Next Generation

MV Drive
2
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
OEMs

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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
Petrochemical
Pipeline pumps
Gas compressors
Brine pumps
Mixers / extruders
Electrical submersible pumps
Induced Draft Fans
Boiler feed water pumps

Cement
Kiln induced draft fans
Forced draft fans
Cooler baghouse fans
Preheat tower fans
Raw mill induced draft fans
Kiln gas fans
Cooler exhaust fans
Seperator fans
Baghouse fans
Forest Products
Fan pumps
Induced draft fans
Boiler feed water pumps
Pulpers
Refiners
Kiln drives
Line shafts

Water / Waste Water
Raw sewage pumps
Bio-roughing tower pumps
Treatment pumps
Freshwater pumps
Miscellaneous
Test stands
Wind tunnels
Agitators
Rubber mixers
Mining & Metals
Slurry pumps
Ventilation fans
De-scaling pumps
Conveyors
Baghouse fans
Cyclone feed pumps


Electric Power
Feed water pumps
Induced draft fans
Forced draft fans
Baghouse fans
Effluent pumps
Compressors
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Product Power Ratings
0
500
1000
1500
2000
2500
3000
3500
4000
2300 3300 4160 6600
HP
kWatts
Motor Voltage
V
F
D

P
o
w
e
r

R
a
t
i
n
g
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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
0
5
10
15
20
25
30
35
40
MV SGCT
PowerFlex
Drive
MV IGBT
Drive
MV IGCT
Drive
LV IGBT
Drive
6
18
36
12
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 Drive
Control Boards
Identical 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 and
troubleshooting.
Robust AC/DC power
supplies with
optional 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 semiconductors
reduce 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 standard
for 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 SGCT MV GTO MV IGBT MV IGCT LV IGBT
Conduction Losses Low Low High Low Medium
Switching Losses Low Low Medium Low Low
Switching Frequency High Low High High High
PIV Rating (Volts) 6500 6500 3300 6500 1700
Gate Drive Integrated Separate Synch. with IGBT Integrated Synch. with IGBT
Failure Rate Low Low High Low Low
Failure Mode No-rupture, no-arc No-rupture, no-arc rupture, arc No-rupture, no-arc rupture, arc
Cooling Double sided Double sided single sided Double sided single sided
Thermal Stress Low Low High Low High
Parts Count Low Medium Medium-High Medium Very High
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 Rectifier
VFD 0.98 0.98 0.98 0.975 0.975
Rectifier Duty Transformer 0.985 0.985 0.985
Line Reactor 0.995 0.995
System 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 Voltage
Tolerance
+ / - 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 reliability
Greater ease of use
Lower total cost of ownership
Summary