Medium Voltage AC Drives Selection Guide

PowerFlex 7000 Direct-to-Drive Technology Air-Cooled Liquid-Cooled

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.

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.

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.

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-toDrive 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. 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. Total Harmonic Distortion (THD) of the input current is within IEEE 519-1992 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.

2286 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)

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 6900. 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.

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.

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.

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 16line, 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.

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

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

POWER QUALITY
LOWER LINE HARMONICS
Line Current Line Voltage (VL-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 519-1992, EN61000-2-4 and G5/4.

Active Front End (AFE) Rectifier The AFE rectifier meets IEEE 519-1992 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 519-1992
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 1990. 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

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.

Motor Voltage (VL-L)

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.

Motor Current

The Direct-to-Drive feature mitigates common mode voltage and does not produce dv/dt or reflected wave voltage stress on motors.

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.

13

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 6pulse and 18-pulse configurations. A second 8,600 kVA transformer powers the high-horsepower test bay.

Features 10,325 ft2 (959 m2) 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

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

INTELLIGENT MOTOR CONTROL

MEETING TOMORROWS MANUFACTURING NEEDS...TODAY
We understand that you need to control performance, reduce downtime, improve safety, increase productivity, and perform diagnostics. Thats why weve combined leading-edge motor control and protection devices with the advanced networking and diagnostic capabilities of Rockwell Automations 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

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

MV SMC Flex Controller

MV ArcShield Controller

PowerFlex 7000 MV AC Drive

SCALABLE FUNCTIONALITY

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.

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

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

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: www.ab.com.catalogs

19

Bulletin 7000

Medium Voltage Drive Specifications

General Design Specifications
POWER
Description Power Rating Motor Type Input Voltage Rating Input Voltage Tolerance Voltage Sag Control Power Loss Ride-Through Input Protection Input Frequency 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 50 kV Copper Tin plated Copper Tin plated 6 x 51 mm ( x 2 inches) Separate and Isolated Vacuum Contactor with Fused Isolating Switch or Circuit Breaker Isolation Transformer or AC Line Reactor 0-2300V, 0-3300V, 0-4160V, 0-6000V, 0-6300V, 0-6600V 220/240V or 110/120V, 1 phase, 50/60 Hz (20 Amp) 0-4160V, 0-6600V, 0-6900V 208-575V, 3 phase, 50/60 Hz Air-Cooled 150-3000 kW (200 to 5500 hp) Liquid-Cooled 2240-6700 kW (3000-9000 hp) 4160V, 6600V, 6900V

Induction or Synchronous 2400V, 3300V, 4160V, 6600V

10% of Nominal Line Voltage -30% 5 cycles (Standard); >5 cycles (optional UPS) Surge Arrester AFE Rectifier / Metal Oxide Varistor (MOV) 18P 50/60 Hz, 5% 5 cycle 2400-6600V (25 kA RMS SYM) 45 kV

For 2300V, 3300V, and 6900V offering, contact factory.

20

Visit our Web site: www.ab.com.catalogs

Bulletin 7000

Medium Voltage Drive Specifications

DESIGN
Description Inverter Design Inverter Switch Inverter Switch Failure Mode Inverter Switch Failure Rate (FIT) Inverter/Rectifier Switch Cooling Inverter Switching Frequency No. of Inverter SGCTs (per phase) 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) AFE: No. of Rectifier Devices (per phase) 18-pulse: SCR Peak Inverse Voltage Rating (per device) Fiber Optic Interface Design Standards 2 at 2400V, 4 at 3300/4160V, 6 at 6600V 6 for all voltages Air-Cooled PWM Symmetrical Gate Commutated Thyristor (SGCT) Non-rupture, Non-arc 100 per 1 Billion Hours Operation Double-sided, Low Thermal Stress 420 540 Hz 2 at 2400V, 4 at 3300/4160V, 6 at 6600V 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 AFE: 4 at 4160V, 6 at 6600V 6 for all voltages 4500V at 4160V 6500V at 6600V 4 at 4160V, 6 at 6600/6900V Liquid-Cooled

18-pulse: 18-pulse:

18-pulse: 4500V at 2400V, 3300V, 4160V 6500V at 6600V

Rectifier Inverter Cabinet (Warning/Trip) CSA, UL, IEC, NEMA, ANSI, IEEE

COOLING
Description Cooling Coolant Coolant Conductivity Detection Heat Exchangers Air-Cooled Forced Air Liquid Iron and chlorine-free ethylene glycol mixed with deionized water 1-2 micro-Siemens per cm/Alarm/Trip Liquid-to-Air; Liquid-to-Liquid Liquid-Cooled

Visit our Web site: www.ab.com.catalogs

21

Bulletin 7000

Medium Voltage Drive Specifications

PERFORMANCE
Description Output Waveform to Motor Medium Voltage Isolation Modulation Techniques Control Method Tuning Method Speed Regulator Bandwidth Torque Response Bandwidth Air-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) Auto Tuning via Setup Wizard 0.1 - 15 Radians/Second 20 - 100 Radians/Second Normal Duty (variable torque): 110% Overload for 1 minute every 10 minutes Heavy Duty (constant torque): 150% Overload for 1 minute every 10 minutes Normal Duty (variable torque): 110% Overload for 1 minute every 10 minutes Heavy Duty (constant torque): Contact Factory Liquid-Cooled

Service Duty Rating (Overload Rating)

Speed Regulation Acceleration/Deceleration Range Acceleration/Deceleration Ramp Rates S Ramp Rate Critical Speed Avoidance Stall Protection Load Loss Detection Control Mode Current Limit Output Frequency Range Typical VFD Efficiency Input Power Factor Harmonic Guidelines VFD Noise Level Regenerative Braking Capability Flying Start Capability

0.1% without Tachometer Feedback 0.01 0.02% with Tachometer Feedback Independent Accel/Decel 1200 sec. 4 x Independent Accel/Decel 2 x Independent Accel/Decel 1200 sec. 3 x Independent with Adjustable Bandwidth Delay / Speed Adjustable level, delay, speed set points Speed or Torque Adjustable in Motoring and Regenerating 0.2 Hz to 85 Hz >98.0% (18-pulse) >97.5% (AFE Rectifier) AFE Rectifier: 0.98 min., 30-100% load 18-pulse Rectifier with PFCC: 0.95 min., 20-100% load IEEE 519-1992 Compliant <85 db(A) per OSHA Standard 3074 Inherent No additional Hardware or Software required Yes Able to Start into and Control a Spinning Load in Forward or Reverse Direction

LANGUAGES
Description Operator Interface Languages Air-Cooled Liquid-Cooled 40-character, 16-line formatted text; 0.1 Hz Display Speed Resolution English, Spanish, Portuguese, Chinese (Mandarin), French, Italian, German

22

Visit our Web site: www.ab.com.catalogs

Bulletin 7000

Medium Voltage Controller Specifications

I/O and COMMUNICATION
Description External I/O External Input Ratings External Output Ratings Analog Inputs Analog Outputs Analog Resolution Communication Interface Communications Protocol (Optional) Scan Time Air-Cooled Liquid-Cooled 16 Digital Inputs, 16 Digital Outputs 50-60 Hz AC or DC, 120-240V 1 mA 50-60 Hz AC or DC, 30-260V 1 Amp (3) Isolated, (1) Non-isolated, 4-20 mA, 0-10V (1) Isolated, (8) Non-isolated, 4-20 mA, 0-10V 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: www.ab.com.catalogs

23

Bulletin 7000

Medium Voltage Drive Configurations

Drive Overview
PowerFlex 7000 A Frame
Air cooling Low end power range, 150-930 kW (200-1250 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, 150-4100 kW (200-5500hp) 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, 2240-6770 kW (3000-9000 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: www.ab.com.catalogs

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: www.ab.com.catalogs

25

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: www.ab.com.catalogs

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: www.ab.com.catalogs

27

Bulletin 7000

Medium Voltage Drives Normal Duty Ratings, Dimensions and Weights

PowerFlex 7000 Air-Cooled MV Drive (A Frame)
Drive Configuration
Normal Duty Ratings Nominal Line Voltage 2400 (60 Hz) VFD Continuous Current 46-140 46-140 46-140 40-93 46-160 46-160 46-160 46-140 40-105 46-160 46-160 46-160 46-140 40-93 105 Nominal Power (kW) 150-450 187-600 261-750 400-895 150-522 187-750 261-933 261-750 400-933 150-522 187-750 261-933 261-750 400-895 933 Nominal Power (HP) 200-600 250-800 350-1000 500-1200 200-700 250-1000 350-1250 350-1000 500-1250 200-700 250-1000 350-1250 350-1000 500-1200 1250 Structure Code 71.9 71.9 71.9 71.10 71.7 71.7 71.7 71.7 71.8 71.3 71.3 71.3 71.3 71.6 71.15 Dimensions and Weights Dimensions in inches (mm) WxHxD 94.49 X 104 X 39.4 (2400 X 2643 X1000) 94.49 X 104 X 39.4 (2400 X 2643 X1000) 94.49 X 104 X 39.4 (2400 X 2643 X1000) 110.24 X 104 X 39.4 (2800 X 2643 X1000) 82.67 X 104 X 39.4 (2100 X 2643 X1000) 82.67 X 104 X 39.4 (2100 X 2643 X1000) 82.67 X 104 X 39.4 (2100 X 2643 X1000) 82.67 X 104 X 39.4 (2100 X 2643 X1000) 94.49 X 104 X 39.4 (2400 X 2643 X1000) 94.49 X 104 X 39.4 (2400 X 2643 X1000) 94.49 X 104 X 39.4 (2400 X 2643 X1000) 94.49 X 104 X 39.4 (2400 X 2643 X1000) 94.49 X 104 X 39.4 (2400 X 2643 X1000) 110.24 X 104 X 39.4 (2800 X 2643 X1000) 114.24 X 104 X 39.4 (2900 X 2643 X1000) Approx. Weight lb. (kg) 6500 (2955) 6500 (2955) 6500 (2955) 7500 (3410) 4300 (1955) 4300 (1955) 4300 (1955) 4300 (1955) 4750 (2160) 9800 (4455) 9800 (4455) 9800 (4455) 9800 (4455) 10000 (4545) 11000 (5000)

Direct-to-Drive
RPDTD

3300 (50 Hz) 4160 (50/60 Hz) 6600 (50/60 Hz) 2400 (60 Hz)

(for connection to separate isolation transformer) RPTX

AFE Rectifier

3300 (50 Hz) 4160 (60 Hz) 4160 (50 Hz) 6600 (50/60 Hz) 2400 (60 Hz)

AFE Rectifier
(c/w integral isolation transformer) RPTXI

3300 (50 Hz) 4160 (60 Hz) 4160 (50 Hz) 6600 (50/60 Hz)

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 114.96 in. (2920 mm). Actual VFD structure height is 89.56 in. (2275 mm).

28

Visit our Web site: www.ab.com.catalogs

Bulletin 7000

Medium Voltage Drives Normal Duty Ratings, Dimensions and Weights

PowerFlex 7000 Air-Cooled MV Drive (B Frame)
Drive Configuration
Normal Duty Ratings Nominal Line Voltage 2400 (60 Hz) VFD Continuous Current 160 185-375 430 160-250 285-375 430 160-250 285-375 430 105-120 140-215 250-285 185-250 285-375 430 185 215-375 430 185-250 4160 (60 Hz) 285 325-375 430 4160 (50 Hz) 6600 (50/60 Hz) 2400 (60 Hz) 160-215 250-375 430 120-140 160-185 215-285 46-430 46-430 46-325 375-430 46-430 40-215 250-430 Nominal Power (kW) 522 600-1300 1500 750-1120 1300-1865 2050 933-1500 1680-2240 2600 933-1120 1300-2050 2240-2600 600-750 933-1300 1500 820 933-1865 2050 1082-1500 1680 1865-2240 2600 933-1120 1500-2240 2600 1120-1300 1500-1680 2050-2600 150-1500 187-2050 261-1865 2240-2600 261-2600 400-2050 2240-4100 Nominal Power (HP) 700 800-1750 2000 1000-1500 1750-2500 2750 1250-2000 2250-3000 3500 1250-1500 1750-2750 3000-3500 800-1000 1250-1750 2000 1100 1250-2500 2750 1450-2000 2250 2500-3000 3500 1250-1500 2000-3000 3500 1500-1750 2000-2250 2750-3500 200-2000 250-2750 350-2500 3000-3500 350-3500 500-2750 3000-5500 Structure Code 70.40 70.41 70.45 70.44 70.45 70.47 70.44 70.45 70.47 70.46 70.47 70.48 70.1 70.25 70.26 70.10 70.27 70.30 70.26 70.27 70.29 70.31 70.27 70.29 70.31 70.28 70.30 70.31 70.8 70.9 70.8 70.9 70.9 70.9 70.18 Dimensions and Weights Dimensions in inches (mm) WxHxD 129.92 X 104 X 39.4 (3300 X 2643 X1000) 137.8 X 104 X 39.4 (3500 X 2643 X1000) 153.54 X 104 X 39.4 (3900 X 2643 X1000) 145.67 X 104 X 39.4 (3700 X 2643 X1000) 153.54 X 104 X 39.4 (3900 X 2643 X1000) 161.42 X 104 X 39.4 (4100 X 2643 X1000) 145.67 X 104 X 39.4 (3700 X 2643 X1000) 153.54 X 104 X 39.4 (3900 X 2643 X1000) 161.42 X 104 X 39.4 (4100 X 2643 X1000) 153.54 X 104 X 39.4 (3900 X 2643 X1000) 161.42 X 104 X 39.4 (4100 X 2643 X1000) 169.29 X 104 X 39.4 (4300 X 2643 X1000) 94.49 X 104 X 39.4 (2400 X 2643 X1000) 102.36 X 104 X 39.4 (2600 X 2643 X1000) 110.24 X 104 X 39.4 (2800 X 2643 X1000) 110.24 X 104 X 39.4 (2800 X 2643 X1000) 118.11 X 104 X 39.4 (3000 X 2643 X1000) 145.67 X 104 X 39.4 (3700 X 2643 X1000) 110.24 X 104 X 39.4 (2800 X 2643 X1000) 118.11 X 104 X 39.4 (3000 X 2643 X1000) 137.8 X 104 X 39.4 (3500 X 2643 X1000) 145.67 X 104 X 39.4 (3700 X 2643 X1000) 118.11 X 104 X 39.4 (3000 X 2643 X1000) 137.8 X 104 X 39.4 (3500 X 2643 X1000) 145.67 X 104 X 39.4 (3700 X 2643 X1000) 125.98 X 104 X 39.4 (3200 X 2643 X1000) 145.67 X 104 X 39.4 (3700 X 2643 X1000) 153.54 X 104 X 39.4 (3900 X 2643 X1000) 122.05 X 104 X 39.4 (3100 X 2643 X1000) 129.92 X 104 X 39.4 (3300 X 2643 X1000) 122.05 X 104 X 39.4 (3100 X 2643 X1000) 129.92 X 104 X 39.4 (3300 X 2643 X1000) 129.92 X 104 X 39.4 (3300 X 2643 X1000) 129.92 X 104 X 39.4 (3300 X 2643 X1000) 165.36 X 104 X 39.4 (4200 X 2643 X1000) Approx. Weight lb. (kg) 9500 (4300) 10000 (4550) 13900 (6300) 12350 (5600) 13900 (6300) 16300 (7395) 12350 (5600) 13900 (6300) 16300 (7395) 13900 (6300) 16300 (7395) 16300 (7395) 4300 (1955) 4750 (2160) 5500 (2500) 5200 (2365) 6250 (2834) 9000 (4100) 5500 (2500) 6250 (2834) 8500 (3900) 9000 (4100) 6250 (2834) 8500 (3900) 9000 (4100) 6250 (2834) 9000 (4100) 9500 (4300) 5800 (2640) 6500 (2955) 5800 (2640) 6500 (2955) 6500 (2955) 6500 (2955) 9000 (4100)

Direct-to-Drive
RPDTD

3300 (50 Hz) 4160 (60 Hz) 6600 (50/60 Hz) 2400 (60 Hz)

3300 (50 Hz) (for connection to separate isolation transformer) RPTX

AFE Rectifier

(for connection to separate isolation transformer) R18TX

18-Pulse Rectifier

3300 (50 Hz) 4160 (60 Hz) 4160 (50 Hz) 6600 (50/60 Hz)

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 118.11 in. (3000 mm). Actual VFD structure height is 89.56 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: www.ab.com.catalogs

29

Bulletin 7000

Medium Voltage Drives Normal Duty Ratings, Dimensions and Weights

PowerFlex 7000 Liquid-Cooled MV Drive (C Frame)
Normal Duty Ratings Nominal Line Voltage 4160 (60 Hz) 4160 (50 Hz) VFD Continuous Current 375 - 495 575 - 625 375 - 430 495 575 325 - 375 6600 (50/60 Hz) 4160 (60 Hz) 4160 (50 Hz) 6600 (50/60 Hz) 4160 (50/60 Hz) 6600 (50/60 Hz) 430 495 575 375 - 495 575 - 625 375 - 430 495 - 575 325 - 375 430 - 495 575 375 - 657 375-575 657 Nominal Power (kW) 2240 - 3000 3360 - 3730 2240 - 2600 3000 3360 3000 - 3730 4100 4850 5595 2240 - 3000 3360 - 3730 2240 - 2600 3000 - 3360 3000 - 3730 4100 - 4850 5595 2240 - 3730 3730-5595 6340 Nominal Power (HP) 3000 - 4000 4500 - 5000 3000 - 3500 4000 4500 4000 5000 5500 6500 7500 3000 - 4000 4500 - 5000 3000 - 3500 4000 - 4500 4000 5000 5500 - 6500 7500 3000 - 5000 5000-7500 8500 70.50 70.50 70.53 Structure Code 70.71 70.76 70.71 70.94 70.76 70.80 70.91 70.92 70.93 Dimensions and Weights Dimensions in inches (mm) WxHxD 244.09 X 99.3 X 39.4 (6200 X 2522 X1000) 267.72 X 99.3 X 39.4 (6800 X 2522 X1000) 244.09 X 99.3 X 39.4 (6200 X 2522 X1000) 251.97 X 99.3 X 39.4 (6400 X 2522 X1000) 267.72 X 99.3 X 39.4 (6800 X 2522 X1000) 263.78 X 99.3 X 39.4 (6700 X 2522 X1000) 295.28 x 99.3 x 41.4 (7500 x 2522 x 1051) 303.15 x 99.3 x 41.4 (7700 x 2522 x 1051) 318.90 x 99.3 x 41.4 (8100 x 2522 x 1051) Contact Factory Contact Factory Contact Factory Contact Factory Contact Factory Contact Factory Contact Factory 200.78 X 99.3 X 39.4 (5100 X 2522 X 1000) 200.78 X 99.3 X 39.4 (5100 X 2522 X 1000) 216.54 X 99.3 X 39.4 (5500 X 2522 X 1000) 14000 (6383) 14000 (6383) 15000 (6818) Approx. Weight lb. (kg) 18000 (8164) 19600 (8890) 18000 (8164) 19000 (8618) 19600 (8890) 20150 (9139) 24144 (10936) 25792 (11699) 28281 (12828)

Drive Configuration

Direct-to-Drive
RPDTD

(for connection to separate isolation transformer) RPTX

AFE Rectifier

(for connection to separate isolation transformer) R18TX

18-Pulse Rectifier

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: www.ab.com.catalogs

Bulletin 7000

Medium Voltage Drives Topology

Topology Rectifier Design Selection
There are two basic rectifier configurations (AFE and 18-Pulse) offered as options for the PowerFlex 7000. It is advantageous when selecting a rectifier design to have a good understanding of what the customers 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 519-1992 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 519-1992 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 todays 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 customers 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).

AFE Rectifier

RECTIFIER 3 Phase Isolation Transformer SGCTs

L+

M+

INVERTER SGCTs

2U (X1) 2V (X2) 2W (X3)

U (T1) V (T2) W (T3)

Input Disconnecting Device LM-

Figure 1 4160V Drive with Isolation Transformer and Active Front End Rectifier

Visit our Web site: www.ab.com.catalogs

31

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 519-1992 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: www.ab.com.catalogs

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) - 6500 volt power devices in series to achieve the optimum electrical peak inverse blocking margin of 13000 volts for each leg.

Leg 1

Leg 4

Leg 3

Leg 6

Leg 5
LNegative Legs

Leg 2
L+ Positive Legs

Figure 5 4160V Rectifier

Visit our Web site: www.ab.com.catalogs

33

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 Input Disconnecting Line Protection 2U (X1) SGCTs

L+

M+

INVERTER SGCTs

DC LINK

U (T1) V (T2) W (T3)

2V (X2) 2W (X3) 3 Phase Line Reactor L

M-

Figure 6 4160 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 customers maximum short circuit rating (ISC) and maximum demand load current (IL). 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: www.ab.com.catalogs

34

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 AFE 18 12 6 Harmonic Order 5 0.037 0.021 0.026 0.175 7 0.005 0.011 0.016 0.110 11 0.001 0.007 0.073 0.045 13 0.019 0.005 0.057 0.029 17 0.022 0.045 0.002 0.015 19 0.015 0.039 0.001 0.009 23 0.004 0.005 0.020 0.009 25 0.003 0.003 0.016 0.008 THD Up to 49th 5.0% 6.6% 11.0% 27.0%

Visit our Web site: www.ab.com.catalogs

35

Rockwell Automation Services & Support

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

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) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb 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

PREDICT PREVENT REACT

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: www.rockwellautomation.com/services.