Bring the Connected Enterprise to Life

Medium Voltage Solutions

Jakrapong Ruankum • CTO SEA | 18 Feb 2021

PUBLIC
Introduction
THE CONNECTED ENTERPRISE

THE ROCKWELL AUTOMATION VISION FOR SMART MANUFACTURING

Rockwell Automation Intelligent Motor Control
Distribution
115 – 500 kV Output voltage 2.4-11kV

High Voltage
13.8 kV
8,000 HP +

Relé 857
OneGear SMC PowerFlex 6000

Medium Voltage
2.3 – 6.9 kV
200 – 8,000 HP

OneGear MCC PowerFlex 6000 & 7000

Low Voltage
380 – 690V
<1 – 800 HP

PowerFlex / SMC 50 / E300 Centerline 2100 & 2500

4
Medium Voltage Portfolio
Medium Voltage Product Portfolio
Motor Soft VFDs: VFDs:
Starters: Starters: General Special
NEMA IEC/NEMA Purpose Purpose

• Bulletin 1500 CENTERLINE® • OneGear - IEC market • PowerFlex® 6000 • PowerFlex® 7000
• 2.3 - 7.2 kV • 10 - 15 kV • IEC/NEMA • IEC/NEMA
• Up to 800 A • Up to 580 A • 2.3 - 11 kV • 2.3 - 6.6 kV
• Various configurations • CENTERLINE® NEMA market • Up to 680A • Up to 720A
for across-the-line, • 2.3 – 7.2 kV
reversing, two speed, • Up to 540A
and so on.

MOTOR CONTROLLERS VARIABLE FREQUENCY DRIVES

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MVB is in the Business of Motor Control

MV POWER DISTRIBUTION

Starters SMC 50 MV Drives

Bulletin 1500 Bulletin 1500 Bulletin 6000 & 7000

 Simplest Starting Solution  Simple Starting and Stopping  Complete Continuous Control
 Full torque applied…motor  Limited Control at any Speed
 Mechanical wear  Reduced torque and current  Full torque at any speed
 ≥6x inrush current during starting without sacrificing current

No Starting Choices Different Unlimited starting

starting/stopping possibilities when sized
modes properly
 Building Our Medium Voltage Expertise…

First Allen-Bradley® Allen-Bradley® MV Smart Motor First Direct-to- 15 kV OneGear™ UL Listed

MV Starter MV Vacuum Controller Drive™ PowerFlex® Reduced Voltage
Contactor 7000 PowerFlex® 6000 VFD
Motor Starter (IEC)

1931 1956 1989 1993 2000 2004 2006 2010 2012 2015

First Allen-Bradley® First Generation Third Generation 50 kA Arc Resistant

MV Air Break Allen-Bradley® MV MV VFD – PowerFlex® 40 kA Arc Resistant 10 kV Drive (IEC)
PowerFlex® 6000 VFD Drive PowerFlex® 7000
Contactor VFD 7000 VFD
THE INDUSTRIES AND
APPLICATIONS WE SERVE

Oil & Gas Power Generation Water / Wastewater Forest Products

• Oil pipeline pumps • Feed water pumps • Raw Sewage Pumps • Fan pumps
• Natural gas pipeline compressors • Induced draft fans • Effluent Pumps • Induced draft fans
• Induced draft fans • Forced draft fans • Low Service/Raw Water Pumps • Boiler feed water pumps
• Axial-vane compressors • Baghouse fans • High Service/Finished Water Pumps • Line shafts
• Reciprocating compressors • Booster Pumps • Slurry pumps
• Centrifugal compressors Cement • Flood Control Pumps
• Kiln induced draft fans • RAS Pumps Commercial
Mining & Steel • Forced draft fans • WAS Pumps • HVAC/OEM
• Slurry pumps • Cooler baghouse fans • Aeration Blowers Chillers/compressors
• Ventilation fans • Raw mill induced draft fans
• Descaling pumps • Kiln gas fans Other
• Single motor, non-regen conveyors • Cooler exhaust fans • Test stands
• Baghouse fans • Baghouse fans • Agitators
• Cyclone feed pumps
• Tailings pumps
• Screw pumps PUBLIC | Copyright ©2020 Rockwell Automation, Inc. | 9
Medium Voltage Drives
Medium Voltage Drive Application Types

GENERAL PURPOSE SPECIAL PURPOSE

Applications Applications
• Fans • Cranes and Hoists
• Pumps • Conveyors
• Compressors • SAG and Ball Mills
20% • Extruders and Mixers
• Electro-submersible
pumps
MV • Marine
• Subsea
DRIVES
MARKET

80%

Data Source: 2019 IHS MV Drives Market Study (2018 base year)

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Medium Voltage Drive Portfolio - Application Alignment

POWERFLEX 6000 POWERFLEX 7000

GENERAL PURPOSE DRIVES SPECIAL PURPOSE DRIVES
Ideally suited for: Ideally suited for:
• Non-regen applications • Regenerative applications

• Long motor cable lengths • Extended motor cable

(up to 800m) lengths (up to 30 km)
(up to 2 km with output filter)

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

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PowerFlex 6000 Portfolio
• General Purpose Medium Voltage Drive: 6000T 6000G
• Fans, pumps, and compressors
• Ideally suited for non-regen applications
• Up to 2 km motor cable length

• Global Standards Compliance:

• IEC (all voltages) / UL - available up to 6.9 kV “B” Frame “A” Frame “H” Frame

• Motor Voltage and Current Scope:

700
• 6000T Versions:
• “A” Frame – 2.4...4.16 kV, 0...215 A 600

Motor Current (A)

• “B” Frame - 2.4 kV to 11 kV, 200...680 A 500
6000T
• 6000G Version: “B” Frame
400
• “H” Frame – 6...11 kV, 0...200 A
300

• Service and support available globally 200

• Regional spare part hubs 6000T 6000G
100 “A” Frame “H” Frame
0 1 2 3 4 5 6 7 8 9 10 11
Motor Voltage (kV)
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PowerFlex 6000 Topology Review
Low Voltage Power Cell: v w x
u Input power fuses
v Three phase diode rectifier bridge u
w DC Bus Capacitor network y
x Single phase IGBT inverter bridge
y Output terminals
Theory of operation (6.6 kV example) Detail of low voltage power cell
 640VAC fed to power cell from dedicated isolation transformer
secondary windings
 The DC bus voltage is approx. 865VDC
 H Bridge can have only three output states:
 + DC Bus Voltage (A+ and B- IGBTs are on)
 - DC Bus Voltage (A- and B+ IGBTs are on)
Phase Current
 0 VDC (A+ and B+ IGBTs are on or A- and B- IGBTs Phase Voltage
are on)

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 PowerFlex 6000T: Best in Class Footprint*
“A” Frame Dimensions - Available from 2.4…4.16 kV (up to 215 A)

Frame A1* Frame A2 Frame A3

Width: Width: Width:
47.6” (1210 mm) 63.4” (1610 mm) 75.2” (1910 mm)
Depth: Depth: Depth:
49.2” (1250 mm) 49.2” (1250 mm) 49.2” (1250 mm)
Height with fan: Height with fan: Height with fan:
110.2” (2798 mm) 113.7” (2888 mm) 113.7” (2888 mm)
Height without fan: Height without fan: Height without fan:
91.7” (2328 mm) 91.7” (2328 mm) 91.7” (2328 mm)

0…70 A @ 60 Hz 71…140 A @ 60 Hz 141…215 A @ 60 Hz

0…54 A @ 50 Hz 55…140 A @ 50 Hz 141…215 A @ 50 Hz

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PowerFlex 6000T Low Harmonic Topology
Cascaded “H” Bridge Topology provides inherent harmonic mitigation and high input power factor
The combination of lower line-side harmonics and high input
power factor reduces the need to oversize electrical power
equipment - to reduce overall system costs and minimize
disruption to other devices and processes

• Inherently high input power factor

• Low input harmonics to meet IEEE 519-2014 and other global

harmonics standards

• 18 to 54 pulses topology, according to voltage level

CHB topology - simplified three-line drawing

• 18 Pulse (9 power cells) for 2.4/3.3 kV

• 24 Pulse (12 power cells) for 4.0/4.16 kV
• 30 Pulse (15 power cells) for 6 kV
• 36 Pulse (18 power cells) for 6.3/6.6/6.9 kV
• 48 Pulse (24 power cells) for 10 kV
• 54 Pulse (27 power cells) for 11 kV
Typical line-side current waveform (Phase A)

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Avoid Equipment Downtime
Power cell bypass, key component redundancy, and ride through

Optional capabilities deployed individually or together can help to

further maximize uptime - enhancing productivity and profitability

• Automatic Power Cell Bypass (Optional)

• Any power cell in any phase can be bypassed

• No size penalty

• Available for all voltage and current configurations

Power Cell Bypass Configuration
Any power cell in any phase can be bypassed

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Flexibility – Synchronous Transfer System
Controlled starting and speed control of multiple motors with one drive

Two motor system example – single line

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Enhanced HIM Interface Overview
Delivers a simplified user experience for at-a-glance
monitoring, intuitive control, and in-context diagnostic help

• Explore the Local Subnet

• Monitor what Matters
• Define the System
• Watch it Work
• Full-Featured Parameter
Configuration
• Root-Cause Analysis Made Easy

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PowerFlex 6000T Technical Specifications
Typical Applications Variable torque and constant torque (non-regenerative)

Drive System Configurations Standalone or Synchronous Transfer

Drive Cooling Requirements Air-cooled

Motor Voltage Rating “A” Frame – up to 4.16 kV, “B” Frame - up to 11 kV

Motor Current Rating “A” Frame – up to 215 A, “B” Frame - up to 680 A

Output Frequency 1…75Hz

Motor Types Induction

Regenerative Braking No (two quadrant operation)

Motor Cable Lengths Up to 800 m (up to 2 km with additional output dv/dt filter)

Rectifier Pulse # 18…54 pulse diode

Inverter Devices IGBTs

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PowerFlex 6000T Technical Specifications - Continued
• < 373 kW = 96%
Efficiency
• 373 kW and above = 96.5%
Input Voltage Tolerance +/- 10%
Input Voltage Sag -30% of nominal, up to 60 seconds
Input Power Factor >.95
• < 215 A = 80 dB(A)
VFD Noise Level
• 215…680 A = 85 dB(A)
Speed Regulation 0.5%
Operator Interface 10” Windows 10 IoT Color Touch Screen
Communication Protocols EtherNet/IP, Modbus-RTU Slave RS485, Modbus-TCP, Modbus-PLUS Slave
(optional) RS485, PROFIBUS Slave, PROFINET IO
Enclosure IP31 (standard), IP42 (optional)
Design MTBF 100,000 hours
Design Standards NEMA, ANSI, IEEE, UL, CSA, IEC, CE, EEMAC
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PowerFlex 6000T Technical Specifications - Continued
Conformal Coating All main control boards, option cards, power cell control boards

Top and Bottom: Removable cable access plates for line and load power
Cable Entry Direction
cabling and control wiring in top plates and floor plates
Rear Access Required? No. Front access only required for installation and maintenance
Surge Arrestors Standard for all configurations. No footprint penalty.
• <200 A not offered
• 201…407 A, offered if Isc/IL >50
Precharge Circuit
• >408 A always included (adds 1205 mm (40”) wide cabinet – all
configurations)
Product Installation Overhead lifting or forklift handling capability

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PowerFlex 7000 MV AC Drives
“B” Frame
 Special purpose MV variable frequency “C” Frame
(high-power air-cooled / heat pipe)

drive (VFD) (liquid-cooled)

• Controls speed, torque, direction,

starting and stopping of induction or
synchronous motors

 Focus on high reliability, ease of use, and

lowest total lifecycle costs “B” Frame
(mid-power air-cooled / heat sink)
“A” Frame
(low-power air-cooled)

• Unlimited motor cable lengths

• Motor-friendly waveforms 700

600
• Patented PowerCage™ allows SGCT M oto r Cu rren t (A) “C” Frame
replacement in less than ten minutes 500

400
• Transformerless design
300 “B” Frame
• Premier Integration into Logix 200
controllers “A” Frame
100
• EtherNet/IP™ communication interface. 2000 3000 4000 5000 6000 7000

Motor Voltage (V)

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PowerFlex 7000 Air-Cooled Product Offering

 Topology: Direct-To-Drive / Active Front End / 18 Pulse

 Four motor voltage class offerings:
 2.4 kV - (up to. 600 HP, 450 kW)  2.4 kV - (up to. 2000 HP, 1500 kW)
 3.3 kV - (up to. 4800 HP, 3600 kW)
 3.3 kV - (up to. 800 HP, 600 kW)
 4.16 kV - (up to 5900 HP, 4400 kW)
 4.16 kV - (up to 1000 HP, 750 kW)
 6.6 kV - (up to 8000 HP, 5968 kW)
 6.6 kV - (up to 1200 HP, 895 kW)

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

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PowerFlex 7000 Liquid-Cooled Product Offering

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

 Heat Exchanger: Liquid to Liquid / Liquid to Air

 Two motor voltage class offerings :

 4.16 kV - (up to 5000 HP, 3730 kW)
 6.6 kV - (up to 8500 HP, 6340 kW)

Frame C, Liquid-Cooled

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PowerFlex 7000 Technical Specifications
PowerFlex7000 “A”
 PWM Current Source Inverter Topology  Friendly Line Side / Motor Side Waveforms
 6500V SGCT’s, low component count  Input Current THD < 5% complies with
 AFE or SCR Rectifier IEEE-519

 Transformer-less AFE (Direct-to-Drive™)  Sinusoidal current and voltage to the

option motor

 Common rectifier / inverter parts  No additional sine filter required

 Inherent Regenerative Braking  Operates on standard or inverter

duty motors
 Medium to high performance
 Motor voltage dv/dt = 10–50 V/micro
 2400V – 6600V, air cooled / water cooled second
 N-1 or N+1 options  No dv/dt filters required High feature set / performance capability.
 Virtually unlimited motor cable distance Transformer-less option (Direct-to-Drive)
RECTIFIER L+ M+ INVERTER  Tested up to 30km
 Transformer-less Design
SGCT’s SGCT’s
 1.0-1.5% higher efficiency than traditional
DC LINK

solutions
 3 power cables in / 3 power cables out
 Compact footprint, low weight
CSI-PWML- Topology
M- with AFE

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PowerFlex 7000 Drive System with ArcShield™

50 kA rated Drive System

 Designed to meet a broad variety of heavy industry
with ArcShield
requirements

 AFE (Direct-to-Drive™) configurations from 2.4 kV

to 4.16 kV, with motor current capability up to 430 A
for synchronous or induction motors

 Fully integrated CENTERLINE® starter and

40 kA rated Drive System
PowerFlex 7000 drive combination
with ArcShield

 Design based on our decade of experience with

medium voltage ArcShield motor controllers

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Synchronous Transfer Configuration

400A 400A 400A 400A

Bypass Bypass 3 3 Bypass Bypass 3

MPR MPR MPR MPR

VFD
or
SMC
VFD

VFD Bus VFD Bus VFD Bus

Output Output Output Output

3 3 3 3

M M M M

Motor 1 Motor 2 Motor 1 Motor 2

Synchronous Transfer Multi-motor Bypass System Synch Transfer Bypass System with backup VFD or SMC

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 Medium Voltage MCC

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CENTERLINE® 1500 Product Offering

• Incoming Line Units

• Load Break Switches
• Full Voltage
Controllers
• Reduced Voltage
Starters
• Two-Speed Starters
• Synchronous
Starters
• Auxiliary Cabinets

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Incoming Line Cabling Units

Used for customer incoming line cable termination

1591A 1591B
Incoming Line Units Incoming Line Units for 2-Unit Structure
 18”, 36”, & 44” wide enclosures  36” wide enclosure
 18” and 36” available with  Available with ArcShield™
ArcShield™
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 Incoming Line Cabling Units- Features

 2400-6900 volts
 Top or bottom incoming arrangements
 Bolted door construction
 Front access to incoming cables
 With or without low voltage panel
 Low voltage panel supplied with units that have LV
components
 Energy metering optional

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Load Break Switches

 200A, 400A, 600A*, and 1200A* sizes available

 2400-6900V

 Protective guard over line terminals as a barrier from MV when power

door is open

 Viewing window to see position of switch

 Handle fully interlocked with door

 Key interlocking available

 *Available in Feeder, Main, or Tie configurations

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600 & 1200A Load Break Switches

Feeder Main
Optional Fusing

Optional
Fusing

Tie

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Full Voltage Non-Reversing Controllers

Transformer or
Motor Control
in one or two high
enclosures

3
3

TX
M

One High Two High

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Full Voltage Non-Reversing Controller-Overview
 400A, 600A or 800A control
 2400V to 6900V, up to 9000HP
 Enclosures
 Type 1, 1 (w/gasket), 12, 3R (IP 10, 21, 52, & 34)
 Arc resistant option (ArcShield™)
 Top/Bottom cable entry/exit
 Power bus located in center of rear of structure
 Separate Low Voltage and Power Cell compartments

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Full Voltage Reversing Controllers

Control Reversing Applications with the 1506

R F

1506
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Reduced Voltage Controllers Product Offering
 1562F, SMC™ Flex solid-state Reduced Voltage,
Non-Reversing
 1572, Reduced Voltage Autotransformer
Non-Reversing Starter
 1576, Reduced Voltage Autotransformer
Reversing Starter
 1582, Non-Reversing Reactor Starter

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MV SMC-50 Overview

 Three MV SMC-50 Offerings:

Isolation
Switch & Power
Fuse
SCR Power Stack
Assembly
Main Contactor

Bypass
Contactor

Current
Complete Motor Transformers Component Kits for
Control Solution OEMs
1562F 1503
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Medium Voltage SMC-50 Overview
Combination – 1562F
Isolation
Switch & Power
Fuse
SCR Power Stack
Assembly
Main Contactor

Bypass
Contactor

Current
Transformers

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Two Speed Controllers- Product Offering and
Features
 Available for separate winding or consequent pole two speed motors

 200A, 400A

 2400V-4800V, up to 3000HP

 High/Low speeds (and High speed shorting for 1522F/G)

 Three R-rated fuses

 Six current transformers

 Control power transformer with primary and secondary fuses

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OneGear 10-15kV SMC-50 Family

Complete Controller OEM Controller Retrofit Controller

Certification Ratings
IEC 62271-1 Current
IEC 62271-200 160, 340, 580 amps
IEC 60947-4-2
IEC 62271-100 Short Circuit and Bus Bracing
IEC 62271-200 Annex A 31.5 kA

CSA Special Inspection for Arc Resistant Protection

North American Markets 31.5 kA, 0.5 sec.
OneGear SMC-50 Controller

 IEC rated enclosure

 Arc resistant option (ArcShield™)
 31.5kA, 0.5s IAC AFLR
 160A, 340A, 580A
 10-13.8kV, up to 11MW
 Three configurations:
 Complete Controller
 OEM Controller
 Retrofit Controller
OneGear, 10-15kV MV SMC-50
Line Cable Start Bypass
Power Converter
Section Controller Controller

Power Bus Located in Upper Rear Section

Additional Additional
MCCs / SMCs MCCs / SMCs

Incoming Cables Motor Cables

Protection Relays

Bulletin 857 Bulletin 865

 Ethernet/IP for Intelligent Motor Control  Ethernet/IP for Intelligent Motor Control inc.
inc. many other communication protocols many other communication protocols
including IEC 61850 including IEC 61850
 Motor or Feeder protection in one relay  Differential protection relay for
 EDS AOP Profile simplifies commissioning transformers, generators and motors
 EDS AOP Profile simplifies commissioning
 Medium Voltage Business Overview…

 Four regional engineering and Canada – Cambridge

350,000 ft2 (32,500 m2) facility
manufacturing facilities
 Manufacturing Experience:
 Medium Voltage Starters - since 1931
 Medium Voltage Drives - since 1989 China – Harbin
165,750 ft2 (15,400 m2) facility

Poland – Katowice
80,000 ft2 (7,400 m2) facility

Brazil – Sao Paulo

70,000 ft2 (6,500 m2) facility