1. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. Direct-to-Drive Technology Product Feature Overview

2. PowerFlex 7000 MV Drive Control Boards Identical line and machine side control boards used for asynchronous and synchronous drives. Floating point Digital Signal Processors (DSP). Field Programmable Gate Arrays (FPGA) used for advanced logic. External I/O with 16 digital inputs and 16 digital outputs. Operator interface terminal with 16-line, 40-character LCD display for easy set-up, monitoring and troubleshooting. Robust AC/DC power supplies with optional redundancy. Low voltage swing out tub for access to cable connection assembly and motor filter capacitor Rugged DC link inductor limits fault current and eliminates nuisance trips. A compact enclosure saves on valuable floor space. Rear access not required 6.5 kV SGCT power semiconductors reduce parts count and increase reliability. Integral cooling fan provides efficient heat transfer from power components. PowerCage modules on the rectifier and inverter reduce manufacturing time and allow easy access to main power components for quick replacement. 6-Pulse, 18-Pulse, or PWM rectifiers available as standard for greater flexibility in meeting power quality needs. Common gate drive power supply module reduces parts count and lowers overall cost

3. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 3 Introduction Why buy a Drive Isolation Transformer if you don’t need one? The PowerFlex 7000 with Direct-to-Drive technology allows you to: –connect utility power directly to the drive without an isolation transformer and –connect a new or existing motor directly to the drive, eliminating unnecessary motor filtering

4. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 4 Why Drives Use Isolation Transformers

5. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 5 Why Use an Isolation Transformer? Harmonic Cancellation Medium Voltage Drive Manufactures traditionally use multi-winding isolation transformers to mitigate unwanted harmonics by phase shifting the transformer secondary windings. An 18 Pulse Drive mitigates harmonics to low levels through it’s three 20 degree phase shitted secondary windings

6. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 6 Why Use an Isolation Transformer? Common Mode Voltage Protection Manufacturers also use transformers to protect motors from Common Mode Voltage stress.

7. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 7 Direct-to-Drive Technology is a Better Solution

8. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 8 Direct-to-Drive: The Better Solution The Direct-to-Drive Active Front End rectifier uses semi-conductor switching to reduce line current harmonics to levels that comply to the worlds most accepted harmonic standards. The Active Front End uses switching and Selective Harmonic Elimination to reduce harmonics. Harmonic Cancellation

9. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 9 Direct-to-Drive: The Better Solution Motor line-to-ground voltage(2kV/div) 4160 Volt - Motor line and neutral to ground voltages at full speed/load Motor neutral-to-ground voltage (200V/div) Common Mode Voltage Protection Direct-to-Drive technology produces almost no common mode voltage so it is suitable for new or existing motors and imposes no voltage stress at the drive input.

10. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 10 Direct-to-Drive: The Better Solution DV/DT and Reflected Wave And, in addition to mitigating Common Mode Voltage, Direct-to-Drive technology does not generate dv/dt or Reflected Wave Voltage Stress on Motors or on the Utility. Current Voltage Line Side Motor Side

11. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 11 The Advantages of Direct-to-Drive Technology

12. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 12 The Advantages of Direct-to-Drive Lower Total Cost of Ownership The simplicity Direct-to-Drive technology results in a lower initial capital investment, lower operating cost, lower installation cost and lower maintenance cost relative to drives that require isolation transformers: No isolation transformer cost, No extra motor insulation, No special line cable insulation, No special motor cable insulation, No shipping splits, No transformer protection relay, No dv/dt, sine filter or motor terminator, No power factor correction required, No harmonic filtering required, No transformer losses, No transformer air conditioning,

13. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 13 The Advantages of Direct-to-Drive Reduced Size and Weight The PowerFlex 7000 with Direct-to-Drive technology is typically smaller and lighter that drive technologies that use Isolation Transformers.

14. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 14 What is Direct-to-Drive Technology?

15. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 15 Direct-to-Drive Technology Direct-to-Drive technology is the combination of three innovations that allow the PowerFlex 7000 to operate without an isolation transformer on both new and existing motors: –The SGCT –The Active Front End Rectifier and –Common Mode Voltage Protection

16. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 16 Direct-to-Drive Technology The SGCT The SGCTs high voltage rating and ability to be connected in series, allow the PowerFlex 7000 to be rated up to 6600 volts without adding complexity. The gentle switching characteristics of the SGCT make dv/dt and reflected wave motor filtering unnecessary.

17. SGCTSymmetrical Gate Commutated Thyristor (SGCT) SGCT blocks voltage in forward & reverse directions up to 6500V, current flow in 1 direction only Non-Punch-Through structure Symmetrical pnp transistor in the wafer Significant advantages –Simplification or elimination of snubber components –operation at a higher switching frequency, hence reducing the size of passive components (by 50%) and improving performance of the drive –reduction of component count, hence improving reliability, cost, and size of the drive

18. MV Drive Topology Comparison PowerFlex 7000 PWM SGCT inverter switch Low component count Simple power structure VSI-PWM 3 Level IGCT or MV IGBT inverter switch Medium component count Power structure complex due to series and parallel diodes required for 3 level VSI-PWM Multi-Level (Series Cell) LV IGBT inverter switch Very high component count. Very Complex power structure and transformer configuration Simple Complex Very Complex

19. Patented* Power Cage Houses main power components Compact, modular package Common design for rectifier & inverter modules

20. Easy to Service Front access Component replacement in less than 5 minutes no special tools required

21. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 21 Direct-to-Drive Technology The Active Front End Rectifier To comply with IEEE 519 while avoiding the use of a phase shifting isolation transformer, the PowerFlex 7000 with Direct-to-Drive technology employs the Active Front End Rectifier. The active font end uses the SGCT to produce a PWM switching pattern that prevents the drive from producing high levels of line harmonics.

22. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 22 Direct-to-Drive Technology The Active Front End Rectifier Harmonic Spectrum for the Active Front End:

23. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 23 Direct-to-Drive Technology Common Mode Voltage Protection Common Mode Voltage Protection technology, provides an alternative to using an isolation transformer. This technology is designed to mitigate common mode voltage stress generated by variable frequency drives. This feature does not require a motor with extra insulation and does not require an isolation transformer.

24. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 24 In Summary The three innovations that define Direct-to-Drive technology allow the PowerFlex 7000 to function with new or existing motors without an isolation transformer: The SGCT The Active Front End Rectifier Common Mode Voltage Protection The result is a smaller, lighter drive that has the lowest total cost of ownership on the market.

25. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. Direct-to-Drive Technology Product Feature Overview