Medium Voltage Solutions

Medium Voltage Solutions

Erich Eckenfellner• Senior Application Engineer, Power Control Business, EMEA

04 • 03 • 2019

PUBLIC | Copyright ©2018 Rockwell Automation, Inc. 2

Agenda

1 2 3 4 Medium Voltage

product portfolio

MV Drives.

Closer look

Application

considerations

Questions and

Answers


Rockwell Automation at a glance

Our strategy is to bring The Connected Enterprise to life. We integrate control and information across the enterprise to help industrial

companies and their people be more productive.

EMPLOYEES

23,000 FISCAL 2017 SALES

$6.7B COUNTRIES

80+

ABOVE-MARKET GROWTH | PRODUCTIVITY | INTELLECTUAL CAPITAL > VALUE CREATION


1 Medium Voltage

product portfolio


Who we are?

Medium Voltage Portfolio

Headquartered in Cambridge, Ontario, Canada (manufacturing plant opened in 1954)

Global business management for Medium Voltage Variable Frequency Drives and Motor Starters

Learn more about the MV Business and the Cambridge Plant: https://www.youtube.com/watch?v=7jGBi1a72tk

Cambridge Headquarters Cambridge Plant – Medium Voltage Final Assembly

https://www.youtube.com/watch?v=7jGBi1a72tk

https://www.youtube.com/watch?v=7jGBi1a72tk


Global capabilities


Four regional engineering and manufacturing facilities in

North America, Asia Pacific, Europe, and South America

Manufacturing Experience:

Medium Voltage Starters - since 1931

Medium Voltage Drives - since 1989

Canada – Cambridge,

Ontario

350,000 ft2 (32,500 m2)

facility

Poland – Katowice

129,000 ft2 (12,000 m2)

facility

China – Harbin

165,750 ft2 (15,400 m2)

facility

Brazil – Sao Paulo

70,000 ft2 (6,500 m2) facility


Support on every step of the way


Lifecycle

Support

• Application evaluation • Product selection • Documentation • Coaching • Packaging • Budget estimates • Final quotation • Factory visits

• Scheduling • Local Project Management • Total Scope co-ordination • Approval/Information Drawings • Logistics • FAT • Start-up co-ordination • User documentation

• Start-up execution • Preventative Maintenance • Parts Management Agreements • Remote Support • Training Courses • Repair Services


Where are we present?


Oil & Gas • Oil Pipeline pumps

• Natural Gas Pipeline compressors

• Electrical submersible pumps

• Induced draft fans

Cement • Kiln induced draft fans

• Forced draft fans

• Cooler baghouse fans

• Raw mill induced draft fans

• Kiln gas fans

• Kiln drives

• Cooler exhaust fans

• Baghouse fans

Marine • Main propulsion

• Positioning thrusters

Water / Wastewater • Raw sewage pumps

• Bio-roughing tower pumps

• Treatment pumps

• Freshwater pumps

Mining & Metals • Slurry pumps

• Ventilation fans

• Descaling pumps

• Conveyors

• Baghouse fans

• Cyclone feed pumps

• Tailings pumps

Power Generation • Feed water pumps


• Forced draft fans

• Baghouse fans

Commercial • HVAC/OEM Chillers/Compressors

• Airport Cogeneration

• Hospital Cogeneration

• University Cogeneration

Forest Products • Fan pumps


• Boiler feed water pumps

• Pulpers

• Refiners

• Kiln drives

• Line shafts

Miscellaneous • Test stands

• Wind tunnels

• Agitators

• Rubber mixers


Where are we present?


A Global MV VFD Market Leader

Manufacturing MV VFDs since 1989

Over 10,000 MV VFDs installed*

Expertise in virtually all industries and

applications

Over 17,000,000 connected HP (12.6 GW)*

Installed base valued over $2 Billion ($US)*

54% in North America

14% in Latin America

14% in Europe. Middle East, and Africa

18% in Asia Pacific

* To end of FY17 – September, 2017


Building the Medium Voltage expertise


First Allen-Bradley Medium Voltage Starter

First Allen-Bradley MV Vacuum Contactor

First Generation Allen-Bradley MV VFD

Third Generation MV VFD – PowerFlex 7000

First Direct-to-Drive PowerFlex 7000 VFD

First High Power Air-cooled PowerFlex 7000 VFD

1931 1989 2000 2004 2009 2012

First 10 kV rated PowerFlex 6000 VFD


What we can offer?


Motor

Starters:

NEMA

Soft

Starters:

IEC/NEMA

VFDs:

General

Purpose

VFDs:

Special

Purpose

• Bulletin 1500 Centerline

• 2.3 - 7.2 kV

• Up to 800A

• Various configurations for across-the-line, reversing, two-speed, etc.

• PowerFlex 6000

• IEC/NEMA

• 2.3 - 11 kV

• Up to 680A

• OneGear - IEC market

• 10 - 15 kV

• Up to 580A

• Centerline - NEMA market

• 2.3 – 7.2 kV

• Up to 540A

• PowerFlex 7000

• IEC/NEMA

• 2.3 - 6.6 kV

• Up to 720A

MOTOR CONTROLLERS VARIABLE FREQUENCY DRIVES


MV MCC and Softstarters


Reversing/Non-Reversing

Full/Reduced Voltage

2400V – 6900V, up to 800A

EtherNet/IP Communications

Logix Designer Implementation

Smart components with connectivity

over IntelliCenter, OEM kits

CENTERLINE ® 1500

Intelligent Topology Complete, OEM, or Retrofit controllers

160A, 340A, 580A

10-13.8kV, up to 11MW


Logix Designer implementation

IEC certified MCC with ability to add on

to the line with help from the power bus

in upper rear section

Premier Integration

Competitive Features

OneGear


MV Drives


PowerFlex 6000

Intelligent Topology

Premier Integration

Competitive Features

PWM Current Source Inverter Topology

2400V – 6600V

Air cooled/water cooled


Logix Designer AOPs

High performance capability, including a

transformer-less option

Cascaded H-Bridge, Voltage Source

Inverter Topology

2400V – 11kV, up to 680A

Air cooled


Logix Designer AOIs

Competitive price for general purpose

applications

PowerFlex 7000


2 Medium Voltage Drives

Closer look


PowerFlex 6000 and PowerFlex 7000. Closer look

PowerFlex Medium Voltage Drives

Pri

ce

Performance / Intelligent Motor Control Capability

PowerFlex 6000

ArcShield™ PowerFlex 7000

PowerFlex 7000

Features

• Cost competitive

• SVC Control

• Basic connectivity into Logix via

faceplates and AOI’s

• Solid-state Automatic Cell Bypass

Features

• Premier Integration

• Transformerless AFE

• High-performance application

capability

• Regenerative

• Long motor cable lengths

Features

• ArcShield™

• 50 kA rating


PowerFlex 6000 and PowerFlex 7000. Closer look

PowerFlex Medium Voltage Drives

POWERFLEX 7000 SPECIAL PURPOSE DRIVE

POWERFLEX 6000 GENERAL PURPOSE DRIVE

Ideally suited for:

• Fans, pumps, compressors

• Two quadrant operation

• Motor cable length <400m

Ideally suited for:

• Cranes and Hoists • Conveyors • SAG and Ball Mills • Extruders and Mixers • Four quadrant

operation (regenerative braking)

• Long motor cable length (>400m)

2.3kV - 6.6kV (up to 720A) 2.3kV - 11kV (up to 680A)


Topology comparison

PowerFlex

M M

Current Source Topology Voltage Source Topology

• CSI? VSI?: different ways of doing things.

• CSI or VSI is the ‘feeling’ of the load.

~V ~

Utility supply

load ~V ~V

Utility supply

load

• Differentiated by DC link components.

• Many VSI variations.


Voltage Source Inverter

PowerFlex 6000



PowerFlex 6000

• Controls speed, stopping and starting of existing

or new MV induction motors helps improve asset

utilization in your critical applications

• Improves efficiency and reduces loses with high-

efficiency transformer and ECO design main

cooling fans

• Integrally mounted multi-pulse isolation

transformer helps ensure low line side harmonics

and high input power factor improving asset

utilization

• Automatic power cell bypass helps achieve less

downtime in your critical applications

• All power modules are identical and designed for

easy removal minimizing Mean Time To Repair

(MTTR)

• Intuitive, easy to use color touchscreen HMI

• Standard supplied on-line UPS helps reduce your

total cost of ownership

• Internally powered cooling fans to reduce

customer supplied control power requirements

• Kirk-key interlocks help protect personnel from

exposure to open medium voltage drive cabinets,

for added safety

User-Friendly Control for General Purpose Applications The PowerFlex 6000 drive provides a cost-

effective, simple solution for new and retrofit, variable and constant torque applications.


Voltage Source Inverter – topology review

PowerFlex 6000

Different rectifier configurations are offered: 18 Pulse (9 power cells) for 2.3/2.4kV

24 Pulse (12 power cells) for 4.0/4.16kV

30 Pulse (15 power cells) for 6.0kV

36 Pulse (18 power cells) for 6.3-6.9kV

48 Pulse (24 power cells) for 10kV

54 Pulse (27 power cells) for 11kV

To reduce line side harmonics, the optimum

phase shift between sets of isolation

transformer secondary windings is:

phase shift = 60o / number of secondary windings

i.e. - 36 pulse rectifier (6 sets of secondary windings), the

phase shift must be 60/6 = 10°

6.6 kV example of Cascaded “H” Bridge (CHB) Topology



PowerFlex 6000

Low Voltage Power Cell:

Input power fuses

Three phase diode rectifier bridge

DC Bus Capacitor network

Single phase IGBT inverter bridge

Output terminals

Theory of operation (6.6 kV example)

640VAC fed to power cell from dedicated isolation transformer secondary windings

The DC bus voltage is approx. 865VDC

H Bridge can have only three output states:

+ DC Bus Voltage (A+ and B- IGBTs are on)

- DC Bus Voltage (A- and B+ IGBTs are on)

0 VDC (A+ and B+ IGBTs are on or A- and B- IGBTs are on)

v

Detail of low voltage power cell

w

u

y

x

u

v

w

x

y

Phase Current

Phase Voltage



PowerFlex 6000

Shipping Split

6600V, 350A Unit

A. Cabling/junction cabinet for Incoming line

cable connection (L1, L2, L3) and

outgoing motor cable connections

(U,V,W)

B. Isolation Transformer

C. Connection cables from isolation

transformer secondary windings to Power

cells

D. Power cells (U Phase – A1 to A6)

E. Power cells (V Phase – B1 to B6)

F. Power cells (W Phase – C1 to C6)

G. LV Control cabinet

H. Voltage Sensing Boards (Line/load)

I. Power Cell Cooling Fans

J. Isolation Transformer Cooling Fans

Shipping Split

6600V, 350A Unit


Voltage Source Inverter - ratings

PowerFlex 6000

2390

3282

4140

6570 6870

9950

10950

1912

2624

3312

5256 5496

7960

8760

2.4KV 3.3KV 4.16KV 6.6KV 6.9KV 10KV 11KV

Po

we

r (k

W)

Motor Voltage

Normal Duty Heavy Duty


Voltage Source Inverter - ratings

PowerFlex 6000

Normal Duty • 120% overload for 1 minute

• Variable torque or constant torque applications

• 100% starting torque

• Contact factory for non-standard requirments,

Constant torque operation below 20 Hz continuously

Heavy Duty

• 150% overload for 1 minute

• Variable torque or constant torque applications

• 125% starting torque

• Contact factory for non-standard requirments,

e.g.150% overload and constant torque operation

below 20 Hz continuously

Centrifugal Water Pump

Screw Gas Compressor


Voltage Source Inverter – new features (200-680A)

PowerFlex 6000

ECO Design Main

Cooling Fans Optional dv/dt Filter

Optional pre-charge

circuit

Optional IP42

Enclosure

Optional Seismic-

Rated Enclosure

Optional Redundant

Fan

ErP directive

2009/125/EG

EC Regulation

327

High efficiency

400V rated

For motor cable

distances

>400m.

RC circuit

Reduces

reflected wave

and dv/dt at the

motor for long

motor cable

lengths.

Reduces in-rush

current to VFD

Reduces stress

on power

components

during startup

Required with

VFD’s greater

than or equal to

408A

Protected against

solid objects over

1mm

Protected against

falling water at

15 degrees from

vertical.

IBC 2013 for

worst-case

level excluding

class F

ASCE/SEI 7-10

Equipment will

not fall over

during or after a

seismic event

ECO Design

rated

Redundant fan

for both

transformer and

power cell

cabinet

Automatic

switchover

Lower Total Cost of

Ownership

Enterprise Risk Management



Improved Asset Utilization


Voltage Source Inverter – Automatic cell bypass

PowerFlex 6000

Additional hardware in power cell

SCR / RC circuit

SCR driver circuit on power cell control board

Fault types that can be bypassed:

DC overvoltage IGBT overcurrent Cell overtemperature Single phase loss

Footprint remains the same !

Available for 0-680A at all voltages


Current Source Inverter

PowerFlex 7000



PowerFlex 7000

• Controls speed, stopping and starting of existing

or new MV induction motors helps improve asset

utilization in your critical applications

• Extends availability and reliability with redundancy

options, simplicity and low parts count

• Transformerless technology reduces complexity

and footprint and helps ensure low line side

harmonics and high input power factor improving

asset utilization

• Simple, fully MV based, robust power structure

ensures highest MTBF, providing maximized

uptime in your critical applications

• Patented PowerCage™ allows SGCT

replacement in less than ten minutes minimizing

Mean Time To Repair (MTTR)

• Intuitive, easy to use color touchscreen HMI

• Low output dv/dt and motor friendly waveforms

allow for unlimited motor cable lengths and

reduce your total cost of ownership

• Kirk-key interlocks help protect personnel from

exposure to open medium voltage drive cabinets,

for added safety

Efficient Control for Special Purpose Applications The PowerFlex 7000 drive provides extended

operation capabilities. It is state of the art solution for new and retrofit, high demanding variable and

constant torque applications.


Current Source Inverter – topology review

PowerFlex 7000

M



PowerFlex 7000

6600 V - AFE Drive

18 Rectifier Devices

18 Inverter Devices

Total 36 Devices

AFE Concept

Line Reactor replaces transformer (great efficiency, 5:

1 reduction in size ) and provide 1.5 % better efficiency

SGCT (Symmetrical Gate Commutated Thyristor)

rectifier / inverter switches

Common Rectifier & Inverter topology

Low component count

Simple power structure - 3 cable input / output concept

Patented CMC DC link Choke offers reduction in

common mode and provides the ability for use of

standard motors and cabling systems.

No shipping splits in most cases reduces installation

cost

Near unity power factor Best Components x Fewest Components =

Highest Reliability

M



PowerFlex 7000

M

PowerFlex 7000 Concept

Four Quadrant Operation

Ideal for Retrofit Applications

Current and voltage waveforms are

near sinusoidal, minimizing voltage

stress on the motor winding, even if

connected through long cables.

Virtually Unlimited Motor Cable Distance

(30 km)

Reduced Mean Time To Repair (MTTR)

with Low Parts Count

M



PowerFlex 7000

AFE Direct-to-Drive Technology

The simplicity of its design results in a lower initial capital investment, lower operating cost, lower installation cost and lower maintenance cost relative to drives that require isolation transformers

No isolation transformer cost,

No extra motor insulation,

No special line cable insulation,

No special motor cable insulation,

No shipping splits,

No transformer protection relay,

No dv/dt, sine filter or motor terminator,

No power factor correction required,

No harmonic filtering required,

No transformer losses,

No transformer air conditioning

Reduction in overall system weight


Current Source Inverter

PowerFlex 7000

Special purpose stand-alone MV variable frequency drive

(VFD)

• Controls speed, torque, direction, starting and stopping of induction

or synchronous motors

• Broad power range: 150 kW to 25,400 kW.

Focus on high reliability, ease of use, and lowest total

lifecycle costs

• Unlimited motor cable lengths

• Motor-friendly waveforms

• Patented PowerCage™ allows SGCT replacement in

less than ten minutes

• Transformerless design

• Premier Integration into Logix controllers

• EtherNet/IP™ communication interface.

“A” Frame

(low-power air-cooled)

“B” Frame

(mid-power air-cooled / heat sink)

“C” Frame

(liquid-cooled)

“B” Frame

(high-power air-cooled / heat pipe)

2000 3000 4000 5000 6000 7000

100

200

300

400

500

600

700

Motor Voltage (V)

Mo

tor

Cu

rre

nt

(A)

“A” Frame

“B” Frame

“C” Frame


Current Source Inverter – air cooled drives

PowerFlex 7000

Topology: Direct-To-Drive or AFE Rectifier

Four motor voltage class offerings: 2.4 kV - (up to. 600 HP, 450 kW)

3.3 kV - (up to. 800 HP, 600 kW)

4.16 kV - (up to 1000 HP, 750 kW)

6.6 kV - (up to 1200 HP, 895 kW)

Frame A, Air-Cooled Frame B, Air-Cooled

2.4 kV - (up to. 2000 HP, 1500 kW)

3.3 kV - (up to. 4800 HP, 3600 kW)

4.16 kV - (up to 5900 HP, 4400 kW)

6.6 kV - (up to 8000 HP, 5968 kW)


Current Source Inverter – Liquid cooled drives

PowerFlex 7000

Frame C, Liquid-Cooled

Topology: Direct-To-Drive, AFE Rectifier, or 18-Pulse Rectifier

Two motor voltage class offerings :

4.16 kV - (up to 5000 HP, 3730 kW)

6.6 kV - (up to 8500 HP, 6340 kW)


Current Source Inverter – Marine Liquid cooled drives

PowerFlex 7000

Marine, Liquid-Cooled

Topology: Direct-To-Drive or 18-Pulse Rectifier

Two motor voltage class offerings : 4.16 kV - (up to 14.4 MW)

6.6 kV - (up to 24 MW)



PowerFlex 7000

PowerFlex 7000 Heat Pipe

A. Large top/bottom cabling access plates and generous

cabinet space for easier line/load cable installation

B. Multi-language operator interface with process monitoring,

trending, and metering

C. Smart temperature/airflow monitoring and adaptive

switching technology using PWM switching patterns to

reduce semiconductor heating

D. Redundant cooling fan system with automatic switchover

E. Integral line and motor capacitors

F. PWM Inverter with near-sinusoidal output motor voltage

and current waveforms

G. Enhanced power topology with arc flash-resistant power

semiconductors

H. Active Front End (AFE) Rectifier

I. PowerCage Design for speedy semiconductor change-out

J. Rectifier and inverter

K. Cabinet configuration options to duct air or use with heat

exchanger systems

L. Common mode choke cabinet

M. Common Mode Choke

N. Sound reduction features

O. SGCT power semiconductors


Current Source Inverter – Arc Shield

PowerFlex 7000

1. Pressure relief vents direct arc gases and

material away from the front, rear, and sides

of the enclosure during an arc flash

2. Gases and materials are vented up and out

of the top of the enclosure through the

plenum exhaust system

3. Patented self-closing vent plates prevent arc

flash gases from escaping through the fan

exhaust vents

4. Cabinet doors are reinforced with welded

channels designed to maintain structural

integrity during an arc flash

5. Robust cabinet construction, including

reinforced side sheets, doors, roof, and

back plates are designed to increase rigidity

to contain the arc fault energy

6. High strength hinges, latches, and bolts

securely attach doors to cabinets for added

protection

7. Patented self-closing vent plates prevent arc

flash gases from escaping out through the

front air intake vents


Current Source Inverter – motor compatibility

PowerFlex 7000

• The PowerFlex 7000 achieves near sinusoidal current and voltage waveforms to the motor,

resulting in no significant additional heating or insulation stress. Temperature rise in the motor

connected to the VFD is typically 3°Celsius higher compared to across the-line operation.

• Dv/dt in the voltage waveform is less than 50 volts / microsecond. Reflected wave and dv/dt

issues often associated with VSI (voltage source inverter) drives do not exist with the PowerFlex

7000.

• Motor friendly waveforms are achieved by utilizing a selective

harmonic elimination (SHE) pattern in the inverter to eliminate

major order harmonics, in conjunction with a small output

capacitor (integral to the drive) to eliminate higher order

harmonics. Standard motors are compatible without de-rating,

even on retrofit applications.

• Motor cable distance is virtually unlimited. This technology is

capable of controlling motors up to 30 km away from the drive.


3 Application considerations


Why use PowerFlex drives?

Application considerations

$ Energy savings

Energy management

Reduced MTTR

Speed control

Energy intelligence

Fewer parts


Why use Frequency converter ???


$ Reduce costs

energy savings on fans, pumps, compressors

reduced maintenance costs on mechanical equipment (gearbox, belt system etc)

increase life of mechanical equipment (example conveyor belt)

Improved process control

increase productivity

flexibility

environmental compliance

Starting large motors on weak systems

eliminate voltage flicker

reduce inrush current

higher starting torque than reduced voltage


Energy Saving


$ Min Data are required

Motor Data

Load diagram

Complete operation time

Operation percentage on the different operation points

Energy cost per kWh or MWh

Regulation type (in/out let dumper, bypass)

Add data

Currently measured system load consumption on the different load

point [kW]

Input dumper regulator

Currently System load


Harmonics and PF consideration


$

0%

2%

4%

6%

8%

10%

12%

14%

16%

18%

5th 7th 11th 13th 17th 19th 23rd 25th

AFE

18-Pulse

12-Pulse

6-Pulse

Harmonics are integer multiples of the fundamental system frequency (h=kq±1,

Ih=I1/h)

For q=6, h=5, 7, 11, 13… Ih=.2, .14, .09, .077…

Harmonics cause the distortion of a pure sine wave

Total Harmonic Distortion (THD) is a way to quantify total distortion in a

waveform

Ithd = √(∑Ih2)/If , Vthd = √(∑Vh2)/Vf

All rectifiers produce current harmonics which flow back into the power system

System impedance determines magnitudes of voltage harmonics

Total P.F. = Displacement P.F X Distortion P.F.

Electric utilities measure and sometimes penalize based on total P.F.

Sometimes only the displacement power factor is quoted

Power factor penalty on fan or pump load is negligible since power levels at

low speed are low (P α 1/S3)

Both 18P and AFE have high distortion PF

AFE also has high displacement PF

Drive TypeDisplacement

PFI(THD)

Distortion

PFTotal PF

6-Pulse 0.950 35.0% 0.944 0.897

12-Pulse 0.970 12.0% 0.993 0.963

18-Pulse 0.990 5.0% 0.999 0.989

Distortion Power Factor

Non-alignment of voltage and current due to the

distortion of the waveforms

Displacement Power Factor

Related to the zero crossing shift or phase angle

between current and voltage

2

1

1

1

THDI

IDF

rms

1cosIDF


Why use PowerFlex Medium Voltage drives?


$ Results in lower

costs related to...

Larger cables

Buswork

Raceways

Peripheral Equipment

… And continues in

ENERGY SAVINGS throughout

the product’s life

MV LV LV with Input XFMR

LV with Input and Output

XFMRs

Cost

Output XFMR

Input XFMR

Cable

VFD

Example: 1000 HP VFD, 1000 kVA Transformers, and 30m. of cabling


Safety with PowerFlex 7000


$ Removes rotational power from

the motor

Simplify machinery

maintenance

Reduce unnecessary

downtime

Reduces system complexity while

saving operational costs

Safety demand placed on the system

Signal sent to the drive and STO

command initiated

Drive removes rotational power

to the motor

Drive monitors “safe state” to prevent it from

starting accidentally

After safety demand has

ended, drive can return power to

the motor


Special applications with PowerFlex 7000 –Bypass configurations


$ Application: Multiple pump or fan systems that are

interdependent within a process.

Advantage: Process flow control with one drive and multiple

motors.

Technical: VFD accelerates motor 1 to full speed and

synchronizes it with the line voltage and frequency

before bypassing it across-the-line. VFD accelerates and

decelerates motor 2 to provide process control as

demand dictates.

Note: System can handle up to 6 motors. For more complex

configurations, contact Commercial Engineering.

Note: Can accommodate motors up to a 2:1 HP ratio.

M1

3

Output

Bypass

1512M

3

VFD Bus

1512DM

M2

3

Output

Bypass

1512M

VFD


Special applications with PowerFlex 7000 – Bypass configurations with synchronous transfer


$ multiple pumps in a common process

controlled by a single AFD

synchronizing motors to line frequency

desynchronizing motors from line frequency

variable control is achieved over full output

of multiple pumps a small PLC is dedicated to the VFD synchronous

transfer system motor and transformer protection equipment

interlocking and switching of starters/breakers

provides feedback on transfers, drive/motor

remote I/O systems are used to monitor starter

signals and reduce interconnect wiring

auxiliary equipment such as blowers, lube oil

systems

0

1

2

3

4

5

6

Pro

ce

ss d

em

and

Flow

Demand vs. Flow

Pump 1 Pump 2 Pump 3

increasing

decreasing


Special applications with PowerFlex 7000 – Bypass configurations with synchronous transfer


$ Process benefits

reduced initial capital outlay

reduced starting currents and voltage drops

reduced stress on mechanical equipment

reduced pump and valve wear

energy savings

Control of different sized motors by the same VFD

• motor/pump size variance on a single drive can be 2:1 for 18 Pulse drives or

1.4:1 for DTD

• additional control may be required for drive re-configuration

• alternate motor parameters are downloaded to drive to match motor size

• operating characteristics may also be changed as required


Backup system


$

Synchronous Bypass System 1 Synchronous Bypass System 2

M1

3

Output

Bypass

1512M

3

VFD Bus

1512DM

M2

3

Output

Bypass

1512M

M3

3

Output

Bypass

1512M

M4

3

Output

Bypass

1512M 1591A 1512AD

3

VFD Bus

1512DM

VF

D VF

D

Application: Critical applications with

synchronous transfer bypass systems

that cannot be shut down for drive

maintenance.

Advantage: Entire synchronous transfer

applications can be backed up by

another. Reduces down time for

maintenance.

Technical: When the drive is isolated for

maintenance, the 1512AD contactor is

closed, like a tie switch. This allows the

drive from System 1 to accelerate the

motors in System 2 (and vice versa)

and synchronize them across the line.

Note: With the tie switch open, it only

allows the disabled system to run

the motors across-the-line. It does

not allow variable speed control.

Note: 1512AD has fusing removed


Hot back-up and redundancy System


$

PowerFlex 7000 Extended Power Configurations

Available up to 34,000 HP (approx 25MW), these high

power air-cooled and liquid-cooled drive modules are

effective solutions for hot back-up and redundancy, Load

Commutated Inverter (LCI) retrofits and power upgrades.

VFD

HUB

M

CONTROL LOGIX

DRIVE CONTROL

VFD

DRIVE CONTROL

DEVICENET

RS485

Follower Starting into a Running Leader

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

F - Speed Feedback

F - Motor Power

F - Torque

L - Speed Reference

L - Motor Power

L - Torque

Extended power configurations of PowerFlex 7000


Parallel system


$ Application: High current and high

horsepower applications.

Advantage: High current loads being

operated by multiple drives using

existing technology cost effectively.

Technical: Combining current capacity of

each drive to achieve full current

carrying ability.

Example: 3 x 300 Amp VFDs can be

applied to one 900 FLA load.

Note: Contact factory for these

applications.

4 drives in total can be connected as

paralel solution

OR

Providing full drive redundancy. Each

drive dimensioned for full

application power demand.

VFD

M

3

1512AD

VFD

3

1512AD

VFD

M

3

1512AD

VFD

3

1512AD

VFD

3

1512AD

7011 7011

Example based on AFE drives with separate input starters and separate transformers


4 Questions & Answers

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Medium Voltage Solutions

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