectifier) Configuration #2 AFE Rectifier (Separate isolation transformer) Optimum installation flexibility with connection to indoor or outdoor isolation transformers Compact packaging for smallest footprint requirements New or existing motors 3 Cables in / 3 cables out, for easy installation Low line harmonics & high power factor (typical current THD < 5%, PF > 0.98) Configuration #3 18-pulse Rectifier Optimum installation flexibility with connection to indoor or outdoor isolation transformers New or existing motors Small system footprint 9 cables in / 3 cables out on entire system for easy installation Low line harmonics (typical current THD < 5%) Visit our Web site: 27

28 Bulletin 7000 Medium Voltage Drives Normal Duty Ratings, Dimensions and Weights PowerFlex 7000 Air-Cooled MV Drive ( A Frame) Drive Configuration Direct-to-Drive RPDTD AFE Rectifier (for connection to separate isolation transformer) RPTX AFE Rectifier (c/w integral isolation transformer) RPTXI Nominal Line Voltage 2400 (60 Hz) 3300 (50 Hz) 4160 (50/60 Hz) 6600 (50/60 Hz) 2400 (60 Hz) 3300 (50 Hz) 4160 (60 Hz) 4160 (50 Hz) 6600 (50/60 Hz) 2400 (60 Hz) 3300 (50 Hz) 4160 (60 Hz) 4160 (50 Hz) VFD Continuous Current Normal Duty Ratings Nominal Power (kw) Nominal Power (HP) Structure Code Dimensions and Weights Dimensions in inches (mm) W x H x D Approx. Weight lb. (kg) X 104 X 39.4 (2400 X 2643 X1000) 6500 (2955) X 104 X 39.4 (2400 X 2643 X1000) 6500 (2955) X 104 X 39.4 (2400 X 2643 X1000) 6500 (2955) X 104 X 39.4 (2800 X 2643 X1000) 7500 (3410) X 104 X 39.4 (2100 X 2643 X1000) 4300 (1955) X 104 X 39.4 (2100 X 2643 X1000) 4300 (1955) X 104 X 39.4 (2100 X 2643 X1000) 4300 (1955) X 104 X 39.4 (2100 X 2643 X1000) 4300 (1955) X 104 X 39.4 (2400 X 2643 X1000) 4750 (2160) X 104 X 39.4 (2400 X 2643 X1000) 9800 (4455) X 104 X 39.4 (2400 X 2643 X1000) 9800 (4455) X 104 X 39.4 (2400 X 2643 X1000) 9800 (4455) X 104 X 39.4 (2400 X 2643 X1000) 9800 (4455) X 104 X 39.4 (2800 X 2643 X1000) (4545) (50/60 Hz) X 104 X 39.4 (2900 X 2643 X1000) (5000) Normal Duty ratings usually apply to variable torque loads / overload rating is 110% for 1 minute, once every 10 minutes. For Heavy Duty ratings (usually apply to constant torque loads / overload rating is 150% for 1 minute, once every 10 minutes). For other ratings, contact factory. Structure code and data shown for Direct-to-Drive includes optional integral input starter. Dimensions and approximate weights are the same without integral input starter. Heights shown include the standard fan shroud (removable for shipping). If a redundant fan (removable for shipping) is specified, the height is in. (2920 mm). Actual VFD structure height is in. (2275 mm). 28 Visit our Web site:

29 Bulletin 7000 Medium Voltage Drives Normal Duty Ratings, Dimensions and Weights PowerFlex 7000 Air-Cooled MV Drive ( B Frame) Drive Configuration Direct-to-Drive RPDTD AFE Rectifier (for connection to separate isolation transformer) RPTX 18-Pulse Rectifier (for connection to separate isolation transformer) R18TX Nominal Line Voltage 2400 (60 Hz) 3300 (50 Hz) 4160 (60 Hz) 6600 (50/60 Hz) 2400 (60 Hz) 3300 (50 Hz) 4160 (60 Hz) 4160 (50 Hz) 6600 (50/60 Hz) 2400 (60 Hz) 3300 (50 Hz) VFD Continuous Current Normal Duty Ratings Nominal Power (kw) Nominal Power (HP) Structure Code Dimensions and Weights Dimensions in inches (mm) W x H x D Approx. Weight lb. (kg) X 104 X 39.4 (3300 X 2643 X1000) 9500 (4300) X 104 X 39.4 (3500 X 2643 X1000) (4550) X 104 X 39.4 (3900 X 2643 X1000) (6300) X 104 X 39.4 (3700 X 2643 X1000) (5600) X 104 X 39.4 (3900 X 2643 X1000) (6300) X 104 X 39.4 (4100 X 2643 X1000) (7395) X 104 X 39.4 (3700 X 2643 X1000) (5600) X 104 X 39.4 (3900 X 2643 X1000) (6300) X 104 X 39.4 (4100 X 2643 X1000) (7395) X 104 X 39.4 (3900 X 2643 X1000) (6300) X 104 X 39.4 (4100 X 2643 X1000) (7395) X 104 X 39.4 (4300 X 2643 X1000) (7395) X 104 X 39.4 (2400 X 2643 X1000) 4300 (1955) X 104 X 39.4 (2600 X 2643 X1000) 4750 (2160) X 104 X 39.4 (2800 X 2643 X1000) 5500 (2500) X 104 X 39.4 (2800 X 2643 X1000) 5200 (2365) X 104 X 39.4 (3000 X 2643 X1000) 6250 (2834) X 104 X 39.4 (3700 X 2643 X1000) 9000 (4100) X 104 X 39.4 (2800 X 2643 X1000) 5500 (2500) X 104 X 39.4 (3000 X 2643 X1000) 6250 (2834) X 104 X 39.4 (3500 X 2643 X1000) 8500 (3900) X 104 X 39.4 (3700 X 2643 X1000) 9000 (4100) X 104 X 39.4 (3000 X 2643 X1000) 6250 (2834) X 104 X 39.4 (3500 X 2643 X1000) 8500 (3900) X 104 X 39.4 (3700 X 2643 X1000) 9000 (4100) X 104 X 39.4 (3200 X 2643 X1000) 6250 (2834) X 104 X 39.4 (3700 X 2643 X1000) 9000 (4100) X 104 X 39.4 (3900 X 2643 X1000) 9500 (4300) X 104 X 39.4 (3100 X 2643 X1000) 5800 (2640) X 104 X 39.4 (3300 X 2643 X1000) 6500 (2955) X 104 X 39.4 (3100 X 2643 X1000) 5800 (2640) (60 Hz) X 104 X 39.4 (3300 X 2643 X1000) 6500 (2955) 4160 (50 Hz) X 104 X 39.4 (3300 X 2643 X1000) 6500 (2955) X 104 X 39.4 (3300 X 2643 X1000) 6500 (2955) (50/60 Hz) X 104 X 39.4 (4200 X 2643 X1000) 9000 (4100) Normal Duty ratings usually apply to variable torque loads / overload rating is 110% for 1 minute, once every 10 minutes. For Heavy Duty ratings (usually apply to constant torque loads / overload rating is 150% for 1 minute, once every 10 minutes), or other ratings, contact factory. For 375A and 430A rated Direct-to-Drive and AFE configurations, maximum ambient temperature is limited to 35 deg. C. Heights shown include the standard fan shroud (removable for shipping). If a redundant fan (removable for shipping) is specified, the height is in. (3000 mm). Actual VFD structure height is in. (2275 mm). Contact Factory for 50 Hz ratings. 430A rating is not available for 6600V 50/60 Hz Direct-to-Drive and AFE air-cooled configurations. Visit our Web site: 29

30 Bulletin 7000 Medium Voltage Drives Normal Duty Ratings, Dimensions and Weights PowerFlex 7000 Liquid-Cooled MV Drive ( C Frame) Drive Configuration Direct-to-Drive RPDTD AFE Rectifier (for connection to separate isolation transformer) Nominal Line Voltage RPTX 6600 (50/60 Hz) 18-Pulse Rectifier (for connection to separate isolation transformer) R18TX VFD Continuous Current Normal Duty Ratings Nominal Power (kw) Nominal Power (HP) Structure Code Dimensions and Weights Dimensions in inches (mm) W x H x D Approx. Weight lb. (kg) X 99.3 X 39.4 (6200 X 2522 X1000) (8164) (60 Hz) X 99.3 X 39.4 (6800 X 2522 X1000) (8890) X 99.3 X 39.4 (6200 X 2522 X1000) (8164) 4160 (50 Hz) X 99.3 X 39.4 (6400 X 2522 X1000) (8618) X 99.3 X 39.4 (6800 X 2522 X1000) (8890) X 99.3 X 39.4 (6700 X 2522 X1000) (9139) x 99.3 x 41.4 (7500 x 2522 x 1051) (10936) (50/60 Hz) x 99.3 x 41.4 (7700 x 2522 x 1051) (11699) x 99.3 x 41.4 (8100 x 2522 x 1051) (12828) Contact Factory (60 Hz) Contact Factory Contact Factory (50 Hz) Contact Factory Contact Factory Contact Factory Contact Factory 4160 (50/60 Hz) 6600 (50/60 Hz) X 99.3 X 39.4 (5100 X 2522 X 1000) (6383) X 99.3 X 39.4 (5100 X 2522 X 1000) (6383) X 99.3 X 39.4 (5500 X 2522 X 1000) (6818) Normal Duty ratings usually apply to variable torque loads / overload rating is 110% for 1 minute, once every 10 minutes. For Heavy Duty ratings (usually apply to constant torque loads / overload rating is 150% for 1 minute, once every 10 minutes), or other ratings, contact factory. Outdoor liquid-to-air heat exchanger dimensions and weights are not shown. Integral liquid-to-liquid HEX versions are also available. Contact factory for details. For 2300 and 3300V ratings, contact factory. Structure codes shown are for use with liquid-to-air heat exchangers. VFD dimensions and weights for use with liquid-to-liquid heat exchangers are the same. Total size and weight of the VFD is shown, however, these three VFD configurations are shipped in two shipping splits to facilitate easier handling. 30 Visit our Web site:

31 Bulletin 7000 Medium Voltage Drives Topology Topology Rectifier Design Selection AFE Rectifier There are two basic rectifier configurations (AFE and 18-Pulse) offered as options for the PowerFlex It is advantageous when selecting a rectifier design to have a good understanding of what the customer s needs and limitations are with regards to power factor, space requirements, harmonic specifications, and cost, etc. Both options offer efficiency, motor protection, energy savings, and optimization of power quality in varying degrees. Both of these options comply with the recommended IEEE requirements regarding harmonic distortion in virtually every power system. An Active Front End (AFE) rectifier is shown in Figure 1. This is a particularly attractive option since it does not require an isolation transformer with multiple secondary windings to meet IEEE requirements. This results in a drive system that has the highest efficiency, simplest configuration, and offers the lowest total cost of ownership. The typical drive efficiency rating at full load full speed is 97.5%. Most available technologies in today s Medium Voltage market require a multi-winding transformer to mitigate by phase shifting the undesirable harmonic distortion in the transformer secondary windings. Depending on the topology, the transformer can have up to 15 sets of secondary windings. This compounds the complexity of the system. The AFE rectifier uses a PWM switching pattern that complies with similar rules as the inverter. The pattern used is a 7-pulse Selective Harmonic Elimination (SHE) pattern that eliminates the 5th, 7th and 11th harmonics. The input capacitors are designed to reduce the current harmonics of the higher order. The filter resonant frequency is placed below 300Hz where no residual harmonics exist. The filter transfer function technique is used to place the filter break frequency in a region where no harmonics are present. This prevents the excitation of system harmonic frequencies. Other factors that are considered when designing the filter are the input power factor and the requirement on Total Harmonic Distortion (THD) of input current and voltage waveforms. The AFE rectifier requires only a three-phase input from the customer s power supply. While an isolation transformer is not required to address harmonics, a transformer can be configured to reduce the higher system voltage to operating voltage level, based on the variable frequency drive and motor operation voltage (see Figure 1). RECTIFIER L+ M+ INVERTER 3 Phase Isolation Transformer 2U (X1) 2V (X2) 2W (X3) SGCTs SGCTs U (T1) V (T2) W (T3) Input Disconnecting Device L- M- Figure V Drive with Isolation Transformer and Active Front End Rectifier Visit our Web site: 31

32 Bulletin 7000 Medium Voltage Drives Topology Direct-to-Drive (AFE Rectifier with DTD DC link) Figure 2 Direct-to-Drive option and its input current/voltage waveforms 18-Pulse Rectifier An 18-pulse phase-controlled rectifier is shown in Figure 3. In an 18-pulse configuration, IEEE requirements regarding harmonic distortion are met without the need for passive filters. However, a multi-winding isolation transformer is required to mitigate the low order harmonics by incorporating phase shifting principles. The resulting line current and voltage are shown in Figure 3. This option is simple, highly efficient, and easy to use involving series rectifiers and only three sets of secondary windings on the isolation transformer. Due to the requirement for the isolation transformer, this option has a larger footprint that requires additional control room space (for indoor transformer option). Figure 3 18-pulse rectifier and its input waveforms (top to bottom: line current and line-to-line voltage at PCC.) 32 Visit our Web site:

33 Bulletin 7000 Medium Voltage Drives Topology The AFE rectifier switching pattern uses a similar control algorithm to the inverter. The pattern used is a 7-pulse selective harmonic elimination (SHE) pattern, which eliminates the 5th, 7th and 11th harmonics. Figure 4 shows the typical rectifier switching pattern with 7-pulse with a single phase representation. This switching pattern is repeated for all three phase shifting 120 electrical degrees, resulting in a 42-pulse overall rectifier switching pattern. The duration of the on-state time will then determine the controlled rectifier voltage to the DC link. Figure 4 Typical Active Front End Rectifier Switching Pattern The drive has a defined firing and applies the above firing pattern to three phases. The drive rectifier has the following firing order: 1, 2, 3, 4, 5, and 6 with the bridge hardware configuration as outlined in Figure 5. As shown, the 4160 V rectifier uses two (2) volt power devices in series to achieve the optimum electrical peak inverse blocking margin of volts for each leg. Leg 1 Leg 4 Leg 3 Leg 6 Leg 5 Leg 2 L+ Positive Legs Negative Legs L - Figure V Rectifier Visit our Web site: 33

34 Bulletin 7000 Medium Voltage Drives Topology The input capacitors connected at the input with the rectifier are designed to reduce the higher frequency current harmonics. The inductance/capacitor resonant frequency is placed below 300 Hz where no characteristic harmonics exist. This prevents the excitation of system harmonic frequencies. The capacitor is selected to provide high input power factor. In most cases, a line reactor can be used to provide the required design impedance, giving additional current limiting features to a line-side short circuit fault. When operating from a power source that does not require voltage matching to the drive rating, a simple line reactor configuration can be adopted. (See Figure 6) RECTIFIER L+ M+ INVERTER Input Disconnecting Line Protection 2U (X1) SGCTs SGCTs U (T1) 2V (X2) 2W (X3) DC LINK V (T2) W (T3) 3 Phase Line Reactor L- M- Figure Volt Drive with Line Reactor and AFE Rectifier The rectifier input current and voltage waveforms are shown in Figure 7. A current Total Harmonic Distortion (THD) of approximately 5.0 % is achieved. The voltage distortion is based on the customer s maximum short circuit rating (I SC ) and maximum demand load current (I L ). With a ratio of 20, the voltage distortion will be less than 3%. I Line V L-L Figure 7 Active Front End Line Input Waveforms Visit our Web site: 34

35 Bulletin 7000 Medium Voltage Drives Power Quality Comparison of Rectifier Types Figure 8 - Input Current Total THD (%) for different rectifier types Comparing the harmonic tables of the different rectifier topologies gives a very quick overview of the individual harmonics produced by different rectifier designs. By comparison, the AFE rectifier provides much lower harmonics when calculating the total harmonic distortion (THD) of all the individual harmonics. Harmonics of the Different Rectifier Topologies Converter Pulses Harmonic Order Up to 49th AFE % % % % THD Visit our Web site: 35

36 Rockwell Automation Services & Support PREDICT PREVENT REACT Assessment Services Baseline evaluations of plant floor technical skills, procedures, equipment operation, spare parts inventory, safety and security as well as other automation-related assessments Condition Monitoring Predictive maintenance products and services for rotating equipment Asset Management Services Maintenance Repair Operations (MRO) process and spare parts management for automation assets Remote Support Services Real-time troubleshooting and monitoring* of automation equipment and systems by off-site automation specialists Safety, Network & Security Services Safety circuit analysis, safety system design/integration/validation, network design and evaluation services, and security policy development/deployment Training Services Instructor-led training, self-paced training and competency testing on automation and related topics OnSite Support Services Startup services, conversion services, preventive maintenance, extended parts and labor warranty, troubleshooting and repair of automation equipment and systems by Rockwell Automation field support engineers Repair Services & Renewal Parts Remanufacturing and exchange services for automation products and build-toorder legacy automation products *System monitoring not available at all service levels FOR MORE INFORMATION To learn which Rockwell Automation Services & Support will be most beneficial to your maintenance strategy, contact your local authorized Allen-Bradley distributor or Rockwell Automation sales office, or go to: Allen-Bradley, ArmorStart, Compact I/O, DeviceLogix, DriveLogix, FORCE Technology, IntelliCENTER, PowerFlex, Rockwell Automation, SMC-Flex, SynchLink and XM are trademarks of Rockwell Automation. Trademarks not belonging to Rockwell Automation are property of their respective companies. Medium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) , Fax: (1) , Publication 7000-SG010C-EN-P January 2009 Supersedes Publication 7000-SG010B-EN-P September 2008 Copyright 2009 Rockwell Automation, Inc. All rights reserved. Printed in Canada