medium voltage solutions
TRANSCRIPT
Medium Voltage Solutions
Erich Eckenfellner• Senior Application Engineer, Power Control Business, EMEA
04 • 03 • 2019
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Agenda
1 2 3 4 Medium Voltage
product portfolio
MV Drives.
Closer look
Application
considerations
Questions and
Answers
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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
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1 Medium Voltage
product portfolio
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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
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Global capabilities
Medium Voltage Portfolio
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
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Support on every step of the way
Medium Voltage Portfolio
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
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Where are we present?
Medium Voltage Portfolio
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
• Induced draft fans
• Forced draft fans
• Baghouse fans
Commercial • HVAC/OEM Chillers/Compressors
• Airport Cogeneration
• Hospital Cogeneration
• University Cogeneration
Forest Products • Fan pumps
• Induced draft fans
• Boiler feed water pumps
• Pulpers
• Refiners
• Kiln drives
• Line shafts
Miscellaneous • Test stands
• Wind tunnels
• Agitators
• Rubber mixers
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Where are we present?
Medium Voltage Portfolio
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
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Building the Medium Voltage expertise
Medium Voltage Portfolio
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
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What we can offer?
Medium Voltage Portfolio
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
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MV MCC and Softstarters
Medium Voltage Portfolio
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
EtherNet/IP Communications
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
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MV Drives
Medium Voltage Portfolio
PowerFlex 6000
Intelligent Topology
Premier Integration
Competitive Features
PWM Current Source Inverter Topology
2400V – 6600V
Air cooled/water cooled
EtherNet/IP Communications
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
EtherNet/IP Communications
Logix Designer AOIs
Competitive price for general purpose
applications
PowerFlex 7000
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2 Medium Voltage Drives
Closer look
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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
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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)
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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.
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Voltage Source Inverter
PowerFlex 6000
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Voltage Source Inverter
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.
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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
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Voltage Source Inverter – topology review
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
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Voltage Source Inverter – topology review
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
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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
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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
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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
Enterprise Risk Management
Enterprise Risk Management
Improved Asset Utilization
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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
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Current Source Inverter
PowerFlex 7000
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Voltage Source Inverter
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.
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Current Source Inverter – topology review
PowerFlex 7000
M
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Current Source Inverter – topology review
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
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Current Source Inverter – topology review
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
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Current Source Inverter – topology review
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
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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
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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)
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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)
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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)
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Current Source Inverter – topology review
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
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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
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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.
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3 Application considerations
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Why use PowerFlex drives?
Application considerations
$ Energy savings
Energy management
Reduced MTTR
Speed control
Energy intelligence
Fewer parts
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Why use Frequency converter ???
Application considerations
$ 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
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Energy Saving
Application considerations
$ 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
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Harmonics and PF consideration
Application considerations
$
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
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Why use PowerFlex Medium Voltage drives?
Application considerations
$ 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
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Safety with PowerFlex 7000
Application considerations
$ 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
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Special applications with PowerFlex 7000 –Bypass configurations
Application considerations
$ 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
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Special applications with PowerFlex 7000 – Bypass configurations with synchronous transfer
Application considerations
$ 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
PUBLIC | Copyright ©2018 Rockwell Automation, Inc. 49
Special applications with PowerFlex 7000 – Bypass configurations with synchronous transfer
Application considerations
$ 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
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Backup system
Application considerations
$
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
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Hot back-up and redundancy System
Application considerations
$
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
PUBLIC | Copyright ©2018 Rockwell Automation, Inc. 52
Parallel system
Application considerations
$ 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
PUBLIC | Copyright ©2018 Rockwell Automation, Inc. 53
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