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Medium Voltage AC Drives

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

www.klinkmann.com
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.

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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-to-
air 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.

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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.

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Innovative Design
Historically, medium voltage motor AC drives Total Harmonic Distortion (THD) of the input
(2.4 kV to 6.9 kV), use power topologies that current is within IEEE 519-1992 and most global
generate common-mode voltage, which can cause harmonic guidelines in virtually every system.
premature failure of the motor winding insulation. Current and voltage waveforms are near
Multi-pulse isolation transformers are typically sinusoidal, minimizing voltage stress on the
used to address this common-mode voltage stress motor winding, even if connected through long
and also to mitigate harmonics. cables.

The innovative PowerFlex 7000 with Direct-to- The Active Front End (AFE) Rectifier
Drive technology connects the power supply To reduce harmonics, the active front end uses
directly to the medium voltage drive without an active switching and Selective Harmonic
isolation transformer. Leading edge technology Elimination (SHE) and provides near-unity
combines three innovations to achieve power factor.
transformerless Direct-to-Drive technology: the
Symmetrical Gate Commutated Thyristor (SGCT) Common Mode Voltage Protection
in both the inverter and rectifier allow operation The integrated common mode choke provides
of high switching frequency to minimize switching a very high impedance to the common mode
losses; the active front end (AFE) rectifier used at current and mitigates motor neutral-to-ground
the input stage; and the common mode choke to voltage.
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.

2286 mm (90 inches) 3100 mm (122 inches) 2400 mm (94.5 inches)


3000 kg (6600 Ibs) 2640 kg (5800 Ibs) 2950 kg (6500 Ibs)

Dimension comparison between and 18-Pulse drive with isolation transformer (left)
and a PowerFlex 7000 drive with Direct-to-Drive technology (right)

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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.

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LIQUID-COOLED
HIGH HORSEPOWER

PowerFlex 7000 Liquid-Cooled Drives Maintenance is simple with the patented


Reduce energy use on motors from 3000 to 8500 PowerCage converter modules that let you replace
hp (2240 to 6340 kW), at 4160 to 6900V nominal power devices in less than ten minutes. You can
supply voltage ratings. Liquid-cooling results in a also reduce installation costs by using a central
more efficient transfer of heat than air-cooling, cabling cabinet for the complete drive package.
with approximately 90% of the heat removed from Liquid-cooled drives are also more tolerant of
the control room via a heat exchanger, so control higher elevations and higher ambient temperatures
room air-conditioning costs are drastically in the control room.
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.

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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.

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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.

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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.

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
The unique characteristics of the SGCT reliable.
and the PowerFlex 7000 drive topology
make it possible to cost-effectively apply SGCT - The Ideal Power Semiconductor Switch for MV
this versatile component into both the Drives The Symmetrical Gate Commutated Thyristor (SGCT) with
PWM inverter and PWM active front end integrated gate drive, high switching frequency, and double-sided
rectifier.
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

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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

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POWER QUALITY LOWER LINE HARMONICS

Most MV drives on the market today


reduce line-side harmonics by increasing
Line the rectifier pulse number through parallel
Current rectifier bridges and phase-shifting
transformers. These drives have a higher
component count, higher complexity and
Line higher number of connections.
Voltage
The PowerFlex 7000 drive offers several
(VL-L)
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.

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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 Motor
large order harmonics at higher Voltage
frequencies. The result is no additional (VL-L)
motor heating or voltage stress to motor
insulation compared to fixed speed
operation.
Motor
Virtually Unlimited Motor Cable Current
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 The Direct-to-Drive feature mitigates common mode
is virtually unlimited. This technology is voltage and does not produce dv/dt or reflected
capable of controlling motors as far away wave voltage stress on motors.
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.

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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 Features


dollar Rockwell Automation medium voltage drive 10,325 ft2 (959 m2) medium voltage test facility.
test facility, in Cambridge, Ontario, Canada 10 test bays.
enables full load testing of medium voltage drives 3 regenerative drives plus 2 customer
up to 7000 hp. The facility also has a motor base demonstration drives.
to mount a customer motor for combined testing 9 MV motors totaling 16,650 hp (12.4 MW).
with the PowerFlex 7000 drive and has the 7 transformers totaling 23,860 kVA.
infrastructure to test large transformers with the
Capabilities
drive system. The dynamometer (the motor and
Tests 6-pulse, 18-pulse or AFE rectifier.
drive arrangement used for load testing) consists
Can simulate 2 load profiles.
of two 2,500 hp (1,865 kW) induction motors
100 hp to 7,000 hp (76 kW to 5,222 kW)
(3,810/6600 volts) and one 5,500 hp (4,103 kW)
drives at voltages from 1,000 to 6,900 V.
induction motor at 2,400/4,160 volts. The
dynamometer is capable of simulating two Benefits
different load types: constant torque found in Reduced start-up time.
conveyor and reciprocating compressor Efficiency testing for energy savings.
applications, and variable torque found in pump, Customer witness testing and training.
fan and centrifugal compressor applications. Overload, system and performance testing.
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.

CAMBRIDGE TEST FACILITY

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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.

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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.

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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 MV FVNR MV SMC Flex MV ArcShield PowerFlex 7000
technology increases the Controller Controller Controller MV AC Drive
control possibilities with
function block diagrams that
SCALABLE FUNCTIONALITY
operate at the device level.
DriveLogix offers embedded
Logix control for application Reuse engineering designs and practices to
programmability and control of auxiliary reduce development time and cost.
functions in one package. Quickly respond to customer or
market demands.
Integrated Architecture enables you to reduce your Reduce maintenance costs and downtime.
total cost of ownership by using a single control Easily access plant and production data from
infrastructure for the entire range of factory business systems for better management
automation applications, large or small. 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.

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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.

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Bulletin 7000
Medium Voltage Drives Specifications

Description of Features

Designed to Maximize Uptime, be Easy to Use, and Lower


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

10 / 2011
www.klinkmann.com 19
Bulletin 7000
Medium Voltage Drive Specifications

General Design Specifications

POWER
Description Air-Cooled Liquid-Cooled
Power Rating 150-3000 kW (200 to 5500 hp) 2240-6700 kW (3000-9000 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 5 cycles (Standard); >5 cycles (optional UPS)
Input Protection Surge Arrester AFE Rectifier / Metal Oxide Varistor (MOV) 18P
Input Frequency 50/60 Hz, 5%
Input Short-Circuit Current Withstand 5 cycle
Short-Circuit Fault Rating 2400-6600V (25 kA RMS SYM)
Basic Impulse Level (based on Altitude
50 kV 45 kV
of 1000 m (3300 ft.))
Power Bus Design Copper Tin plated
Copper Tin plated
Ground Bus
6 x 51 mm ( x 2 inches)
Customer Control Wireway Separate and Isolated
Input Power Circuit Protection (optional) Vacuum Contactor with Fused Isolating Switch or Circuit Breaker
Input Impedance Device Isolation Transformer or AC Line Reactor
0-2300V, 0-3300V, 0-4160V,
Output Voltage 0-4160V, 0-6600V, 0-6900V
0-6000V, 0-6300V, 0-6600V
220/240V or 110/120V,
Control Power 208-575V, 3 phase, 50/60 Hz
1 phase, 50/60 Hz (20 Amp)
For 2300V, 3300V, and 6900V offering, contact factory.

10 / 2011
20 www.klinkmann.com
Bulletin 7000
Medium Voltage Drive Specifications

DESIGN
Description Air-Cooled Liquid-Cooled
Inverter Design PWM
Inverter Switch Symmetrical Gate Commutated Thyristor (SGCT)
Inverter Switch Failure Mode Non-rupture, Non-arc
Inverter Switch Failure Rate (FIT) 100 per 1 Billion Hours Operation
Inverter/Rectifier Switch Cooling Double-sided, Low Thermal Stress
Inverter Switching Frequency 420 540 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 6500V per device
Rectifier Designs Active Front End (AFE) Rectifier or 18-pulse
Typical Line Harmonic Content <5% Current THD (AFE Rectifier)
Typical Power Factor Selectable up to unity (AFE Rectifier)
Rectifier Switch SGCT (AFE Rectifier), SCR (18-pulse Rectifier)
Rectifier Switch Failure Mode Non-rupture, Non-arc
Rectifier Switch Failure Rate (FIT) 50 (SCR), 100 (SGCT) per 1 Billion Hours Operation
AFE: 2 at 2400V, AFE: 4 at 4160V,
4 at 3300/4160V, 6 at 6600V
No. of Rectifier Devices (per phase) 6 at 6600V
18-pulse: 6 for all voltages 18-pulse: 6 for all voltages
SCR Peak Inverse Voltage Rating 18-pulse: 4500V at 2400V, 3300V, 4160V 18-pulse: 4500V at 4160V
(per device) 6500V at 6600V 6500V at 6600V
Fiber Optic Interface Rectifier Inverter Cabinet (Warning/Trip)
Design Standards CSA, UL, IEC, NEMA, ANSI, IEEE

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

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Bulletin 7000
Medium Voltage Drive Specifications

PERFORMANCE
Description Air-Cooled Liquid-Cooled
Output Waveform to Motor Sinusoidal Current/Voltage
Medium Voltage Isolation Fiber Optic
Modulation Techniques SHE (Selective Harmonic Elimination); PWM (Pulse Width Modulation)
Control Method Digital Sensorless Direct Vector, Full Vector Control with Tach Feedback (Optional)
Tuning Method Auto Tuning via Setup Wizard
Speed Regulator Bandwidth 0.1 - 15 Radians/Second
Torque Response Bandwidth 20 - 100 Radians/Second
Normal Duty (variable torque): Normal Duty (variable torque):
110% Overload for 1 minute 110% Overload for 1 minute
Service Duty Rating every 10 minutes every 10 minutes
(Overload Rating) Heavy Duty (constant torque): Heavy Duty (constant torque):
150% Overload for 1 minute Contact Factory
every 10 minutes
Speed Regulation 0.1% without Tachometer Feedback
0.01 0.02% 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
>98.0% (18-pulse)
Typical VFD Efficiency
>97.5% (AFE Rectifier)
AFE Rectifier: 0.98 min., 30-100% load
Input Power Factor
18-pulse Rectifier with PFCC: 0.95 min., 20-100% load
Harmonic Guidelines IEEE 519-1992 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

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Bulletin 7000
Medium Voltage Controller Specifications

I/O and COMMUNICATION


Description Air-Cooled Liquid-Cooled
External I/O 16 Digital Inputs, 16 Digital Outputs
External Input Ratings 50-60 Hz AC or DC, 120-240V 1 mA
External Output Ratings 50-60 Hz AC or DC, 30-260V 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 Input 12-bit (4-20 mA)
Internal Parameter 32-bit resolution
Analog Resolution
Serial Communication 16-bit resolution (0.1 Hz)
(Digital Speed Reference)
Communication Interface DPI
RI/O DeviceNet, ControlNet, Ethernet, Profibus, Modbus, Modbus Plus,
Communications Protocol (Optional)
Interbus, Lonworks, Can Open, RS485 HVAC, RS485 DF1, RS232 DF1, RS232 C
Scan Time Internal DPI 5 ms

Drive Configurations

Dimension Comparison

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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-to-


liquid 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)

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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 Direct-
An integrated system solution for fewer connections to-Drive
(Optional
and reduced installation costs
Input
New or existing motors Starter)
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

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 AFE
Low line harmonics & high power factor (typical Rectifier
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)

Configuration #3
AFE Rectifier
(Integral isolation transformer) ____________________________________________
An integrated system solution for fewer connections
and reduced installation costs Integral
Small system footprint Isolation
Transformer
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)

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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%)

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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%)

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Bulletin 7000
Medium Voltage Drives Normal Duty Ratings, Dimensions and Weights

PowerFlex 7000 Air-Cooled MV Drive (A Frame)

Normal Duty Ratings Dimensions and Weights


Drive Nominal VFD Nominal Nominal Dimensions in
Configuration Structure Approx. Weight
Line Continuous Power Power inches (mm)
Code lb. (kg)
Voltage Current (kW) (HP) WxHxD
2400
46-140 150-450 200-600 71.9 94.49 X 104 X 39.4 (2400 X 2643 X1000) 6500 (2955)
(60 Hz)
3300
Direct-to-Drive 46-140 187-600 250-800 71.9 94.49 X 104 X 39.4 (2400 X 2643 X1000) 6500 (2955)
(50 Hz)

RPDTD 4160
46-140 261-750 350-1000 71.9 94.49 X 104 X 39.4 (2400 X 2643 X1000) 6500 (2955)
(50/60 Hz)
6600
40-93 400-895 500-1200 71.10 110.24 X 104 X 39.4 (2800 X 2643 X1000) 7500 (3410)
(50/60 Hz)
2400
46-160 150-522 200-700 71.7 82.67 X 104 X 39.4 (2100 X 2643 X1000) 4300 (1955)
(60 Hz)
3300
AFE Rectifier 46-160 187-750 250-1000 71.7 82.67 X 104 X 39.4 (2100 X 2643 X1000) 4300 (1955)
(50 Hz)
(for connection to
separate isolation 4160
46-160 261-933 350-1250 71.7 82.67 X 104 X 39.4 (2100 X 2643 X1000) 4300 (1955)
transformer) (60 Hz)
RPTX
4160
46-140 261-750 350-1000 71.7 82.67 X 104 X 39.4 (2100 X 2643 X1000) 4300 (1955)
(50 Hz)
6600
40-105 400-933 500-1250 71.8 94.49 X 104 X 39.4 (2400 X 2643 X1000) 4750 (2160)
(50/60 Hz)
2400
46-160 150-522 200-700 71.3 94.49 X 104 X 39.4 (2400 X 2643 X1000) 9800 (4455)
(60 Hz)
3300
AFE Rectifier 46-160 187-750 250-1000 71.3 94.49 X 104 X 39.4 (2400 X 2643 X1000) 9800 (4455)
(50 Hz)
(c/w integral
isolation 4160
46-160 261-933 350-1250 71.3 94.49 X 104 X 39.4 (2400 X 2643 X1000) 9800 (4455)
transformer) (60 Hz)
RPTXI 4160
46-140 261-750 350-1000 71.3 94.49 X 104 X 39.4 (2400 X 2643 X1000) 9800 (4455)
(50 Hz)
6600 40-93 400-895 500-1200 71.6 110.24 X 104 X 39.4 (2800 X 2643 X1000) 10000 (4545)
(50/60 Hz) 105 933 1250 71.15 114.24 X 104 X 39.4 (2900 X 2643 X1000) 11000 (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 114.96 in. (2920
mm). Actual VFD structure height is 89.56 in. (2275 mm).

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Bulletin 7000
Medium Voltage Drives Normal Duty Ratings, Dimensions and Weights

PowerFlex 7000 Air-Cooled MV Drive (B Frame)

Normal Duty Ratings Dimensions and Weights


Drive Nominal VFD Nominal Nominal Dimensions in
Configuration Structure Approx. Weight
Line Continuous Power Power inches (mm)
Code lb. (kg)
Voltage Current (kW) (HP) WxHxD
160 522 700 70.40 129.92 X 104 X 39.4 (3300 X 2643 X1000) 9500 (4300)
2400
185-375 600-1300 800-1750 70.41 137.8 X 104 X 39.4 (3500 X 2643 X1000) 10000 (4550)
(60 Hz)
430 1500 2000 70.45 153.54 X 104 X 39.4 (3900 X 2643 X1000) 13900 (6300)
160-250 750-1120 1000-1500 70.44 145.67 X 104 X 39.4 (3700 X 2643 X1000) 12350 (5600)
3300
285-375 1300-1865 1750-2500 70.45 153.54 X 104 X 39.4 (3900 X 2643 X1000) 13900 (6300)
(50 Hz)
Direct-to-Drive 430 2050 2750 70.47 161.42 X 104 X 39.4 (4100 X 2643 X1000) 16300 (7395)
RPDTD 160-250 933-1500 1250-2000 70.44 145.67 X 104 X 39.4 (3700 X 2643 X1000) 12350 (5600)
4160
(60 Hz) 285-375 1680-2240 2250-3000 70.45 153.54 X 104 X 39.4 (3900 X 2643 X1000) 13900 (6300)

430 2600 3500 70.47 161.42 X 104 X 39.4 (4100 X 2643 X1000) 16300 (7395)
105-120 933-1120 1250-1500 70.46 153.54 X 104 X 39.4 (3900 X 2643 X1000) 13900 (6300)
6600
(50/60 Hz) 140-215 1300-2050 1750-2750 70.47 161.42 X 104 X 39.4 (4100 X 2643 X1000) 16300 (7395)

250-285 2240-2600 3000-3500 70.48 169.29 X 104 X 39.4 (4300 X 2643 X1000) 16300 (7395)
185-250 600-750 800-1000 70.1 94.49 X 104 X 39.4 (2400 X 2643 X1000) 4300 (1955)
2400
285-375 933-1300 1250-1750 70.25 102.36 X 104 X 39.4 (2600 X 2643 X1000) 4750 (2160)
(60 Hz)
430 1500 2000 70.26 110.24 X 104 X 39.4 (2800 X 2643 X1000) 5500 (2500)
185 820 1100 70.10 110.24 X 104 X 39.4 (2800 X 2643 X1000) 5200 (2365)
3300
215-375 933-1865 1250-2500 70.27 118.11 X 104 X 39.4 (3000 X 2643 X1000) 6250 (2834)
(50 Hz)
430 2050 2750 70.30 145.67 X 104 X 39.4 (3700 X 2643 X1000) 9000 (4100)
AFE Rectifier 185-250 1082-1500 1450-2000 70.26 110.24 X 104 X 39.4 (2800 X 2643 X1000) 5500 (2500)
(for connection to
separate isolation 4160 285 1680 2250 70.27 118.11 X 104 X 39.4 (3000 X 2643 X1000) 6250 (2834)
transformer) (60 Hz) 325-375 1865-2240 2500-3000 70.29 137.8 X 104 X 39.4 (3500 X 2643 X1000) 8500 (3900)
RPTX
430 2600 3500 70.31 145.67 X 104 X 39.4 (3700 X 2643 X1000) 9000 (4100)
160-215 933-1120 1250-1500 70.27 118.11 X 104 X 39.4 (3000 X 2643 X1000) 6250 (2834)
4160
250-375 1500-2240 2000-3000 70.29 137.8 X 104 X 39.4 (3500 X 2643 X1000) 8500 (3900)
(50 Hz)
430 2600 3500 70.31 145.67 X 104 X 39.4 (3700 X 2643 X1000) 9000 (4100)
120-140 1120-1300 1500-1750 70.28 125.98 X 104 X 39.4 (3200 X 2643 X1000) 6250 (2834)
6600
(50/60 Hz) 160-185 1500-1680 2000-2250 70.30 145.67 X 104 X 39.4 (3700 X 2643 X1000) 9000 (4100)

215-285 2050-2600 2750-3500 70.31 153.54 X 104 X 39.4 (3900 X 2643 X1000) 9500 (4300)
2400
46-430 150-1500 200-2000 70.8 122.05 X 104 X 39.4 (3100 X 2643 X1000) 5800 (2640)
(60 Hz)
3300
46-430 187-2050 250-2750 70.9 129.92 X 104 X 39.4 (3300 X 2643 X1000) 6500 (2955)
18-Pulse (50 Hz)
Rectifier 46-325 261-1865 350-2500 70.8 122.05 X 104 X 39.4 (3100 X 2643 X1000) 5800 (2640)
(for connection to 4160
separate isolation (60 Hz) 375-430 2240-2600 3000-3500 70.9 129.92 X 104 X 39.4 (3300 X 2643 X1000) 6500 (2955)
transformer) 4160
R18TX 46-430 261-2600 350-3500 70.9 129.92 X 104 X 39.4 (3300 X 2643 X1000) 6500 (2955)
(50 Hz)

6600 40-215 400-2050 500-2750 70.9 129.92 X 104 X 39.4 (3300 X 2643 X1000) 6500 (2955)
(50/60 Hz) 250-430 2240-4100 3000-5500 70.18 165.36 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 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.

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Bulletin 7000
Medium Voltage Drives Normal Duty Ratings, Dimensions and Weights

PowerFlex 7000 Liquid-Cooled MV Drive (C Frame)

Normal Duty Ratings Dimensions and Weights


Drive Nominal VFD Nominal Nominal Structure Dimensions in
Configuration Approx. Weight
Line Continuous Power Power Code inches (mm)
lb. (kg)
Voltage Current (kW) (HP) WxHxD
4160 375 - 495 2240 - 3000 3000 - 4000 70.71 244.09 X 99.3 X 39.4 (6200 X 2522 X1000) 18000 (8164)
(60 Hz) 575 - 625 3360 - 3730 4500 - 5000 70.76 267.72 X 99.3 X 39.4 (6800 X 2522 X1000) 19600 (8890)
375 - 430 2240 - 2600 3000 - 3500 70.71 244.09 X 99.3 X 39.4 (6200 X 2522 X1000) 18000 (8164)
4160
495 3000 4000 70.94 251.97 X 99.3 X 39.4 (6400 X 2522 X1000) 19000 (8618)
Direct-to-Drive (50 Hz)
575 3360 4500 70.76 267.72 X 99.3 X 39.4 (6800 X 2522 X1000) 19600 (8890)
RPDTD
325 - 375 3000 - 3730 4000 5000 70.80 263.78 X 99.3 X 39.4 (6700 X 2522 X1000) 20150 (9139)
6600 430 4100 5500 70.91 295.28 x 99.3 x 41.4 (7500 x 2522 x 1051) 24144 (10936)
(50/60 Hz) 495 4850 6500 70.92 303.15 x 99.3 x 41.4 (7700 x 2522 x 1051) 25792 (11699)
575 5595 7500 70.93 318.90 x 99.3 x 41.4 (8100 x 2522 x 1051) 28281 (12828)
4160 375 - 495 2240 - 3000 3000 - 4000 Contact Factory
(60 Hz) 575 - 625 3360 - 3730 4500 - 5000 Contact Factory
AFE Rectifier
4160 375 - 430 2240 - 2600 3000 - 3500 Contact Factory
(for connection to
separate isolation (50 Hz) 495 - 575 3000 - 3360 4000 - 4500 Contact Factory
transformer)
325 - 375 3000 - 3730 4000 5000 Contact Factory
RPTX 6600
430 - 495 4100 - 4850 5500 - 6500 Contact Factory
(50/60 Hz)
575 5595 7500 Contact Factory
18-Pulse 4160
375 - 657 2240 - 3730 3000 - 5000 70.50 200.78 X 99.3 X 39.4 (5100 X 2522 X 1000) 14000 (6383)
Rectifier (50/60 Hz)
(for connection to
separate isolation 6600 375-575 3730-5595 5000-7500 70.50 200.78 X 99.3 X 39.4 (5100 X 2522 X 1000) 14000 (6383)
transformer) (50/60 Hz)
R18TX 657 6340 8500 70.53 216.54 X 99.3 X 39.4 (5500 X 2522 X 1000) 15000 (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.

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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.

AFE Rectifier 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).

RECTIFIER L+ M+ INVERTER

3 Phase Isolation SGCTs SGCTs


Transformer 2U (X1) U (T1)
2V (X2) V (T2)
2W (X3) W (T3)

Input Disconnecting
Device
L- M-

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

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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.)

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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 Leg 2
L-

L+
Negative Legs

Positive Legs


Figure 5 4160V Rectifier

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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 SGCTs SGCTs
2U (X1) U (T1)

DC LINK
2V (X2) V (T2)

2W (X3) W (T3)

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

10 / 2011
34 www.klinkmann.com
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 Harmonic Order THD


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

Rockwell_Medium_Voltage_Drives_Select_en_0611.pdf

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