Medium Voltage
AC Drive
Technical Data
Guide
www.abpowerflex.com
PowerFlex 7000
Technical Data Guide
1
TABLE OF CONTENTS
1.
Overview of Drive ...................................................................................................................................3
1.1 Introduction .....................................................................................................................................3
1.2 Benefits of MV Drives .....................................................................................................................3
1.3 Applications.....................................................................................................................................4
1.4 Topology .........................................................................................................................................5
1.5 Rectifier Designs.............................................................................................................................6
1.6 Motor Compatibility .........................................................................................................................9
1.7 SGCT Features.............................................................................................................................10
2.
Control Overview..................................................................................................................................11
2.1 Direct Vector .................................................................................................................................11
2.2 Control Hardware..........................................................................................................................12
2.3 Operator Interface.........................................................................................................................13
2.4 Simplified Electrical Drawings – 2400V ........................................................................................15
2.5 Simplified Electrical Drawings – 3300V / 4160V...........................................................................16
2.6 Simplified Electrical Drawings – 6600V ........................................................................................17
3.
MV Drive Selection Explanation...........................................................................................................18
3.1 Drive Service Duty ........................................................................................................................18
3.2 Service Duty Rating, Continuous Current Rating, & Altitude Rating Code...................................18
3.3 Typical Application Load Torque Profiles .....................................................................................20
4.
Drive Ratings........................................................................................................................................21
4.1 2400 Volt .......................................................................................................................................21
4.2 3300 Volt .......................................................................................................................................22
4.3 4160 Volt .......................................................................................................................................23
4.4 4160 Volt .......................................................................................................................................24
4.5 6600 Volt .......................................................................................................................................25
4.6 Drive Options, Modifications and Accessories .............................................................................26
4.7 Tachometer Requirements ...........................................................................................................30
4.8 Tachometer Specifications ...........................................................................................................31
4.9 Dimensions and Weights of the PowerFlex™ 7000 Air Cooled Drive ..........................................32
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PowerFlex 7000
Technical Data Guide
2
5.
PowerFlex™ 7000 Dimensional Drawings............................................................................................33
6.
Hardware Description...........................................................................................................................45
6.1 Air Flow Pattern for PowerFlex™ 7000 from Inverter / Converter to DC Link / Fan Cabinet .......51
6.2 Air Flow Requirements* ................................................................................................................52
6.3 Air Filter Collection Efficiency .......................................................................................................52
6.4 PowerFlex™ 7000 Typical Losses (Includes Fan Losses and Control Circuit Power Supplies)...53
6.5 General Design Specifications......................................................................................................54
6.6 Typical Auxiliary Equipment..........................................................................................................56
7.
APPENDIX A : Full Load Currents of 3-phase, 50/60 Hz Medium Voltage AC Induction
Motors ..................................................................................................................................................61
8.
APPENDIX B : Transformer Secondary Winding Insulation Levels Table ..........................................62
9.
APPENDIX C : Applicable Requirements of MV Controllers ...............................................................63
9.1 Critical Standards..........................................................................................................................63
9.2 Components Standards ................................................................................................................63
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
3
1. Overview of Drive
1.1
Introduction
The PowerFlex™ 7000 represents the third generation of
medium voltage drives at Rockwell Automation. The
PowerFlex™ 7000 medium voltage AC drive is part of the
PowerFlex™ family of AC drive products. The Allen-Bradley
PowerFlex™ Family of Drives incorporates leading-edge
technology, embedded communications, and significant
commonality across multiple platforms, networks, operator
interface programming and hardware. Designed for end-users,
solution providers and OEMs, PowerFlex™ 7000 air-cooled
drives meet applications ranging from fractional to 5,500
horsepower.
The PowerFlex™ 7000 is a general purpose, stand-alone
medium voltage drive that controls speed, torque, direction,
starting, and stopping of standard asynchronous or
synchronous AC motors. It is a global product that adheres to
the most common standards from NEC, IEC, NEMA, UL, and
CSA. It is available with the world’s most common supply
voltages at medium voltage, from 2400-6600 volts.
The design focus is on high reliability, ease of use, and lower
total cost of ownership.
1.2
Benefits of MV Drives
1. Reduced costs
energy savings on fans, pumps, compressors
reduced maintenance costs on mechanical equipment
increase life of mechanical equipment
2. Improved process control
increase productivity
greater flexibility
environmental compliance
3. Starting large motors on weak power systems
eliminate voltage flicker
reduce inrush current
higher starting torque than reduced voltage starter
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PowerFlex 7000
Technical Data Guide
4
1.3
Applications
The PowerFlex 7000™ is intended for use on a host of
standard and specialty applications in many different
industries:
Petrochemical
Forest Products
• Pipeline pumps
• Gas compressors
• Brine pumps
• Mixers/extruders
• Electric submersible pumps
• Induced draft fans
• Boiler feed water pumps
• Fan pumps
• Induced draft fans
• Boiler feed water pumps
• Pulpers
• Refiners
• Kiln drives
• Line shafts
Mining & Metals
Cement
• Slurry pumps
• Ventilation fans
• De-scaling pumps
• Conveyors
• Baghouse fans
• Cyclone feed pumps
• Ball mills
• Sag mills
• Kiln induced draft fans
• Forced draft fans
• Cooler baghouse fans
• Preheat tower fans
• Raw mill induced draft fans
• Kiln gas fans
• Cooler exhaust fans
• Separator fans
• Baghouse fans
• Ball Mills
• Vertical roller mills
• Kilns
Water/Waste Water
• Raw sewage pumps
• Bio-roughing tower pumps
• Treatment pumps
• Freshwater pumps
Miscellaneous
• Test stands
• Wind tunnels
• Agitators
• Rubber mixers
7000-TD200A-EN-P – October 2001
Electric Power
• Feed water pumps
• Induced draft fans
• Forced draft fans
• Baghouse fans
• Effluent pumps
• Compressors
PowerFlex 7000
Technical Data Guide
1.4
5
The PowerFlex™ 7000 utilizes a Pulse Width Modulated
(PWM) – Current Source Inverter (CSI) for the machine side
converter as shown in Figure 1.1. This topology offers a
simple, reliable, cost-effective power structure that is easy to
apply to a wide voltage and power range. Power semiconductor
switches are easy to series for any medium voltage level.
Semiconductor fuses are not required for the power structure
due to the current limiting DC link inductor.
Topology
With 6500 volt PIV rated power semiconductor devices, the
number of inverter components is kept to a minimum. For
example, only six inverter switching devices are required @
2400V, 12 @ 3300-4160V, and 18 @ 6600V.
The PowerFlex™ 7000 has the additional benefit of inherent
regenerative braking for applications where the load is
overhauling the motor, or where high inertia loads need to be
slowed down quickly. Symmetrical Gate Commutated
Thyristors (SGCTs) are used for machine converter switches.
Silicon-controlled rectifiers (SCRs) (for 6/18 pulse) or SGCTs
(for PWM rectifier) are used for the line converter switches.
LINE CONVERTER
DC LINK
L+
SGCT’s
LR
MACHINE CONVERTER
M+
SGCT’s
2U (X1)
U (T1)
1V
2V (X2)
V (T2)
1W
2W (X3)
W (T3)
1U
L-
M-
Figure 1.1 – PWM-CSI AC Drive
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PowerFlex 7000
Technical Data Guide
6
1.5
Rectifier Designs
There are three standard designs for the front-end rectifier of
the drive, all of which meet the recommended IEEE-519
harmonic guideline requirements.
6-Pulse Rectifier
A 6-pulse thyristor phase controlled rectifier with passive
tuned filters is shown in Figure 1.2. The line current before and
after the filter is shown. It can be seen that the current before
the filter contains the 5th, 7th and 11th harmonics, however, the
current after the filter is more sinusoidal since these harmonics
are redirected through the tuned filters. The tuned filters also
serve to improve input power factor to near unity. The total
harmonic distortion (THD) of line current with the 6-pulse
rectifier and tuned filters is approximately 5.2%. The THD of
line voltage (line to line) is approximately 2.6%. THD values
with tuned filters are power system dependant.
The 6-pulse rectifier can be used in conjunction with a
rectifier duty isolation transformer as shown or with an AC line
reactor. A rectifier duty isolation transformer is required when
the drive is being applied to existing or retrofit motors or when
the supply voltage is higher than the drive rated voltage. (Refer
to Specification 80001-005, Rectifier Duty Transformers for
more details on transformer requirements and features.)
An AC line reactor can be used in front of the 6-pulse rectifier
when the drive is being applied to new motors. (Refer to
Specification 80001-004, Stator Insulation Requirements for
MV Motors Applied to MV Drives with Line Reactor Option).
Elimination of the isolation transformer reduces capital and
installation costs, saves on valuable floor space, and increases
overall system efficiency.
a)
b)
c)
Figure 1.2 – 6-pulse Rectifier with input waveforms
a) Line current before the filter
b) Line current after the filter
c) Line-to-line voltage at point of common coupling (PCC)
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PowerFlex 7000
Technical Data Guide
7
18-Pulse Rectifier
An 18-pulse phase controlled rectifier is shown in Figure 1.3.
In an 18-pulse configuration, the IEEE-519 requirements are
met without the need for passive filters. A multi-winding
isolation transformer is required to mitigate the low order
harmonics by phase shifting principles. The 18-pulse solution is
superior to 6- or 12-pulse offerings in terms of lowering line
side harmonics.
The isolation transformers are available in both indoor dry type
and outdoor oil-filled designs for maximum flexibility in dealing
with floor space, installation costs, and control room air
conditioner loading. (Refer to Specification 80001-005,
Rectifier Duty Transformers, for more details on transformer
requirements and features.)
The line current and voltage are also shown in Figure 1.3. The
THD of line current shown is approximately 5.6%, while the
THD of line voltage (line to line) shown is approximately
2.0%. The 18-pulse rectifier consists of one master bridge and
two slave bridges and will always have a total of 18 SCR
switching devices.
a)
b)
Figure 1.3 – 18-pulse Rectifier and its input waveforms
a) Line current
b) Line-to-line voltage at point of common coupling (PCC)
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
8
PWM Rectifier (Active Front-End)
An active front-end suitable for the PowerFlex™ 7000 topology
is called a PWM rectifier. This is particularly attractive for
applications with new motors since it does not require an
isolation transformer to meet IEEE-519. (See Specification
80001-004, Stator Insulation Requirements for MV Motors
Applied to MV Drives with Line Reactor Option). Most
available technologies in today’s MV market require a multiwinding transformer to mitigate the unwanted harmonics
through cancellation by phase shifting the transformer
secondary windings. Depending on the topology, the
transformer can have up to 15 sets of secondary windings.
Elimination of the isolation transformer reduces capital and
installation costs, saves on valuable floor space, and increases
overall system efficiency.
The PWM rectifier requires a switching pattern that complies
with similar rules as the inverter. The pattern used for the
example shown in Figure 1.4 is a 7-pulse selective harmonic
elimination (SHE) pattern, which 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 300 Hz 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.
a)
b)
Figure 1.4 – PWM rectifier (active front-end) and its input current/voltage waveforms
a) Line current
b) Line-to-line voltage at PCC
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PowerFlex 7000
Technical Data Guide
9
The small AC line reactor (see Fig. 1.4) provides additional
filtering and current limiting features to a line side short circuit
fault. The line current and voltage waveforms are shown in
Figure 1.4. The line current THD shown is approximately
4.5%, while line-to-line voltage THD shown is approximately
1.5%. Input power factor with the PWM rectifier is near unity
from 30-100% load, when applied to variable torque loads.
1.6
Motor Compatibility
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 °C higher compared
to across-the-line operation. Dv/dt in the voltage waveform is
less than 10 volts / microsecond. The peak voltage that the
motor insulation will see is the rated motor RMS voltage
divided by 0.707. Reflected wave and dv/dt issues often
associated with VSI (voltage source inverter) drives are a nonissue with the PowerFlex™ 7000. Typical motor waveforms are
shown in Figure 1.5. These 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 harmonics at higher speeds.
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 15 km away from the drive.
Arms
300.00
200.00
Motor current
100.00
0.00
-100.00
-200.00
-300.00
Vrms
10.00K
7.50K
Motor voltage
5.00K
2.50K
0.00K
-2.50K
-5.00K
-7.50K
-10.00K
100.00
110.00
120.00
TIME (ms)
130.00
140.00
150.00
Figure 1.5 – Motor waveforms @ full load, full speed
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PowerFlex 7000
Technical Data Guide
10
1.7
SGCT Features
and Benefits
An SGCT is a modified gate turn-off thyristor (GTO) with an
integrated gate drive. Positioning the gate drive close to the
SGCT as shown in Figure 1.6, creates a low inductance path
that provides more efficient and uniform gating of the device.
As a result, the device is better suited than a conventional GTO
to handle the fluctuating levels of voltage and current while it
is switching on and off during gating.
An SGCT has similar characteristics to an IGCT (used on VSI3 level drives), including low conduction and switching losses,
low failure rate, and double sided cooling for low thermal
stress. However, the SGCT achieves voltage blocking
capability in both forward and reverse directions up to 6500
volts by a NPT (Non-Punch-Through) structure and nearly
symmetrical pnp transistor in the wafer, while the current is
unidirectional.
The IGCT only blocks voltage in one direction and allows
current flow in both forward and reverse direction, thus needs a
built-in anti-parallel diode.
Implementing SGCTs in the PowerFlex™ 7000 results in
significant advantages including:
1. Simplification of the snubber design and a reduction in the
size of the snubber capacitor by a factor of 10.
2. Operation at a higher switching frequency (420-540 Hz),
hence reducing the size of passive components (DC link
inductor and motor filter cap) by 50%.
3. Improved performance of the drive.
4. Reduction of component count, hence improving
reliability, cost, and size of the drive.
5. Ease of service.
CATHODE
GATE
nE
pB
nB
pE
ANODE
Figure 1.6 – SGCT with integrated gate drive (left) and unit cell structure (right).
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
11
2. Control Overview
LINE CONVERTER
MACHINE CONVERTOR
DC LINK INDUCTOR
MOTOR
MOTOR
FILTER
CAPACITOR
FAULTS
CURRENT
CONTROL
LINESYNCH
Idc REF
MACHINE
GATING AND
DIAGNOSTIC
FEEDBACK
MACHINE
CONVERTER
PROTECTION
(HW)
MACHINE
CONVERTER
FEEDBACK
FAULTS
REF.
CURRENT AND
PHASE SHIFT
MAG. CURRENT
REGULATOR
COMMAND
MACHINE
CONVERTER
PROTECTION
(SW)
SLIP FREQ.
MOTOR
MODEL
FLUX
STATOR FREQ.
TACH. FEEDBACK
LINE
CONVERTOR
PROTECTION
MACHINE
SIDE
CONTROL
FAULTS
LINE
SIDE
CONTROL
SYNC. ANGLE
LINE GATING
AND
DIAGNOSTIC
FEEDBACK
MACHINE CONVERTER
FIRING ANGLE
LINE
CONVERTER
PROTECTION
(HW)
LINE CONVERTER FIRING ANGLE
LINE
CONVERTER
FEEDBACK
SPEED
COMMAND
SPEED FEEDBACK
FLUX
CONTROL
TORQUE
SPEED
CONTROL
SPEED REF.
SKIP SPEED
AND SPEED
RAMP
TORQUE CURRENT COMMAND
SYNCH.
TRANSFER
Figure 1.7 – PowerFlex™ 7000 Function Block Diagram
2.1
Direct Vector Control
The method of control in the PowerFlex™ 7000 medium
voltage AC drive is called sensorless direct vector control,
meaning that the stator current is divided into torque producing
and flux producing components, allowing the motor torque to
be changed quickly without affecting motor flux. This method
of control is used without tachometer feedback for applications
requiring continuous operation above 6 Hertz and less than
100% starting torque.
Full vector control can also be achieved with tachometer
feedback for applications requiring continuous operation down
to 0.2 Hertz with up to 150% starting torque. Vector control
offers superior performance over volts/hertz type drives. The
speed bandwidth range is 5-25 radians per second, while the
torque bandwidth range is 15-50 radians per second.
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
12
2.2
Control Hardware
The control hardware includes identical drive control boards
for machine and line side complete with up to three fiber optic
interface boards (depending on the voltage and number of
switching devices), signal conditioning boards for machine and
line side, customer interface board and external I/O board. The
common drive control boards are used for the rectifier and
inverter, induction or synchronous drive control, and the three
rectifier types (6 / 18 Pulse, or PWM Rectifier).
The drive control boards feature a floating point digital signal
processor and field programmable gate arrays for advanced
functions such as gating and diagnostics, fault handling, and
drive synchronization control.
SIGNAL
CONDITIONING
BOARD
MACHINE
SIGNAL
CONDITIONING
BOARD
LINE
FIBRE
OPTIC
BOARD
FIBRE
OPTIC
BOARD
FIBRE
OPTIC
BOARD
FIBRE
OPTIC
BOARD
FIBRE
OPTIC
BOARD
FIBRE
OPTIC
BOARD
DRIVE
CONTROL
BOARD
MACHINE
DRIVE
CONTROL
BOARD
LINE
CUSTOMER
INTERFACE
BOARD
EXTERNAL I/O
BOARD
Figure 1.8 – Control Hardware Layout for
™
PowerFlex 7000 (Series B)
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
2.3
13
Operator Interface
™
Figure 1.9 – PowerFlex 7000 Operator interface terminal
The operator interface terminal features a 16-line, 40-character,
pixel based LCD display that makes text and graphics easy to
read. Bar chart meters are configurable for common process
variables including speed, voltage and load. Elapsed time in
hours is also displayed on the main screen.
Everything is user-friendly about the PowerFlex™ 7000
operator interface terminal including the greeting on the
opening screen. The terminal is designed for the greatest ease
of use for start-up, monitoring and troubleshooting. The setup
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 setup wizard, combined
with the auto-tuning feature, allows the drive to be tuned to the
motor and load as quickly and accurately as possible, resulting
in fast start-ups, smooth operation, and less down time.
Up to five test modes are available including low voltage gate
check, and running at full current without motor connected.
Enhanced diagnostic functions are available on the operator
interface terminal including separate fault and warning queues
in non-volatile RAM (NVRAM), extended fault text strings
and on line help, and trend buffers for 8 variables.
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PowerFlex 7000
Technical Data Guide
14
The following operator devices are included as standard on the
low voltage door:
Start Pushbutton
Stop Pushbutton
E-Stop Pushbutton
Speed Potentiometer
Local/Remote Selector Switch
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
2.4
15
Simplified Electrical Drawings – 2400V
LINE CONVERTER
ISTX
DC LINK
MACHINE CONVERTER
M+
L+
4U (Z1)
4V (Z2)
4W (Z3)
SGCT’s
SCR’S
U (T1)
3U (Y1)
3V (Y2)
3W (Y3)
V (T2)
W (T3)
2U (X1)
2V (X2)
2W (X3)
L-
M-
2400 Volt – 18 Pulse
LINE CONVERTER
MACHINE CONVERTER
DC LINK
L+
M+
SCR’s
SGCT’s
2U (X1)
U (T1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
M-
2400 Volt – 6 Pulse
LINE CONVERTER
DC LINK
L+
SGCT’s
LR
MACHINE CONVERTER
M+
SGCT’s
2U (X1)
U (T1)
1V
2V (X2)
V (T2)
1W
2W (X3)
W (T3)
1U
L-
M-
2400 Volt – PWM
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
16
2.5
Simplified Electrical Drawings – 3300V / 4160V
LINE CONVERTER
ISTX
DC LINK
MACHINE CONVERTER
M+
L+
4U (Z1)
4V (Z2)
4W (Z3)
SGCT’s
SCR’s
U (T1)
3U (Y1)
3V (Y2)
3W (Y3)
V (T2)
W (T3)
2U (X1)
2V (X2)
2W (X3)
L-
M-
3300 / 4160 Volt – 18 Pulse
LINE CONVERTER
MACHINE CONVERTER
DC LINK
L+
M+
SGCT’s
SCR’s
2U (X1)
U (T1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
M-
3300 / 4160 Volt – 6 Pulse
LINE CONVERTER
DC LINK
L+
SGCT’s
SGCT’s
LR
MACHINE CONVERTER
M+
2U (X1)
U (T1)
1V
2V (X2)
V (T2)
1W
2W (X3)
W (T3)
1U
L-
3300 / 4160 Volt - PWM
7000-TD200A-EN-P – October 2001
M-
PowerFlex 7000
Technical Data Guide
2.6
17
Simplified Electrical Drawings – 6600V
LINE CONVERTER
ISTX
DC LINK
MACHINE CONVERTER
M+
L+
4U (Z1)
SGCT’s
4V (Z2)
4W (Z3)
SCR’s
U (T1)
3U (Y1)
3V (Y2)
3W (Y3)
V (T2)
W (T3)
2U (X1)
2V (X2)
2W (X3)
L-
M-
6000-6600 Volt – 18 Pulse
LINE CONVERTER
MACHINE CONVERTER
DC LINK
L+
M+
SCR’s
SGCT’s
2U (X1)
U (T1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
M-
6000-6600 Volt – 6 Pulse
LINE CONVERTER
DC LINK
L+
SGCT’s
SGCT’s
LR
MACHINE CONVERTER
M+
2U (X1)
U (T1)
1V
2V (X2)
V (T2)
1W
2W (X3)
W (T3)
1U
L-
M-
6000-6600 Volt - PWM
7000-TD200A-EN-P – October 2001
18
PowerFlex 7000
Technical Data Guide
3. MV Drive Selection Explanation
3.1 Drive Service Duty
The PowerFlex™ 7000 Drive selection and pricing tables are based on two (2) types of drive
service duty ratings:
1. Normal Duty (110% overload for one (1) Minute, once every 10 minutes) – used for
Variable Torque (VT) applications only.
Drives with this rating are designed for 100% continuous operation, with 110% overload for
one (1) minute, once every 10 minutes.
2. Heavy Duty (150% overload for one (1) Minute, once every 10 minutes) – used for
Constant Torque (CT) or Variable Torque (VT) applications.
Drives with this rating are designed for 100% continuous operation, with 150% overload for
one (1) minute, once every 10 minutes.
3.2 Service Duty Rating, Continuous Current Rating, & Altitude Rating Code
There are nine different codes (Refer to table on page 19) that define service duty and altitude in
the drive catalog number.
For example:
Catalog number 7000 – A105DEHD-R18TX, has a continuous current rating of 105 amps, with a
“normal duty” service rating up to 1000 meters altitude.
Catalog number 7000 – B105DEHD-R18TX has a continuous rating of 105 amps with a “normal
duty” service rating up to 5000 meters altitude. Catalog number 7000 – C105DEHD-R18TX, has
a continuous current rating of 105 amps, with a “heavy duty” service rating up to 1000 meters
altitude.
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
Service Duty Rating and
Altitude Rating Code
A = Normal Duty
0-1000 m Altitude (@ 40 C Ambient)
B = Normal Duty
1001-5000 m Altitude (@ Reduced Ambient)
C = Heavy Duty
0-1000 m Altitude (@ 40 C Ambient)
D = Heavy Duty
1001-5000 m Altitude (@ Variable Ambient)
E = Normal Duty
0-1000 m Altitude (@ Variable Ambient)
F = Normal Duty
1001-5000 m Altitude (@ Variable Ambient)
G = Heavy Duty
0-1000 m Altitude (@ Variable Ambient)
19
Continuous Current
Capability
Code
Rating
40
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
430
495
575
657
40 Amp
46 Amp
53 Amp
61 Amp
70 Amp
81 Amp
93 Amp
105 Amp
120 Amp
140 Amp
160 Amp
185 Amp
215 Amp
250 Amp
285 Amp
325 Amp
375 Amp
430 Amp
495 Amp
575 Amp
657 Amp
Type
Air-Cooled
Air and Liquid-Cooled
Liquid-Cooled
H = Heavy Duty
1001-5000 m Altitude (@ Variable Ambient)
Z = Custom Configuration (Contact Factory)
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PowerFlex 7000
Technical Data Guide
20
3.3
Typical Application Load Torque Profiles
Application
Load
Torque
Profile
Load Torque as Percent
of Full-Load Drive Torque
Break-away Accelerating Peak Running
Required Drive
Service
Duty Rating
Tachometer
Required for Extra
Starting Torque?
Agitators
Liquid
Slurry
CT
CT
100
150
100
100
100
100
Heavy
Heavy
Yes
Yes
Damper Closed
Damper Open
VT
VT
30
40
50
110
40
100
Normal
Normal
No
No
Chipper ( Wood) Starting Empty
CT
50
40
200
Contact Factory
No
VT
VT
40
100
100
50
100
100
Normal
Normal
No
Yes
Belt type, loaded
Drag type
Screw type, loaded
CT
CT
CT
150
175
200
130
150
100
100
100
100
Heavy
Contact Factory
Contact Factory
Yes
Yes
Yes
Extruders (Rubber or Plastic)
CT
150
150
100
Contact Factory
Yes
VT
VT
25
25
60
110
50
100
Normal
Normal
No
No
Damper closed
Damper open
VT
VT
25
25
60
200
100
175
Normal
Contact Factory
No
No
Fans ( Propeller, axial flow)
VT
40
110
100
Normal
No
Kilns ( Rotary, loaded)
CT
250
125
125
Contact Factory
Yes
Chemical
Liquid
Slurry
Solids
CT
CT
CT
CT
175
100
150
175
75
100
125
125
100
100
100
175
Contact Factory
Heavy
Heavy
Contact Factory
Yes
Yes
Yes
Yes
Pulper
VT
40
100
150
Contact Factory
No
Centrifugal, Discharge open
Oil field Flywheel
Propeller
Fan Pump
Reciprocating / Positive Displacement
Screw type, started dry
Screw type, primed, discharge open
Slurry handling, discharge open
Turbine, Centrifugal, deep-well
Vane-type, positive displacement
VT
CT
VT
VT
CT
VT
CT
CT
VT
CT
40
150
40
40
175
75
150
150
50
150
100
200
100
100
30
30
100
100
100
150
100
200
100
100
175
100
100
100
100
175
Normal
Contact Factory
Normal
Normal
Contact Factory
Normal
Heavy
Heavy
Normal
Contact Factory
No
Yes
No
No
Yes
No
Yes
Yes
No
Yes
Separators, air ( fan type )
VT
40
100
100
Normal
No
Blowers ( Centrifugal)
Compressors
Axial-vane, Loaded
Reciprocating, start unloaded
Conveyors
Fans ( Centrifugal, ambient)
Damper closed
Damper open
Fans ( Centrifugal, hot gases)
Mixers
Pumps
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
21
4. Drive Ratings
4.1
2400 Volt
Normal Duty Rating for 6-Pulse Rectifiers (Without Line Reactor) and 18-Pulse Rectifiers
Nominal
Line
Voltage
2400
(60Hz)
VFD
Continuous
Current
(Amps)
Nominal
Motor
Kilowatts
Nominal
Motor
Horsepower
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
430
150
168
187
225
261
300
335
373
450
522
600
670
750
933
1120
1300
1500
200
225
250
300
350
400
450
500
600
700
800
900
1000
1250
1500
1750
2000
Structure
Code
(6) Pulse
(18) Pulse
70.1 (6)
70.8 (18)
70.8 (18)
CATALOG NUMBER
Enclosure Type
D = NEMA Type 1 w/gaskets
& vents (IEC IP 21)
7000 - A46DA_D – R_TX
7000 - A53DA_D – R_TX
7000 - A61DA_D – R_TX
7000 - A70DA_D – R_TX
7000 - A81DA_D – R_TX
7000 - A93DA_D – R_TX
7000 - A105DA_D – R_TX
7000 - A120DA_D – R_TX
7000 - A140DA_D – R_TX
7000 - A160DA_D – R_TX
7000 - A185DA_D – R_TX
7000 - A215DA_D – R_TX
7000 - A250DA_D – R_TX
7000 - A285DA_D - R18TX
7000 – A325DA_D - R18TX
7000 - A375DA_D - R18TX
7000 - E430DA_D - R18TX
Normal Duty Rating for 6-Pulse and PWM Rectifiers with Line Reactor
Nominal
Line
Voltage
2400
(60Hz)
VFD
Continuous
Current
(Amps)
Nominal
Motor
Kilowatts
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
150
168
187
225
261
300
335
373
450
522
600
670
750
933
1120
1300
Structure
Nominal
Code
Motor
6-Pulse (6)
Horsepower
PWM
(PWM)
200
225
250
300
350
400
450
500
600
700
800
900
1000
1250
1500
1750
70.14 (6)
70.14(PWM)
70.14(PWM)
CATALOG NUMBER
Enclosure Type
D = NEMA Type 1 w/gaskets
& vents (IEC IP 21)
7000 – A46DA_D – R_LR
7000 – A53DA_D – R_LR
7000 – A61DA_D – R_LR
7000 – A70DA_D – R_LR
7000 – A81DA_D – R_LR
7000 – A93DA_D – R_LR
7000 – A105DA_D – R_LR
7000 – A120DA_D – R_LR
7000 – A140DA_D – R_LR
7000 – A160DA_D – R_LR
7000 – A185DA_D – R_LR
7000 – A215DA_D – R_LR
7000 – A250DA_D – R_LR
7000 – A285DA_D - RPLR
7000 – A325DA_D - RPLR
7000 – E375DA_D - RPLR
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
22
Drive Ratings (continued)
4.2
3300 Volt
Normal Duty Rating for 6-Pulse (Without Line Reactor) and 18-Pulse Rectifiers (cont.)
CATALOG NUMBER
Nominal
Line
Voltage
VFD
Continuous
Current
(Amps)
Nominal
Motor
Kilowatts
Nominal
Motor
Horsepower
3300
(50Hz)
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
430
187
225
261
300
373
410
450
560
600
750
820
933
1120
1300
1500
1865
2050
250
300
350
400
500
550
600
750
800
1000
1100
1250
1500
1750
2000
2500
2750
Structure
Code
(6) Pulse
(18) Pulse
70.10 (6)
70.9 (18)
70.9 (18)
Enclosure Type
D = NEMA Type 1 w/gaskets
& vents (IEC IP 21)
7000 – A46DC_D – R_TX
7000 – A53DC_D – R_TX
7000 – A61DC_D – R_TX
7000 – A70DC_D – R_TX
7000 – A81DC_D – R_TX
7000 – A93DC_D – R_TX
7000 – A105DC_D – R_TX
7000 – A120DC_D – R_TX
7000 – A140DC_D – R_TX
7000 – A160DC_D – R_TX
7000 – A185DC_D – R_TX
7000 – A215DC_D – R_TX
7000 – A250DC_D – R_TX
7000 – A285DC_D - R18TX
7000 – A325DC_D - R18TX
7000 – A375DC_D - R18TX
7000 – E430DC_D - R18TX
Normal Duty Rating for 6-Pulse and PWM Rectifiers with Line Reactor
Nominal
Line
Voltage
VFD
Continuous
Current
(Amps)
Nominal
Motor
Kilowatts
3300
(50Hz)
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
187
225
261
300
373
410
450
560
600
750
820
933
1120
1300
1500
1865
7000-TD200A-EN-P – October 2001
Structure
Nominal
Code
Motor
6 Pulse (6)
Horsepower
PWM
(PWM)
250
300
350
400
500
550
600
750
800
1000
1100
1250
1500
1750
2000
2500
70.15 (6)
70.15(PWM)
70.15(PWM)
CATALOG NUMBER
Enclosure Type
D = NEMA Type 1 w/gaskets
& vents (IEC IP 21)
7000 – A46DC_D – R_LR
7000 – A53DC_D – R_LR
7000 – A61DC_D – R_LR
7000 – A70DC_D – R_LR
7000 – A81DC_D – R_LR
7000 – A93DC_D – R_LR
7000 – A105DC_D – R_LR
7000 – A120DC_D – R_LR
7000 – A140DC_D – R_LR
7000 – A160DC_D – R_LR
7000 – A185DC_D – R_LR
7000 – A215DC_D – R_LR
7000 – A250DC_D – R_LR
7000 – A285DC_D - RPLR
7000 – A325DC_D - RPLR
7000 – E375DC_D - RPLR
PowerFlex 7000
Technical Data Guide
4.3
23
4160 Volt
Normal Duty Rating for 6-Pulse (Without Line Reactor) and 18-Pulse Rectifiers (cont.)
CATALOG NUMBER
Nominal
Line
Voltage
4160
(60Hz)
4160
(50Hz)
VFD
Continuous
Current
(Amps)
Nominal
Motor
Kilowatts
Nominal
Motor
Horsepower
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
430
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
430
261
300
335
373
450
522
600
671
750
933
1082
1120
1500
1680
1865
2240
2600
261
300
335
373
450
522
600
671
750
933
1082
1120
1500
1680
1865
2240
2600
350
400
450
500
600
700
800
900
1000
1250
1450
1500
2000
2250
2500
3000
3500
350
400
450
500
600
700
800
900
1000
1250
1450
1500
2000
2250
2500
3000
3500
Structure
Code
(6) Pulse
(18) Pulse
70.2 (6)
70.8 (18)
70.10 (6)
70.8 (18)
70.8 (18)
70.9 (18)
70.10 (6)
70.9 (18)
70.9 (18)
Enclosure Type
D = NEMA Type 1 w/gaskets
& vents (IEC IP 21)
7000 – A46DE_D – R_TX
7000 – A53DE_D – R_TX
7000 – A61DE_D – R_TX
7000 – A70DE_D – R_TX
7000 – A81DE_D – R_TX
7000 – A93DE_D – R_TX
7000 – A105DE_D – R_TX
7000 – A120DE_D – R_TX
7000 – A140DE_D – R_TX
7000 – A160DE_D – R_TX
7000 – A185DE_D – R_TX
7000 – A215DE_D – R_TX
7000 – A250DE_D – R_TX
7000 – A285DE_D – R18TX
7000 – A325DE_D – R18TX
7000 – A375DE_D – R18TX
7000 – E430DE_D – R18TX
7000 – A46DE_D – R_TX
7000 – A53DE_D – R_TX
7000 – A61DE_D – R_TX
7000 – A70DE_D – R_TX
7000 – A81DE_D – R_TX
7000 – A93DE_D – R_TX
7000 – A105DE_D – R_TX
7000 – A120DE_D – R_TX
7000 – A140DE_D – R_TX
7000 – A160DE_D – R_TX
7000 – A185DE_D – R_TX
7000 – A215DE_D – R_TX
7000 – A250DE_D – R_TX
7000 – A285DE_D – R18TX
7000 – A325DE_D – R18TX
7000 – A375DE_D – R18TX
7000 – E430DE_D – R18TX
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
24
Drive Ratings (continued)
4.4
4160 Volt
Normal Duty Rating for 6-Pulse and PWM Rectifiers with Line Reactor
CATALOG NUMBER
Nominal
Line
Voltage
4160
(60Hz)
4160
(50Hz)
VFD
Continuous
Current
(Amps)
Nominal
Motor
Kilowatts
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
261
300
335
373
450
522
600
671
750
933
1082
1120
1500
1680
1865
2240
261
300
335
373
450
522
600
671
750
933
1082
1120
1500
1680
1865
2240
7000-TD200A-EN-P – October 2001
Nominal Structure Code
Motor
Horsepower
6 Pulse (6)
PWM (PWM)
350
400
450
500
600
700
800
900
1000
1250
1450
1500
2000
2250
2500
3000
350
400
450
500
600
700
800
900
1000
1250
1450
1500
2000
2250
2500
3000
70.16 (6)
70.16(PWM)
70.15 (6)
70.16(PWM)
70.15(PWM)
70.15 (6)
70.15(PWM)
70.15(PWM)
Enclosure Type
D = NEMA Type 1 w/gaskets
& vents (IEC IP 21)
7000 – A46DE_D – R_LR
7000 – A53DE_D – R_LR
7000 – A61DE_D – R_LR
7000 – A70DE_D – R_LR
7000 – A81DE_D – R_LR
7000 – A93DE_D – R_LR
7000 – A105DE_D – R_LR
7000 – A120DE_D – R_LR
7000 – A140DE_D – R_LR
7000 – A160DE_D – R_LR
7000 – A185DE_D – R_LR
7000 – A215DE_D – R_LR
7000 – A250DE_D – R_LR
7000 – A285DE_D – RPLR
7000 – A325DE_D - RPLR
7000 – E375DE_D - RPLR
7000 – A46DE_D – R_LR
7000 – A53DE_D – R_LR
7000 – A61DE_D – R_LR
7000 – A70DE_D – R_LR
7000 – A81DE_D – R_LR
7000 – A93DE_D – R_LR
7000 – A105DE_D – R_LR
7000 – A120DE_D – R_LR
7000 – A140DE_D – R_LR
7000 – A160DE_D – R_LR
7000 – A185DE_D – R_LR
7000 – A215DE_D – R_LR
7000 – A250DE_D – R_LR
7000 – A285DE_D – RPLR
7000 – A325DE_D - RPLR
7000 – E375DE_D – RPLR
PowerFlex 7000
Technical Data Guide
4.5
25
6600 Volt
Normal Duty Rating for 6-Pulse (Without Line Reactor) and 18-Pulse Rectifiers
CATALOG NUMBER
Nominal
Line
Voltage
6600
(50Hz)
VFD
Continuous
Current
(Amps)
Nominal
Motor
Kilowatts
40
46
53
61
70
81
93
105
120
140
160
185
215
250
285
325
375
430
400
410
450
560
671
750
895
933
1120
1300
1500
1680
2050
2240
2600
3000
3730
4100
Nominal
Structure
Motor
Code
Horsepower (6) Pulse (18)
Pulse
500
550
600
750
900
1000
1200
1250
1500
1750
2000
2250
2750
3000
3500
4000
5000
5500
70.11 (6)
70.9 (18)
70.9 (18)
70.18 (18)
Enclosure Type
D = NEMA Type 1 w/gaskets
& vents (IEC IP 21)
7000 – A40DJ_D –R_TX
7000 – A46DJ_D – R_TX
7000 – A53DJ_D – R_TX
7000 – A61DJ_D – R_TX
7000 – A70DJ_D – R_TX
7000 – A81DJ_D – R_TX
7000 – A93DJ_D – R_TX
7000 – A105DJ_D – R_TX
7000 – A120DJ_D – R_TX
7000 – A140DJ_D – R_TX
7000 – A160DJ_D – R_TX
7000 – A185DJ_D – R_TX
7000 – A215DJ_D –R18TX
7000 – A250DJ_D –R18TX
7000 – A285DJ_D –R18TX
7000 – A325DJ_D –R18TX
7000 – A375DJ_D –R18TX
7000 – E430DJ_D –R18TX
Normal Duty Rating for 6-Pulse and PWM Rectifiers with Line Reactor
CATALOG NUMBER
Nominal
Line
Voltage
6600
(50Hz)
VFD
Continuous
Current
(Amps)
Nominal
Motor
Kilowatts
Nominal
Motor
Horsepower
40
46
53
61
70
81
93
105
120
140
160
185
215
250
285
400
410
450
560
671
750
895
933
1120
1300
1500
1680
2050
2240
2600
500
550
600
750
900
1000
1200
1250
1500
1750
2000
2250
2750
3000
3500
Structure
Code
6 Pulse (6)
PWM (PWM)
70.17 (6)
70.17(PWM)
70.17(PWM)
70.19(PWM)
Enclosure Type
D = NEMA Type 1 w/gaskets
& vents (IEC IP 21)
7000 – A40DJ_D –R_LR
7000 – A46DJ_D – R_LR
7000 – A53DJ_D – R_LR
7000 – A61DJ_D – R_LR
7000 – A70DJ_D – R_LR
7000 – A81DJ_D – R_LR
7000 – A93DJ_D – R_LR
7000 – A105DJ_D – R_LR
7000 – A120DJ_D – R_LR
7000 – A140DJ_D – R_LR
7000 – A160DJ_D – R_LR
7000 – A185DJ_D – R_LR
7000 – A215DJ_D - RPLR
7000 – A250DJ_D – RPLR
7000 – A285DJ_D - RPLR
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
26
4.6
Drive Options, Modifications and Accessories
Device
Option
Number
Description
1 X➋
1DD X
1M
3FF
Door Mounted
Selector Switches 3LL X
4FF__
Pilot Lights
(Transformer Type) 4M__ ➋
Z
4N__ ➋
13GD1
13GD2
Door Mounted
Push Buttons
Communication
Modules
START, STOP
EMERGENCY STOP (Push-Pull)
JOG
FORWARD-REVERSE
LOCAL-REMOTE
FORWARD-REVERSE
SYSTEM READY
READY,RUN,FAULT,WARNING
Single point Remote I/O interface, panel mounted.
RS232/422/485 (with DF1 Protocol) or DH485, panel mounted.
DeviceNet Network interface, panel mounted. (This option requires 24V DC power via
13GK5
DeviceNet cable.)
Enhanced DeviceNet Network interface, panel mounted. (This option requires 24V DC
13GK6
power via DeviceNet cable.)
13COMMD PowerFlex DeviceNet Adapter mounted on drive Customer Interface Board
13COMMR PowerFlex RIO Adapter mounted on drive Customer Interface Board
13COMMC PowerFlex ControlNet Adapter mounted on drive Customer Interface Board
Prosoft Modbus to ScanPort network interface, panel mounted
13GX1
Prosoft Modbus Plus to ScanPort network interface, panel mounted
13GX2
Prosoft MetaSys to ScanPort network interface, panel mounted
13GX3
Prosoft Profibus-DP to ScanPort network interface, panel mounted
13GX4
PC Card Modem interface mounted on drive Common Interface Board
13MOD
Door Printer
14DP
Redundant Power
Supply
14PS
Redundant Fan
14RF
Provision for
14RD
Ducting Exhaust Air
Extended Ride
14RT2
Through
Customer Supplied
14RT3
UPS
Tachometer
Interface
14TF
Feedback
Isolated
Analog
Signal
Interfaces
➍
14TS1
14TS2
14TS3
14TS4
14TS5
14TS6
Door mounted diagnostic printer.
Spare AC/DC power supply provided and switched on automatically during failure of
standard unit provided with drive. Drive will continue to run with an alarm indication
Redundant cooling fan with automatic switchover in event of main fan failure.
Alarm signal is sent to operator interface terminal. (Overall drive height increases to
119.31” (3030 mm).
Provision for ducting VFD exhaust air outside control room. Customer is responsible for
duct, installation, and required make-up air. Contact factory for specific VFD fan CFM and
static pressure drop requirements.
UPS mounted in VFD control section for extended ride through up to 2 minutes. (Standard
ride through is 5 cycles)
Provision for remote customer supplied UPS for extended ride through.
Tachometer Interface feedback. Note: This option does not include the tachometer.
Customer is responsible for sourcing and mounting the tachometer.
Speed reference input (4-20 mA input signal).
Speed output (4-20 mA output signal).
Voltage output (4-20 mA output signal).
Current output (4-20 mA output signal).
Load (kW) output (4-20 mA output signal).
Torque output (4-20 mA output signal).
L.V. Surge
(1) - Low voltage surge suppressor across each coil in the control circuit, where possible.
17
Suppressor(s)
X These options are defaulted ON automatically as part of standard cluster.
Y Mutually exclusive with 24*ST options.
Z To specify pilot light lens color, add letter(s) to the option number: A = Amber, B = Blue, C = Clear, G = Green, R = Red.
➍ Maximum of 4 isolated outputs allowed. The first one is no charge and can be configured for speed, voltage, current, load or torque.
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
Device
Option
Number
27
Description
24AST
24BST
24CST
24DST
Single motor synchronous transfer control circuit.
Two motor synchronous transfer control circuit.
Drive System
Three motor synchronous transfer control circuit.
See Table below for
Control
operator interfaces
Four motor synchronous transfer control circuit.
Circuits
featured with options
Isolated
bypass
control
circuit
(no
synchronization)
X
24AMB c/w DRIVE-OFF-BYPASS keylock selector switch
24AOP Output contactor control circuit.
X These options do not include appropriate contactors. Refer to Bulletins 1512M or 1512DO.
Drive Control Circuit Features
OPERATOR INTERFACE DESCRIPTION
24AST
24BST
24CST
24DST
DRIVE-OFF-BYPASS keylock selector switch
24AMB
1
DRIVE START illuminated pushbutton (red incandescent)
1
2
3
4
BYPASS START illuminated pushbutton (red incandescent)
1
2
3
4
STOP illuminated pushbutton (green incandescent)
1
2
3
4
BYPASS ENABLE-BYPASS DISABLE Keylock selector switch
(mounted in LV panel)
1
1
1
1
TEST START pushbutton (mounted in LV panel)
1
1
1
1
TEST STOP pushbutton (mounted in LV panel)
1
1
1
1
PILOTLIGHT TEST pushbutton (mounted in LV panel)
1
1
1
1
VFD READY pilot light (blue incandescent)
1
1
1
1
VFD RUN pilot light (red incandescent)
1
1
1
1
FAULT pilot light (red incandescent)
1
1
1
1
WARNING pilot light (amber incandescent)
1
1
1
1
SYSTEM READY pilot light (blue incandescent)
1
1
1
1
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
28
Drive Options, Modifications and Accessories (continued)
Device
Thermistor
Relay
Option
Number
84A1 Y
Tec System
84L__ Y
Temp. Relay ➊
➊
Y
Description
Bulletin 817M manual reset thermistor protection relay.
TecSystem T-538 temperature monitor/controller for use with up to eight (8), three-wire
RTD inputs. Note: A separate channel scanner is not required.
The catalog string number is not complete.
Select the appropriate suffix from Table 2 below to identify the RTD type.
Mutually exclusive with 24*ST options. Motor protection options must be added to each 1512M if required.
Table 2 – RTD Type
RTD Type
Option Number Suffix
(Add to Option Number from above
Table above, e.g. 84FXPA.)
100 Ohm Platinum
10 Ohm Copper
100 Ohm Nickel
120 Ohm Nickel
P
C
N
M
Device
Panel Type
(3-1/2”)
Metering
➊
Option
Number
85MV10
85MV11
Auxiliary Contacts 89D5
Description
Panel mounted analog meters (cluster of 4) including output voltage, output amps (load
current), output % speed, and output kilowatt
Panel mounted analog meters (cluster of 4) including output voltage, output amps (load
current), output (motor) RPM, and output kilowatt
(2) Form ‘C’ auxiliary contacts for remote indication for each of Ready, Run, Fault, and
Warning
Door Mounted
Speed
760A Y 10k ohm, single turn potentiometer for ‘SPEED’ control
Potentiometer
Terminal Blocks 804
Twenty (20) additional unwired terminal blocks
➊ Note: The main menu on the operator interface terminal includes a bar type digital display of the motor RPM, amps, volts and kW.
Only one option selection allowed (85MV10 or 85MV11).
Y This option is defaulted ON automatically as part of standard cluster.
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
Device
High Altitude
Option
Cabinet Space
Heaters
Motor
Space Heater
Circuits
➌
29
Option
Number
Description
3990A
1001-2000 m (3300-6600 ft).
3990B
2001-3000 m (6600-9900 ft).
3990C
3001-4000 m (9900-11200 ft).
3990D
4001-5000 m (11200-16500 ft).
5010D
Cabinet space heater and thermostat supplied in each section of the unit.
Power supplied from an external power source. The wattage depends on
AC voltage, i.e. 85W @110V, 100W @120V, 125W @ 220V.
Option
Number
Heater Circuit
Voltage
5025D
110/120 V
5035D
220/240 V
Power Source
Heater Size
= 2700 watts
External Power
= 2500 watts
Contact Factory for CMOD pricing and dimensions.
Description
Structure Width
Enclosure
Sandtex gray ➊
–
Paint
(Per structure) Y
Special – Customer Specified Color ➊➋
Finish
➊ The low voltage control door and horizontal wireway covers are always painted Sandtex Black.
➋ When special paint is specified, all external surfaces shall be painted. Consult Cambridge to ensure the specified color is available.
The pricing may vary depending upon availability.
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
30
4.7
Tachometer Requirements
When is a tachometer required?
A tachometer is required under the following conditions:
1. When speed regulation accuracy must be between 0.01 – 0.02% of nominal speed.
2. When the zero speed breakaway torque needed is greater than 90% of continuous running
torque.
3. When continuous running speed is greater than or equal to 0.1 Hz, but less than 6 Hz.
4. For minimizing restart times using the flying start capability in forward or reverse direction.
Power Flex Speed Regulation
< 6 Hertz
Not applicable
0.02 %
Without Tachometer
With Tachometer
Frequency Output
6 – 15 Hertz
0.1 %
0.01%
Above 15 Hertz
0.1 %
0.01%
Notes:
5. Speed Regulation is based on % of motor synchronous speed.
6. Tachometer to be mounted on the AC machine
7. Operational 15 V Dc Power Supply mounted in drive to power the tachometer as a standard
option with the tachometer feed back card.
8. Customer is responsible for providing and mounting of tachometer
9. Sleeve bearing motors require the tachometer to have an axial movement tolerance.
10. Recommended tachometers are the shaft mounting type, examples are the Avtron 585 and
685 models or the Northstar (Lakeshore) RIM Tach HS85, 12 to 15V models or equivalent.
Magneto resistive models are more adaptable to harsh environments.
11. When installing, the tachometer body and electronics must be isolated from ground (options
available from the tachometer manufacturer to accomplish this).
12. When cable lengths exceed 1000ft. for the Northstar or 2000ft. for the Avtron consult the
factory.
Tachometer Selection:
Recommended Tach PPR
Motor RPM
3600
3000
1800
1500
1200
1000
900
720
600
7000-TD200A-EN-P – October 2001
Tach ppr
600
600
1024
1024
2048
2048
2048
2048
2048
PowerFlex 7000
Technical Data Guide
4.8
31
Tachometer Specifications
Avtron : 685 Magneto Resistive
ELECTRICAL
Electrical Outputs (continued)
Input Operating Power
Volts(V+):
Current
11.5 VDC to 15.5 VDC
120mA no load, per output. As loads are
added, required current increases. See
following examples for added loads:
Cable impedance switching
examples:
320 mA @ 0.05 uF, 15 VDC, 72 kHz
Differential
15mA @ 0.05 uF, 12VDC, 12
kHz,Single ended
28 mA for Quadrature output into 1K , 15
VDC
+V (OUT) for Alarm 50 mA max.
Square wave from 4428 differential line
driver with transient protection
(+V) – 1.8, min. (0.05 uF, 15VDC, 72
kHz, differential, +V (OUT) @50mA
(+V) – 0.6, max. (0.0 uF, no load)
Note: Does not include cable IR drop
0.12 typical, 0.5 max.
1.5 amps peak, 30 mA average typical
Quadrature square wave, phase A leads
phase B for CW rotation as viewed from
anti-drive end of the motor (tach mounting
end).
50% +/- 5% (Average)
25% +/- 5% (Average)
up to 1200 PPR (see resolution table in the
description section).
Output Example
Alarm example:
Outputs:
Volts, High:
Volts, Low:
Current:
Incremental channel:
Duty cycle:
Transition separation:
Resolution:
Marker channel:
Alarm Output:
+V (OUT):
Refer to Engineering Note 30.
This is a convenience output, internally
jumpered to +V operating voltage. It is
intended for alarm circuits like solid state
relays that can be referenced to +V.
Open collector, sink 100 mA max.,
withstand 50 V max referenced to
common. Output goes low on alarm.
Alarm:
MECHANICAL
Speed range:
Speed range:
0-4500 RPM for base PPR of 480
0-4200 RPM for base PPR of 512
Speed range:
0-3600 RPM for base PPR of 600
Weight:
14 lbs.
Operating temperature
Dust and Water
Once per revolution. Pulse width
approximately 1/3 of base PPR period
ENVIRONMENTAL
-20 C to 71 C
A standard M685 pulse generator is
shipped with a universal breather/drain to
equalize pressure if the M685 is exposed
to tempearture cycles and providea drain
for condensate. The labyrinth design limits
the entry od dust to normally satisfactory
levels, and water spray in any direction
has no harmful effect. In environments with
stable temperatures, the breather may be
replacdwith a ¼” pipe plug – making the
pulse generator water-tight and dust-tight
Features and Specifications subject to change without notice.
Lakeshore/ Northstar 8500
ELECTRICAL
Resolution
MECHANICAL
Maximum operational speed
3,600 RPM
Frequency Response
Pulse Code
Output Pulses
Pulse Duty Cycle
QuadratureAccuracy
60, 64, 75, 120, 128, 150, 240, 256, 300, 480, 480Z,
512, 512Z, 600, 600Z, 960, 960Z, 1024, 1024Z,
1200, 1200Z 2048, 2048Z
0 – 120 kHz
A, B, Z (Index) and complements (A, B, Z)
A phase, B phase, @ quadrature 90
50 +/- 15% (within defined mechanical specifications)
90 +/- 22 (within defined mechanical specifications)
Enclosure material
Radial Runout
Allowable axial movement
Unit Weight
Box dimensions/Weight
Ductile iron casting, steel flanges
.010” (.260 mm) Totai Indicated Runout
0.25” (6.4 mm) max.
25 lbs. Typical (11.4 kg)
33.5” (851 mm) x 23” (585mm) x 7.25”
(185mm)/5.10 lbs. 2.40 kg.
Output Type
Rise and fall time
Current consumption
High speed, differential line driver
Less than 1 s @ 10,000 pf typical load
45mA typical plus line driver load
Power
Output
Output current capability
150 mA maximum continuous
Connector
ESD Protection
2kV
Suggested Cable
Operating Temperature
Operating Humidity
Vibration
Shock
Chemical Resistance
Box dimensions/Weight
-40 to 70 C
Maximum 90%
Minimum 18 g’s RMS, 5 – 2000Hz shock spectrum
1 meter drop tested, min. 30 g’s
Salt spray, most solvents, mild acids and bases
33.5” (851 mm) x 23” (585mm) x 7.25” (185mm)/5.10 lbs. 2.40 kg.
INTERFACE
+5.0 to +15.0 VDC
Differential Output swinging between
Vcc – 0.6V and ground
10 pin industrial latching connector with
½ inch NPT fitting. IP-65 NEMA 4, 12
rated
22 – 14 AWG, 6 conductor, shilded,
twisted pair
ENVIRONMENTAL
Features and Specifications subject to
change without notice.
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
32
4.9
Dimensions and Weights of the PowerFlex™ 7000 Air Cooled Drive
Structure
Code ➊ Y
Dimensions in Inches (mm)
WxHxD Z
70.1
70.2
70.8
70.9
70.10
70.11
70.14
70.15
70.16
70.17
70.18
70.19
94.49 x 104.05 x 39.37 (2400 x 2643 x 1000)
102.36 x 104.05 x 39.37 (2600 x 2643 x 1000)
122.05 x 104.05 x 39.37 (3100 x 2643 x 1000)
129.92 x 104.05 x 39.37 (3300 x 2643 x 1000)
110.24 x 104.05 x 39.37 (2800 x 2643 x 1000)
118.11 x 104.05 x 39.37 (3000 x 2643 x 1000)
129.92 x 104.05 x 39.37 (3300 x 2643 x 1000)
145.67 x 104.05 x 39.37 (3700 x 2643 x 1000)
137.80 x 104.05 x 39.37 (3500 x 2643 x 1000)
153.54 x 104.05 x 39.37 (3900 x 2643 x 1000)
165.36 x 104.05 x 39.37 (4200 x 2643 x 1000)
161.42 x 104.05 x 39.37 (4100 x 2643 x 1000)
Approx.
Weight
lb (kg)
4300 (1955)
4750 (2160)
5800 (2640)
6500 (2955)
5200 (2365)
5550 (2525)
6000 (2727)
7000 (3182)
7000 (3182)
7200 (3272)
7500 (3409)
7300 (3318)
➊ See Drive ratings and related structure codes on previous pages.
Y The structures are available in a NEMA Type 1 with gasket (IP 21) enclosure only. The power cell doors
are vented and an exhaust fan is included inside the structure. (VFD height includes fan housing)
Z When the redundant fan option (-14RF) is included with the unit, the height of the structure changes to
119.31 inches (3030 mm). The structure code also changes (Add suffix “F”, eg 70.1F).
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
33
5. PowerFlex™ 7000 Dimensional Drawings
Figure 5.1 : Structure Code 70.1 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
34
PowerFlex 7000™ Dimensional Drawings (continued)
Figure 5.2 : Structure Code 70.2 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
35
Figure 5.3 : Structure Code 70.8 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
36
PowerFlex 7000™ Dimensional Drawings (continued)
Figure 5.4 : Structure Code 70.9 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
37
Figure 5.5 : Structure Code 70.10 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
38
PowerFlex 7000™ Dimensional Drawings (continued)
Figure 5.6 : Structure Code 70.11 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
39
Figure 5.7 : Structure Code 70.14 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
40
PowerFlex 7000™ Dimensional Drawings (continued)
Figure 5.8 : Structure Code 70.15 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
41
Figure 5.9 : Structure Code 70.16 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
42
PowerFlex 7000™ Dimensional Drawings (continued)
Figure 5.10 : Structure Code 70.17 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
43
Figure 5.11 : Structure Code 70.18 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
44
PowerFlex 7000™ Dimensional Drawings (continued)
Figure 5.12 : Structure Code 70.19 – Dimensional Drawing
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
45
6. Hardware Description
Typical PowerFlex™ 7000 Drive Structure Layout
CABLING CABINET
(6-PULSE RECTIFIER)
CONVERTER
CABINET
DC LINK/FAN
CABINET
™
Figure 6.1 : Power Flex 7000 Drive Enclosure Layout
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
46
Hardware Description (continued)
LEM’s
LOW VOLTAGE WIREWAY
GROUNDING NETWORK
ASSEMBLY
VOLTAGE
SENSING
MODULES
TERMINAL
ASSEMBLY
CUR ENT
CURRENT
TRANSFORMERS
FUSE ASSEMBLIES FOR
TRANSIENT SUPPRESSION
MODULES
CUR ENT
CURRENT
TRANSFORMERS
GROUND BUS
Figure 6.2 : Cabling Cabinet for 18-Pulse Topology – Main Components
(Low Voltage Tub Removed)
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
47
FAN EXHAUST HOOD
325.6 [12.82]
LINE FILTER
CAPACITORS
91.12
[2314]
AC LINE REACTOR
35.43 [900.0]
Figure 6.3 : Line Reactor and Capacitor Cabinet (PWM Rectifier Only) – Main Components
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
48
Hardware Description (continued)
HALL EFFECT SENSORS
GROUNDING
NETWORK
SENSING
BOARDS
POWER
TERMINALS
MOTOR FILTER
CAPACITORS
CURRENT
TRANSFORMERS
TRANSIENT
SUPPRESSION
NETWORK
Figure 6.4 : Cabling Cabinet for Six-Pulse and PWM Topologies – Main Components
(Low Voltage Tub Removed)
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
49
GROUND BUS
DIFFERENTIAL
PRESSURE
SENSOR
INVERTER
MODULES
GATE DRIVER
POWER SUPPLIES
RECTIFIER
MODULES
Figure 6.5 : Convertor Cabinet – Main Components
(2400V version shown)
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
50
Hardware Description (continued)
FAN
EXHAUST
HOOD
GROUND
BUS
3-PHASE
CONTROL
POWER
TRANSFORMER
“HOLD-UP”
CAPACITORS
FUSE
BLOCKS
OR
CIRCUIT
BREAKERS
FAN POWER
DISCONNECT
AC/DC
POWER
SUPPLIES
DC LINK
INDUCTOR
FAN POWER
CABLE ENTRY
(BOTTOM)
Figure 6.6 : DC Link and Fan Cabinet – Main Components
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
6.1
51
Air Flow Pattern for PowerFlex™ 7000
from Converter to DC Link / Fan Cabinet
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
52
6.2
Air Flow Requirements*
Line
Voltage (V)
Frequency
(Hz)
Rectifier
Type
Flow
(m3/h)
Flow
(CFM)
Pressure
(Pa)
Pressure
(inch H2O)
2300
2300
3300
3300
4160
4160
4160
4160
6600
60
60
50
50
50
50
60
60
50
6P or PWMR
18P
6P or PWMR
18P
6P or PWMR
18P
6P or PWMR
18P
6P,PWMR or 18P
4050
6100
6580
7660
6580
7660
6100
6930
8660
2380
3590
3870
4510
3870
4510
3590
4080
5100
900
780
860
830
860
830
780
730
790
3.6
3.1
3.5
3.3
3.5
3.3
3.1
2.9
3.2
*Notes:
1. External ducting must not add more than ( 0.10 inches of water – 25 Pa) to the system output
pressure.
2. The control room must provide at least the same amount make up air for proper ventilation.
The make up air must be filtered and clean to prevent contamination of the drive intake
filters.
3. The make up air must have a temperature between 0-40 degrees C.
4. 5% of drive losses are still rejected to the control room when external ducting is adapted to
the drive.
6.3
Air Filter Collection Efficiency
Particle Size (Microns)
Collection Efficiency (%)
0.7 - 1.0
12.25
1.0 - 2.0
27
2.0 - 3.0
41
3.0- 5.0
43
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
6.4
53
PowerFlex™ 7000 Typical Air Conditioner Loading Requirements
Nominal
Line
Voltage
VFD
Nominal Motor
Continuous
hp
Current (Amps)
120
500
140
600
160
700
185
800
2400 V
215
900
60 Hz
250
1000
285
1250
325
1500
375
1750
430
2000
81
500
93
550
105
600
120
750
140
800
160
1000
3300 V
185
1100
50 Hz
215
1250
250
1500
285
1750
325
2000
375
2500
430
2750
70
500
81
600
93
700
105
800
120
900
140
1000
4160 V
160
1250
50 / 60 Hz
185
1450
215
1500
250
2000
285
2250
325
2500
375
3000
430
3500
40
500
46
550
53
600
61
750
70
900
81
1000
93
1200
105
1250
120
1500
6600 V
140
1750
50 Hz
160
2000
185
2250
215
2750
250
3000
285
3500
325
4000
375
5000
430
5500
Nominal Motor
kw
6 pulse (BTU/hr)
373
450
522
600
670
750
933
1120
1300
1500
373
410
450
560
600
750
820
933
1120
1300
1500
1865
2050
373
448
522
597
671
746
933
1082
1119
1492
1679
1865
2238
2600
373
410
448
560
671
746
895
933
1119
1306
1492
1679
2052
2238
2611
2984
3730
4103
38,213
41,491
44,564
47,126
50,336
51,224
48,403
49,004
50,711
57,370
57,370
66,591
70,005
73,280
84,143
52,224
56,555
60,631
63,178
66,490
68,783
79,610
84,960
80,247
101,901
108,906
121,007
145,208
168,696
64,962
64,452
62,669
70,694
77,954
78,973
85,597
82,794
91,711
98,079
101,901
108,906
126,102
129,923
142,661
163,041
191,064
210,170
VFD Losses
18 Pulse
(BTU/hr)
39,486
44,564
48,130
51,224
54,912
58,907
70,094
84,143
97,666
112,692
45,855
46,204
47,638
55,458
55,321
64,029
67,205
73,280
84,143
93,227
102,447
127,376
140,011
47,129
51,969
55,281
59,102
61,905
63,688
73,241
81,266
76,425
96,806
108,906
114,638
137,566
159,817
62,414
61,650
61,140
68,783
75,661
73,878
82,539
79,610
87,889
93,621
101,901
103,174
119,096
122,281
133,745
142,661
178,326
196,159
PWM Rect.
(BTU/hr)
40,760
44,564
49,912
53,272
54,912
58,907
73,280
84,143
97,666
57,319
58,805
59,931
68,844
69,664
81,958
84,007
89,211
103,267
115,424
133,181
159,220
59,867
65,726
69,547
73,368
77,954
78,973
92,347
99,735
95,532
122,281
137,566
146,482
168,136
195,332
73,878
72,859
71,840
82,157
89,418
91,711
100,882
98,716
106,996
115,912
122,281
131,834
147,119
152,851
178,326
193,611
242,014
266,215
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
54
6.5
General Design Specifications
Description
Power Rating (Air Cooled)
Motor Type
Input Voltage Rating
Input Voltage Tolerance
Voltage Sag
Power Loss Ride-Through
Input Protection
Input Frequency
Input Power Circuit Protection
Input Impedance Device
Output Voltage
Inverter Design
Inverter Switch
Inverter Switch Failure Mode
Inverter Switch Failure Rate (FIT)
Inverter Switch Cooling
Inverter Switching Frequency
Number of Inverter SGCT’s
SGCT PIV Rating
(Peak Inverse Voltage)
Rectifier Designs
Rectifier Switch
Rectifier Switch Failure Mode
Rectifier Switch Failure Rate (FIT)
Rectifier Switch Cooling
Number of Rectifier Devices per phase
SCR PIV Rating
(Peak Inverse Voltage)
Output Waveform to Motor
Medium Voltage Isolation
7000-TD200A-EN-P – October 2001
NEMA
IEC
200 to 5,500 hp
150 to 4,100 kW
Induction or Synchronous
2400V, 3300V, 4160V, 6600V
± 10% of Nominal
-30%
5 Cycles (Std)
> 5 Cycles (Optional UPS)
Metal Oxide Varistor (MOV)
50/60 Hz, +/- 5%
Vacuum Contactor with Fused Isolating Switch
or
Circuit Breaker
Isolation Transformer or AC Line Reactor
0 – 2300 V
0 – 3300 V
0 – 4160 V
0 – 6600 V
PWM
Symmetrical Gate Commutated Thyristor (SGCT)
Non-rupture, Non-arc
100 per 1 Billion Hours Operation
Double Sided, Low Thermal Stress
420-540 Hz
Voltage
SGCT’s (per phase)
2400 V
2
3300 V
4
4160 V
4
6600 V
6
Voltage
PIV
2400 V
6500 V
3300 V
6500 V
4160 V
6500 V
6600 V
6500 V
6 Pulse
18 Pulse
PWM (Active Front End)
SCR (6/18 Pulse), SGCT (PWM Rectifier)
Non-rupture, Non-arc
50 (SCR) 100 (SGCT) per 1 Billion Hours Operation
Double Sided, Low Thermal Stress
Voltage
2400 V
3300 V
4160 V
6600 V
Voltage
2400 V
3300 V
4160 V
6600 V
6-Pulse
2
4
4
6
6-Pulse
6500 V
6500 V
6500 V
6500 V
18-Pulse
6
6
6
6
18-Pulse
4500 V
4500 V
4500 V
6500 V
Sinusoidal Current / Voltage
Fiber Optic
PWM
2
4
4
6
PWM
6500 V
6500 V
6500 V
6500 V
PowerFlex 7000
Technical Data Guide
Description
Modulation techniques
Control Method
Tuning Method
Speed Regulator Bandwidth
Torque Regulator Bandwidth
Speed Regulation
Output Frequency Range
Service Duty Rating
Typical VFD Efficiency
VFD Noise Level
Regenerative Braking Capability
Flying Start Capability
Operator Interface
Languages
Control Power
External I/O
Analog Inputs
Analog Outputs
Communication Interface
Communications Protocols
(Optional)
Enclosure
Ambient Temperature
Storage and Transportation
Temperature Range
Relative Humidity
Altitude (Standard)
Altitude (Optional)
Seismic (UBC Rating)
55
NEMA
IEC
SHE (Selective Harmonic Elimination)
PWM (Pulse Width Modulation)
Digital Sensorless Direct Vector
Full Vector Control with Tach Feedback (Optional)
Auto Tuning via Setup Wizard
5-25 Radians / Second
15-50 Radians / Second
0.1% without Tachometer Feedback
0.01-0.02% with Tachometer Feedback
0.2-85 Hz
Normal Duty
Heavy Duty
150% Overload for 1
110% Overload for 1
minute every 10 minutes
minute every 10 minutes
(Constant or Variable
(Variable Torque Load)
Torque Load)
> 98% (6/18 Pulse)
> 97.5% (PWM)
Contact Factory for Guaranteed Efficiency of Specific
Drive Rating
< 85 dB(A) per OSHA Standard 3074
Inherent – No Additional Hardware or Software Required
Yes – Able to Start into and Control a Spinning Load in
Forward or Reverse Direction
40-character, 16-line formatted text
English
French
Spanish
Russian
208-575 V, 3 Phase, 50/60 Hz
16 Digital Inputs, 16 Digital Outputs
(1) Isolated, (1) Non-isolated, 4-20 mA or 0-10 V
(1) Isolated, (7) Non-isolated, 4-20 mA or 0-10 V
SCANPort /DPI
RS232/422/485
DH485
Remote I/O
DeviceNet
ControlNet
Modbus/Modbus Plus
Profibus
NEMA 1
IP21
0° to 40°C (32°F to 104°F)
-40°C to 70°C (-40°F to 185°F)
95% Non-Condensing
0 to 3300 ft. (0 to 1000 m)
0 to 16400 ft. (1001 to 5000 m)
1, 2, 3, 4
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
56
6.6
Typical Auxiliary Equipment
Bulletin No.
Description
1508T
Isolation Transformer Unit
1512AD
1-High, VFD Input Contactor Unit
VFD Input Contactor Unit with Output Isolator for Output or Bypass, Single
1512DM
or Multi-Motor Applications
1512DO VFD Output Contactor Unit
1512M
Output-Bypass Starter Unit
Bulletin 1508T - Isolation Transformer Unit
The isolation transformer is defined by Bulletin number 1508T. It is purchased from a 3rd party
and normally shipped from the supplier directly to the job site. It is available in a variety of
enclosure types, sizes, winding materials, voltages and phase shifting configurations (6 or 18
pulse).
For variable torque applications, transformers will be sized 1.0 kVA / Motor hp X Drive Service
Factor.
For constant torque applications, transformers will be sized 1.11 kVA / Motor hp X Drive
Service Factor.
Applications at altitudes greater than 1000 meters, will be treated as custom designs.
Bulletin 1512AD, 1512BD - VFD Input Contactor Unit
The input contactor is defined by Bulletin numbers 1512AD and 1512BD. The unit is FVNR
available in 400, 600 and 800A sizes. The 400A unit is available in 1-High and 2-High
configurations. The 600 and 800A sizes and configurations are available only in 1-High units.
The enclosed power cell rating is based on the configuration and voltage. The input contactor is
controlled by the drive. There are several options available with this type of unit that effect the
configuration of the structures and wiring of the system. When the load is the isolation
transformer, the power fuses will be “E” rated, and “R” rated when “E” rated are NOT available.
When the load is a line reactor, the power fuses will be “R” rated.
Typical Bulletin 1512AD, MV Drive Input Starter Feeding Isolation Transformer
1512ADBD
400 amp
LV
Structure Code: 1.2
Catalog No: 1512AD-AA_-6-14TX-kVA
Dimensions: 26”W x 36”D x 91”H
MV
VFD
M
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
57
Typical Bulletin 1512AD, MV Drive Input Starter Feeding Line Reactor
1512ADBD
400 amp
LV
Structure Code: 1.2
Catalog No: 1512AD-AA_-6-14LR-hp
Dimensions: 26”W x 36”D x 91”H
3
LR
MV
VFD
M
Bulletin 1512DM - VFD Input Contactor Unit with Output Isolator for OUTPUT or BYPASS, Single or
Multi-Motor Applications
The input contactor unit is a FVNR starter with an output isolating switch on the output of the
VFD that will feed a VFD power bus. The output isolator and FVNR starter isolating switches
are mechanically interlocked for the 400 amp design and key interlocked for the 600 amp design.
The OUTPUT or BYPASS configurations are available on the 400 and 600 amp sizes as
standard. The same options used on the 1512AD (above) are available with this unit. This unit
shall also include a 500 VA CPT as standard (like a starter application), to supply the control
circuit power only for the starter. The catalog number will also included a hp (-14LR) or kVA (14TX) rating. When the load is the isolation transformer, the power fuses will be “E” rated, and
“R” rated when “E” rated are NOT available. When the load is a line reactor, the power fuses
will be “R” rated.
NOTE: For any OUTPUT or BYPASS configuration, Allen-Bradley prefers to supply the Input
Contactor. This is to ensure that there is proper isolation and protection (interlocking).
A double power bus configuration is utilized in the bus compartment (one is the main power bus,
the other is the variable frequency bus). The variable frequency bus is located above the standard
main horizontal power bus.
NOTE: When this unit is located on the left most side of the MCC, only bottom incoming cables can
be terminated to the main horizontal power bus. For top incoming direction, an incoming line unit
is required.
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
58
Typical Bulletin 1512DM, MV Drive Input Starter ( For use with Output - Bypass Starter)
400 amp
MV
Output
Contactor
1512M
1512DM
Structure Code: 1.40
Catalog No: 1512DM-AA_-6-14TX-kVA
Dimensions: 36”W x 36”D x 91”H
Bypass
3
LV
MV
Input
Contactor
VFD
VFD Bus
Output
3
M
Bulletin 1512M - Output-Bypass Starter Unit
The output-bypass starters are allowed in the line-up when the 1512DM unit is used. The unit
can be used for both single or multi-motor applications. The catalog number includes a
horsepower rating and option numbers. When used in a drive system configuration, the 1512M
units shall always be located on the left hand side of the input starter (1512DM). A double
power bus configuration is utilized in the bus compartment (one is the main power bus, the other
is the variable frequency bus). The variable frequency bus is located above the standard main
horizontal power bus. This unit shall include a 500 VA CPT as standard (like a starter
application), to supply the control circuit power only for the starter. The power fuses will be
“R”.
NOTE: When this unit is located on the left most side of the MCC, only bottom incoming cables can
be terminated to the main horizontal power bus. For top incoming direction, an incoming line unit
is required.
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
59
Typical Bulletin 1512M, Output-Bypass Starters
1512M
400 amp
LV
MV
Output
Starter
LV
Structure Code: 1.15
Catalog No: 1512M-AA_-6-7F-hp
Dimensions: 36”W x 36”D x 91”H
Main Bus
Bypass
400A
MV
Bypass
Starter
VFD Bus
Output
3
M
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
60
Bulletin 1512DO - Output Contactor Unit
The Bulletin 1512DO is an output contactor for the drive and is allowed in the line-up when a
1512DM unit is used. This unit includes an isolating switch and contactor only. The catalog
number includes a horsepower rating and option numbers. When used in a drive system
configuration, the 1512DO unit shall always be located on the left hand side of the input starter
(1512DM). A double power bus configuration is utilized in the bus compartment (one is the main
power bus, the other is the variable frequency bus). The variable frequency bus is located above
the standard main horizontal power bus. This unit does not include CPT for the control circuit
power. An external power source is required. This unit also does not include power fuses or CT’s
and is controlled by the drive control circuit. If additional relays, CT’s, etc are required, they shall
be included by using CMODs.
Typical Bulletin 1512DO, VFD Output Contactor
LV
MV
1512DO
1512DM
Structure Code: 1.17
Catalog No: 1512DO-AA_-6-7F-HP
Dimensions: 36”W x 36”D x 91”H
Output
Contactor
3
1:1
VFD
MV
VFD Bus
Output
M
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
61
7. APPENDIX A
Full Load Currents of 3 Phase, 50/60 Hz, Medium Voltage AC Induction Motors
This table is FOR REFERENCE ONLY. The full load currents listed below are “average
values” for horsepower rated motors. These “average values,” along with the similar values
listed in NEC/CEC, should be used only as a guide for selecting appropriate components for the
Motor Branch Circuit. The rated full load current, shown on the motor nameplate, may vary
considerably from the list value depending on the specific motor design and RPM.
IMPORTANT: The motor nameplate full load current should always be used in determining the
rating of the devices used for Motor Running Overcurrent Protection.
kW
Rating
75
95
110
130
150
170
187
225
260
300
335
373
450
522
560
600
670
750
933
1120
1300
1500
1680
1865
2050
2240
2600
3000
3360
3730
4100
4475
5225
6000
6720
7500
hp
Rating
100
125
150
175
200
225
250
300
350
400
450
500
600
700
750
800
900
1000
1250
1500
1750
2000
2250
2500
2750
3000
3500
4000
4500
5000
5500
6000
7000
8000
9000
10000
2300V
23
29
34
40
46
52
57
68
80
91
103
113
134
158
169
177
202
216
273
326
376
434
485
537
591
647
750
857
964
1071
1179
1286
1500
1714
1929
2143
3300V
16
20
24
28
32
36
40
48
56
64
72
79
94
110
118
124
141
151
190
227
262
303
338
375
412
451
523
597
672
747
821
896
1046
1195
1344
1494
Full Load Current at 1800 RPM (Amperes)
4000V
4600V
6000V
6300V
13
11
9
8
16
14
11
10
20
17
13
13
23
20
15
15
26
23
18
17
30
26
20
19
33
29
22
21
39
34
26
25
46
40
31
29
52
46
35
33
59
51
39
38
65
57
43
41
77
67
52
49
91
79
60
58
97
85
65
62
102
89
68
65
116
101
77
74
124
108
83
79
157
137
105
100
188
163
125
119
216
188
144
137
250
217
166
159
279
242
186
177
309
269
206
196
340
296
227
216
372
324
248
236
431
375
288
274
493
429
329
313
554
482
370
352
616
536
411
391
678
589
452
430
739
643
493
469
863
750
575
548
986
857
657
626
1109
964
739
704
1232
1071
821
782
6600V
8
10
12
14
16
18
20
24
28
32
36
39
47
55
59
62
70
75
95
114
131
151
169
187
206
226
261
299
336
373
411
448
523
597
672
747
6900V
8
10
11
13
15
17
19
23
27
30
34
38
45
53
56
59
67
72
91
109
125
145
162
179
197
216
250
286
321
357
393
429
500
571
643
714
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
62
8. APPENDIX B
Transformer Secondary Winding Insulation Levels Table
Rated
Motor
L-L
Voltage
(Vrms)
:
2300
3300
4000
6000
6300
6600
:
;
Number of
Secondary
Windings
:
1 (6 Pulse)
2 (12 Pulse)
3 (18 Pulse)
1 (6 Pulse)
2 (12 Pulse)
3 (18 Pulse)
1 (6 Pulse)
2 (12 Pulse)
3 (18 Pulse)
1 (6 Pulse)
2 (12 Pulse)
3 (18 Pulse)
1 (6 Pulse)
2 (12 Pulse)
3 (18 Pulse)
1 (6 Pulse)
2 (12 Pulse)
3 (18 Pulse)
Rated Secondary
L-L Voltage
(Vrms)
2400
1200/1200
800/800/800
3450
1725/1725
1150/1150/1150
4200
2100/2100
1400/1400/1400
6300
3150/3150
2100/2100/2100
6600
3300/3300
2200/2200/2200
6900
3450/3450
2300/2300/2300
Minimum
Secondary
Winding
Insulation
Level
(kVrms)
;
Short
Duration
Power
Frequency
Withstand
Voltage Test
(kVrms)
5.0
Primary Winding
Impulse Withstand
Voltage (BIL) Test
(for 1:1 ratio only)
(kVpk)
Air
Liquid
12.0
30
60
7.2
16.5
40
60
7.2
16.5
45
75
12.0
26.0
60
95
12.0
26.0
60
95
12.0
26.0
60
95
Secondary Winding
Impulse Withstand
Voltage (BIL) Test
(kVpk)
Air
Liquid
30
20
20
40
20
20
45
30
20
60
40
30
60
40
30
60
40
30
60
45
45
60
40
40
75
60
45
95
75
60
95
75
60
95
75
60
Refer to rectifier duty transformer specification 80001-005.
Minimum required insulation level from phase to ground, neutral to ground for 6, 12, 18pulse transformers and from secondary to secondary windings of 12 and 18-pulse
transformers.
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
63
9. APPENDIX C : Applicable Requirements of MV Controllers
9.1
Critical Standards
Code
CEC-1998
NEC-1999
CSA C22.2
No.14/73
TIL NO D-21
UL347
IEEE –C37
NEMA-ICS1
NEMA-ICS3
NEMA-ICS6
IEC 60129
IEC 60298
IEC 60470
IEC 60694
89/336/EEC, AND
92/31/EEC
ASSOCIATED EN
STANDARDS: EN 50812, EN 5082-2
92/59/EEC AND
ASSOCIATED EN
STANDARDS: EN 6010,
EN60204-1.
9.2
Governing Association/Description
Canadian Electrical Code- SAFETY STANDARD FOR ELECTRICAL
INSTALLATIONS
NATIONAL ELECTRICAL CODE (NFPA-70)
INDUSTRIAL CONTROL EQUIPMENT (MV)
CERTIFICATION REQUIREMENTS FOR CONTROL DEVICES RATED AT
MORE THAN 1500V BUT NO MORE THAN 7200V FOR ELECTRIC
MOTORS
HIGH VOLATGE INDUSTRIAL CONTROL EQUIPMENT
CIRCUIT BREAKERS, SWITCHGEAR, SUBSTATIONS, AND FUSE
STANDARDS COLLECTION
GENERAL STANDARD FOR INDUSTRIAL CONTROL SYSTEM
FACTORY BUILT ASSMBLIES
ENCLOSURES
ALTERNATING CURRENT DISCONNECTORS (ISOLATORS) AND
EARTHING SWITCHES
AC METAL-ENCLOSED SWITCHGEAR AND CONTROLGEAR FOR RATED
VOLTAGE ABOVE 1KV AND UP TO INCLUDING 52KV
HIGH-VOLTAGE ALTERNATING CURRENT CONTACTORS
COMMON SPECIFICATIONS FOR HIGH-VOLTAGE SWITCHGEAR AND
CONTROLGEAR STANDARDS
EMC DIRECTIVE
GENERAL PRODUCT SAFETY DIRECTIVE (GPSD)
Components Standards
Code
C22.2 NO14/95
C22.2 No. 58
C22.2 NO 201
C22.2 NO 127
C22.2 NO 190
C22.2 NO 193
UL508
UL 1072
UL 1562
NEMA-MG1
IEC 60056
IEC 60076
IEC 60265-1
IEC 60420
IEC 60282-1
IEC 60871-1
Description
INDUSTRIAL CONTROL EQUIPMENT (LV)
HIGH-VOLTAGE ISOLATING SWITCHES
METAL-ENCLOSED HIGH VOLTAGE BUSSWAYS
HIGH-VOLTAGE ISOLATING SWITCHES
CAPACITORS FOR POWER FACTOR CORRECTION
HIGH VOLTAGE FULL LOAD INTERRUPTER SWITCHES
INDUSTRIAL CONTROL EQUIPMENT (LV)
MEDIUM, VOLTAGE POWER CABLES
TRANSFORMERS, DISTRIBUTION, DRY TYPE OVER 600V
MOTOR AND GENERATORS
HIGH-VOLTAGE ALTERNATING-CURRENT CIRCUIT-BREAKERS
POWER TRANSFORMERS
HIGH-VOLTAGE SWITCHES - PART 1: HIGH-VOLTAGE SWITCHES FOR
RATED VOLTAGES ABOVE 1 kV AND LESS THAN 52 kV
HIGH-VOLTAGE ALTERNATING CURRENT SWITCH-FUSE
COMBINATIONS
HIGH-VOLTAGE FUSES
SHUNT CAPACITORS FOR A.C. POWER SYSTEMS HAVING A RATED
VOLTAGE ABOVE 1000 V
7000-TD200A-EN-P – October 2001
64
7000-TD200A-EN-P – October 2001
PowerFlex 7000
Technical Data Guide
www.rockwellautomation.com
Corporate Headquarters
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Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions
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Headquarters for Dodge and Reliance Electric Products
Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433
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Web site: www.ab.com/mvb
Publication 7000-TD200A-EN-P – October 2001
Copyright © 2001 Rockwell Automation. All rights reserved. Printed in Canada.