Next Generation MV Drive

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PowerFlex 7000 Overview

• General purpose stand alone MV drive– Controls speed, torque, direction, starting, stopping of induction or

synchronous motors• Global product

– IEC / NEMA / UL / CSA– 2400-6600 Volts

• Focus on high reliability, ease of use, lower total cost of ownership• Target audience

– Industrial / commercial users– Consultants– OEM’s

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Benefits of MV Drives

• Reduce costs– energy savings on fans, pumps, compressors– reduced maintenance costs on mechanical equipment– increase life of mechanical equipment

• 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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Target Industries / Applications

PetrochemicalPipeline pumpsGas compressorsBrine pumpsMixers / extrudersElectrical submersible pumpsInduced Draft FansBoiler feed water pumps

CementKiln induced draft fansForced draft fansCooler baghouse fansPreheat tower fansRaw mill induced draft fansKiln gas fansCooler exhaust fansSeperator fansBaghouse fans

Forest ProductsFan pumpsInduced draft fansBoiler feed water pumpsPulpersRefinersKiln drivesLine shafts

Water / Waste WaterRaw sewage pumpsBio-roughing tower pumpsTreatment pumpsFreshwater pumps

MiscellaneousTest standsWind tunnelsAgitatorsRubber mixers

Mining & MetalsSlurry pumpsVentilation fansDe-scaling pumpsConveyorsBaghouse fansCyclone feed pumps

Electric PowerFeed water pumpsInduced draft fansForced draft fansBaghouse fansEffluent pumpsCompressors

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Product Power Ratings

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Advanced CSI-PWM Technology

• Simple, reliable power structure

– easy to series devices

• Fuseless• Low component count• Inherent regeneration• SGCT inverter switch• SCR or SGCT rectifier switch

M

SGCT Inverter

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Symmetrical Gate Commutated Thyristor (SGCT)

• Modified GTO with integrated gate drive

• Gate drive close to the device creates low inductance path– more efficient and uniform gating

• Low conduction & switching losses• Low failure rate

– 100 failures per billion hours operation

• Double sided cooling

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• SGCT blocks voltage in forward & reverse directions up to 6500V, current flow in 1 direction only

• Non-Punch-Through structure• Symmetrical pnp transistor in the wafer• Significant advantages

– Simplification or elimination of snubber components– operation at a higher switching frequency, hence reducing the size of

passive components (by 50%) and improving performance of the drive– reduction of component count, hence improving reliability, cost, and size of

the drive.

SGCT Symmetrical Gate Commutated Thyristor (SGCT)

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High Reliability

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18

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Inverter Power Device Component Count

Best Components X Fewest Components = Highest Reliability

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MV Drive Topology Comparison

PowerFlex 7000 PWM •SGCT inverter switch•Low component count•Simple power structure

VSI-PWM 3 Level •IGCT or MV IGBT inverter switch•Medium component count•Power structure complex due to series and parallel diodes required for 3 level

VSI-PWM Multi-Level (Series Cell) •LV IGBT inverter switch•Very high component count. •Very Complex power structure and transformer configuration

Simple Complex Very Complex

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Patented* Power Cage

• Houses main power components

• Compact, modular package• Common design for rectifier

& inverter modules

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Easy to Service

• Front access • Component replacement in

less than 5 minutes• no special tools required

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PowerFlex 7000 MV DriveControl BoardsIdentical line and machine side control boards used for asynchronous and synchronous drives.• Floating point Digital Signal Processors (DSP).• Field Programmable Gate Arrays (FPGA) used for advanced logic.• External I/O with 24 digital inputs and 24 digital outputs.

Operator interface terminal with 16-line, 40-character LCD display for easy set-up, monitoring andtroubleshooting.

Robust AC/DC power supplies withoptional redundancy.

Low voltage swing out tub for access to cable connection assembly and motor filter capacitor

Rugged DC link inductor limits fault current and eliminates nuisance trips.

A compact enclosure saves on valuable floor space. Rear access not required

6.5 kV SGCT power semiconductorsreduce parts count and increase reliability.

Integral cooling fan provides efficient heat transfer from power components.

PowerCage modules on the rectifier and inverter reduce manufacturing time and allow easy access to main power components for quick replacement.

6-Pulse, 18-Pulse, or PWM rectifiers available as standardfor greater flexibility in meeting power quality needs.

Common gate drive power supply module reduces parts count and lowers overall cost

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MV Power Semiconductor Comparison

SGCT- The Ideal Switch for MV Drives

Symmetrical Gate Commutated Thyristor (SGCT)

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6 Pulse Rectifier with Optional Filter

18 Pulse Rectifier

PWM Rectifier with AC Line Reactor

Lower Harmonics without Increasing Complexity• 6 pulse rectifier with optional filter

– most economical– ideal when VFD is small percentage of total plant load– available with transformer or AC line reactor

• elimination of transformer on new motor applications – highest efficiency, smallest footprint, low total cost of ownership

• 18 pulse rectifier– Meets IEEE 519-1992 Harmonic Guidelines– Low complexity & component count compared to other 18 pulse

solutions• series rectifiers• only 3 secondary windings on transformer

– Most common solution• PWM rectifier

– Meets IEEE 519-1992 Harmonic Guidelines– Near unity PF on variable torque loads– Optimum drive performance– Available with transformer or line reactor

• elimination of transformer on new motor applications – highest efficiency, smallest footprint, low total cost of ownership

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Line Friendly

• 18 Pulse and PWM rectifier meet IEEE 519 Harmonic Guidelines without filters or additional complexity

• Typically, no harmonic analysis required

• Specify 18 pulse minimum– some competitor use 12 pulse

only with high impedance(12-14%) transformer

• low harmonics, poor efficiency

Typical input waveforms (18 Pulse Rectifier)

@ full load, full speed

Line current 4.6% THD (top)

Line voltage 2.0% THD (bottom)

4160V, 933kW, 60 Hz

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Motor Friendly

• Near sinusoidal current and voltage @ all speeds and loads

– no additional motor heating or voltage stress to insulation compared to sine wave operation

• Compatible with standard motors– induction or synchronous motors– no de-rating – inverter duty motor not required– new or retrofit applications

• Virtually unlimited motor cable distance

– stable operation up to 15 Km– no capacitive coupling or dv/dt issues

Typical motor waveforms @ full load, full speed

•4160V, 933 kW, 60 Hz

•Top - Motor Voltage

•Bottom - Motor Current

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Typical Drive & System Efficiency*

6 Pulse 6 Pulse 18 Pulse PWM Rectifier PWM RectifierVFD 0.98 0.98 0.98 0.975 0.975Rectifier Duty Transformer 0.985 0.985 0.985Line Reactor 0.995 0.995System Efficiency 0.9653 0.9751 0.9653 0.9701 0.9604

* Efficiency at full load, full speed

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Control Enhancements

• Common control boards– for inverter / rectifier– for induction / synchronous drive– for 6- / 18-pulse / PWM rectifiers

• Floating point digital signal processors (DSP)

– provides high speed internal processing capabilities resulting in a higher degree of speed response to variations in the end process

• Field programmable gate arrays ( FPGA)

– result in higher speed handling of diagnostics and fault handling routines previously handled by software

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• Remote I/O• DeviceNet• ControlNet• DPI protocol• SCANPort /DPI

connectivity

Embedded Communication Options

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Control Enhancements• Common control boards for inverter / rectifier

– common for induction / synchronous drive– common for 6 pulse / 18 pulse / PWM rectifiers– floating point Digital Signal Processors (DSP)– Field Programmable Gate Arrays ( FPGA) used for advanced logic

• PWM gating• protection• digital I/O• synchronous transfer

• Drive Identity Module will capture order data from business systems– provides info to firmware about specific order hardware (hp, voltage, rectifier type,

dc link, capa, etc)

• Rugged AC/DC power supplies with optional redundancy• 3 phase control power

– 208-480 Volts for cooling fans supplied by customer– 208-230 Volts for AC/DC from fan power with step-down transformer (if required)

• 5 cycle ride-through is standard– optional extended ride-through with UPS

• Commonality with Mequon standard drives

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User Friendly Operator Interface

• Modified PV550 terminal with unique bootcode and functionality for PowerFlex 7000

• 16 line, 40 character LCD display• Start-up wizard

– prompts user through set-up, operation and trouble shooting

• Bar type LCD metering– speed – load– voltage

• Auto tuning• Test modes• Trending

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Specifications

Design Standards CSA, UL, IEC, IEEE, NEMA, ANSI

Inverter Type PWM

Power Rating 373-3000 kW (500-4000 hp)

Motor Type Asynchronous, Synchronous

Input VoltageTolerance

+ / - 10 % of Nominal Line Voltage

Input Frequency 50 / 60 Hz, +/- 10%

Output Voltage Rating 0 – 2300, 0 – 3300, 0 – 4160, 0 – 6,600

Output Frequency 0 – 75 Hz

Output Waveform Near Sinusoidal Current & Voltage

Rectifier Designs 6 / 18 Pulse, PWM- Active Front End

Input Protection Metal Oxide Varistors

Efficiency > 98.0%

Availability > 99.9%

Modulation Technique Pulse Width Modulation (PWM) / Selective Harmonic Elimination (SHE)

Control Method Sensorless Direct Vector

(Full Vector Control Optional)

Tuning Method Automatic Self Tuning Control

Overload Capability 110 % - 1 Minute / 150% - 1 Minute

Speed Regulation 0.5% Open Loop

0.1% with Shaft Encoder

Operator Interface 40 Character / 16 Line – LCD

Control Power 208-480V 3 Phase, 50/60 Hz

Analog Inputs (1) Isolated, (3) Non-isolated 4 – 20 Ma / 0 – 10 V

Control I/O 24 Digital Inputs / 24 Digital Outputs

Communication Interface.

RS – 232, Remote I/O, DeviceNet, ControlNet

Enclosure IEC Type IP42 (NEMA 1with gasket)

Ambient Temp. 0 – 40 Deg. C

Cooling Forced Air

Relative Humidity

95% Non – condensing

Altitude 1000 M above sea level without de rating

Paint Powder Epoxy

Analog Outputs (1) Isolated, (7) Non-isolated 4 – 20 Ma / 0 – 10 V

Inverter Switch SGCT

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Availability

Available for sale• January 2000:

Release for Shipment• July 2000:

– 6 and 18 pulse configurations– Induction motor drive

• October 2000– PWM configurations– Synchronous motor drive

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High reliabilityGreater ease of use Lower total cost of ownership

Summary