Normal Duty and Heavy Duty Powerflex Drives

Normal Duty and
Heavy Duty
PowerFlex Drives
LV MCC Specialists WebEx

April 06, 2006
Todd Sauve –
Senior LV MCC Product Marketing
Engineer
Confidential -- For Internal Use Only. Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 1
Topics for Today
• Announce that the LV MCC Business now offers Heavy Duty

drive sizing on our quick delivery program for 480V and 600V
PowerFlex 70 (Bulletin 2162Q & 2163Q) and PowerFlex 700
(Bulletin 2162R & 2163R) drive units
• Provide an explanation of the LV MCC unit catalog numbering
scheme and ratings
• Discuss the differences between Variable and Constant Torque
Loads, explain Normal and Heavy Duty sizing and how to select
the proper drive for a given application
LV MCC Heavy Duty Unit Availability
• Prior to March 27, all quick delivery PowerFlex drives were Normal Duty
only
– Heavy Duty was available on the engineered delivery program
– Users may have been specifying one drive larger to get “heavy duty” using the quick
delivery program
• Heavy Duty, it’s not just using a quick delivery Normal Duty drive unit with a
smaller load. The drive component might be correct, but…
– Circuit Breaker or Power Fuses could be oversized
– Line and load reactors may be oversized (i.e. lower percent impedance)
– The MCC documentation will not reflect the correct ratings
• The LV MCC Business is now offering 480V and 600V PowerFlex 70 and
700 drive units sized for Heavy Duty applications on the quick delivery
program
– On the quick delivery program, units with isolated, manual bypass (Bulletin 2164 and
2165) remain Normal Duty only
– Heavy duty units with isolated, manual bypass are available on the engineered delivery
program
Catalog Numbers and Ratings
• A Normal Duty catalog number for a 10Hp load used to look like this:
– 2162QA-014KB-14C0-14HA0-41
• A Normal Duty catalog number for a 10Hp load now looks like this:
– 2162QA-014NKB-14C0-14HA0-41
– The MCC unit label (sticker) for this unit will say that it is a
14 Amp, 10HP, ND drive unit
• A Heavy Duty catalog number for a 10Hp load looks like this:
– 2162QA-022HKB-14C0-14HA0-41,
– The MCC unit label (sticker) for this unit will say that it is a
14 Amp, 10HP, HD drive unit
• We’ll talk more about the ampere ratings later in the presentation
Variable Torque and Constant Torque Are Not
The Same As Normal Duty and Heavy Duty
• Variable and Constant Torque ratings are associated with the
1336 family of drives.
• Normal and Heavy Duty ratings/sizing are associated with the
PowerFlex family of drives (excluding PowerFlex 40)
• Replacing a Constant Torque 1336 drive with a PowerFlex drive
doesn’t necessarily mean that Heavy Duty sizing is required
• Overload capabilities are different between the Variable Torque
and Constant Torque drives and the PowerFlex drives
Variable Torque Loads and
Variable Torque Drives
• Load torque requirements
change with speed
– Low speed = low torque
200% – Full speed = full torque
• Typical applications
150% – Fans
% of
FLC – Pumps
100% – Blowers
VT, 110%, 60 Sec • Usually no overload
capabilities are required
• The drive can provide up to
3 (sec) 60 110% of FLC for up to 60
seconds
Constant Torque Loads and
Constant Torque Drives
• Loads require the same
amount of torque throughout
the entire speed range
• Typical applications
200%
– Conveyors & Mining
– Other applications where
150% initial clearing torque is
% of CT, 150%, 60 Sec needed
FLC
100%
• May require high current
VT, 110%, 60 Sec
during startup and during
momentary overload
conditions
• The drive can provide up to
3 (sec) 60 150% of FLC for up to 60
seconds
Overload Capabilities of Variable and Constant Torque
Drives Compared to Normal and Heavy Duty Drives
3 sec. overload capability

to provide breakaway
torque
HD, 200%
200% ND, 150%
150% HD, 150%, 60 Sec

% of CT, 150%, 60 Sec
FLC
100%
VT, 110%, 60 Sec ND, 110%, 60 Sec
3 60 3 60
(sec)
Variable Torque and Constant Torque Drive
Load and Overload Capabilities
• Variable Torque Drive • Constant Torque Drive
– Satisfies only Variable Torque loads – Satisfies Constant Torque loads, but
could also be used for Variable
Torque loads
– Can provide a very limited amount of – Can provide a significant amount of
overload torque/current for a overload torque/current for a
significant period of time significant period of time
• Up to 110% of FLC • Up to 150% of FLC
for up to 60 sec for up to 60 sec
• Some power ratings can
provide more than 150% of
FLC for 3 sec
PowerFlex Drive Load and Overload
Capabilities
• Normal Duty Sizing • Heavy Duty Sizing
– Satisfies all variable torque and some – Satisfies all traditional constant torque
constant torque applications applications and can also be used for
– Can provide a very limited amount of all variable torque applications
overload torque/current for a
significant period of time
• 110% OL – 60 sec.
– Can provide a significant amount of
– Can provide a significant amount of
overload torque/current
for a short period of time overload torque/current
for a significant period of time
• 150% OL – 3 sec.
• 150% OL – 60 sec.
– In addition, can provide two times
FLC for a short period of time
• 200% OL – 3 sec.
Load Characteristics
• Does the load need:
– Up to 110% of FLC for up to 60 seconds, or up to 150% of FLC for up to 3 seconds?
If so, then this is a Normal Duty application
or
– Up to 150% of FLC for up to 60 seconds, or up to 200% FLC for up to 3 seconds?
If so, then this is a Heavy Duty application
• With the Variable Torque drives, any load requirements greater than 110%
of FLC for any period of time would require the use of a Constant Torque
drive.
• PowerFlex 70 and 700 drives sized for Normal Duty can supply 150% of
FLC for 3 seconds.
This capacity allows the PowerFlex drive sized for normal duty to be used
in many Constant Torque applications
Drives and Loads, Summary
• Variable Torque loads require low torque at low speeds and full torque at
full speed, typically no overload capabilities are required
• Constant Torque loads require the same amount of torque throughout the
entire speed range
They sometimes require overload capabilities
• VT rated drives can satisfy only VT loads
PowerFlex ND sizing is more than capable of satisfying all VT loads
PowerFlex HD sizing for a VT application could be used,
but would be overkill and add unnecessary cost
• CT loads can be satisfied by CT rated drives, PowerFlex ND sizing or,
PowerFlex HD sizing, depending on how much overload is required.
• Not all CT loads are equal!
150% of FLC for 3 seconds, PowerFlex ND sizing will satisfy the load
requirements
150% of FLC for 60 seconds, PowerFlex HD sizing will be required
LV MCC Drive Unit Normal Duty Ratings
• The Normal Duty catalog number for the 10Hp load looks like this:
– 2162QA-014NKB-14C0-14HA0-41
The MCC unit label (sticker) for this unit will say that it is a
14 Amp, 10HP, ND drive unit
– This unit uses a 20AD014 drive, which has component current ratings of:
14A continuous, 16.5A for 60 sec., and 22A for 3 sec.
– For normal duty sizing, the LV MCC drive unit continuous current rating is the same
as the drive component continuous current rating.
– A 14A FLC motor being controlled by this “normal duty” drive unit can be provided
with:
• 100% FLC continuously
• 118% FLC for 60 seconds ( 16.5A / 14A )
• 157% FLC for 3 seconds ( 22A / 14A )
LV MCC Drive Unit Heavy Duty Ratings
• A typical Heavy Duty catalog number will look like this:
– 2162QA-022HKB-14C0-14HA0-41,
The MCC unit label (sticker) for this unit will say that it is a
14 Amp, 10HP, HD drive unit
– This unit uses a 20AD022 drive, which has component current ratings of:
22A continuous, 24.2A for 60 sec., and 33A for 3 sec.
– For heavy duty sizing, the LV MCC drive unit continuous current rating is the same as
for the normal duty drive with the same nominal load rating.
For the Heavy Duty drive with a 10Hp load, this rating is 14 amps.
– If the LV MCC unit rating was listed as 22 Amp, 10HP, HD, it could be misunderstood
to mean “Heavy duty sizing means 150% for 60 sec., so I can run 33A (22A * 150%)
through this drive for 60 seconds”. We know that this would be wrong because the
20AD022 drive can only provide 33A for 3 seconds!
– A 14A FLC motor being controlled by this “heavy duty” drive unit can be provided with:
• 100% FLC continuously
• 173% FLC for 60 seconds ( 24.2A / 14A )
• 235% FLC for 3 seconds ( 33A / 14A )
Understanding Load Requirements —
“It’s Your Duty”
Normal Duty Applications Heavy Duty Applications
Include all variable torque loads
Include some constant torque loads
May require limited overload current or May require a significant amount

a significant amount of overload current, of overload current for a
but only for a short period of time significant period of time
Normal Duty Sizing can provide Heavy Duty Sizing can provide
110% overload for 60 seconds 150% overload for 60 seconds
or or
150% overload for 3 seconds 200% overload for 3 seconds
Variable Torque Loads Constant Torque Loads

Typically have no overload Usually have overload current requirements,
current requirements. but not always the same amount of current
(e.g. fans and pumps) or the same amount of time
Remember to make sure the motor FLC is less than or equal to

the drive unit’s continuous current rating!

Normal Duty and Heavy Duty Powerflex Drives

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Normal Duty and Heavy Duty Powerflex Drives

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Normal Duty and

LV MCC Specialists WebEx

• Announce that the LV MCC Business now offers Heavy Duty

3 sec. overload capability

150% HD, 150%, 60 Sec

May require limited overload current or May require a significant amount

Variable Torque Loads Constant Torque Loads

Remember to make sure the motor FLC is less than or equal to

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