Rockwell Automation 7703E User Manual
Installation Instructions
Medium Voltage SMC™ OEM Components (10…15 kV)
Publication 7703E-IN001E-EN-P
Important User Information
IMPORTANT
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Allen-Bradley, Rockwell Software, Rockwell Automation, PowerFlex, and TechConnect are trademarks of Rockwell
Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Summary of Changes
This manual contains new and updated information. Changes throughout this
revision are marked by change bars, as shown to the right of this paragraph.
New and Updated Information
This table contains the changes made to this revision.
Top ic Pag e
Migrated manual to FrameMaker
Updated PowerBrick catalog numbers and removed footnotes about them 11
Added 580 A to PowerBrick specifications table 12
Updated PowerBrick dimension and arrangement diagrams 14, 15, 16
Removed 160/340 A description from power circuit wiring diagram 38
Added 580 A to component derating table 47
Added 580 A to PowerBrick replacements table 53
Added Index 55
Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014 3
Summary of Changes
Notes:
4 Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014
Introduction
Table of Contents
Chapter 1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 2
Receiving and General Information
PowerBrick™ Installation
Control Component Installation
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Handling Procedures for Electrostatic Sensitive Devices . . . . . . . . . . . . . . . 9
Standards and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Sizing the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PowerBrick Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Mounting Arrangement, 10…12 kV PowerBrick System . . . . . 15
Typical Mounting Arrangement, 12.1…14.4 kV PowerBrick System. . 16
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PowerBrick Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Voltage Sensing Board Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mounting and Connecting the Voltage Sensing Board . . . . . . . . . . . . . . 21
Current Loop Gate Drive Power Assembly (CLGD) . . . . . . . . . . . . . . . . 23
Chapter 4
Interface Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Interface Board Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SMC Flex Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
EMC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Connecting Interface Board to Voltage Sensing Board. . . . . . . . . . . . . . . 32
Connecting Fiber Optic Multiplexer Board to Gate Driver Board . . . . 33
Additional Control Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Main and Bypass Switching Device
Installation
Chapter 5
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Main Contactor or Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Bypass Contactor or Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014 5
Table of Contents
Chapter 6
Typical Wiring Diagrams
Final Test Procedures
Component Deratings
Typical Schematic Diagrams
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Chapter 7
Final Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dielectric Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Additional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MV SMC Flex Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Voltage Sensing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Power Supply Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Appendix A
Deratings Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Appendix B
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Spare Parts
Index
Appendix C
PowerBricks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6 Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014
Introduction
Chapter 1
Scope
Additional Publications
This document pertains to the Bulletin 7703E SMC OEM components for 1015 kV. These components allow an OEM to fabricate a medium voltage soft
starting solution.
Most of the components described herein are provided in various 7703E kits;
however, some of the devices described are not provided. These must be acquired
separately.
A key part of the Bulletin 7703E components is the power stack assembly which
uses PowerBrick™ technology. PowerBricks are a superior means of packaging
SCRs, heatsinks, passive devices (for circuit protection) and gate drive circuit
boards. Each PowerBrick is a self-contained assembly with inherent insulation
and flexible mounting features. PowerBricks are easily connected in series to
service the required system voltage level.
PowerBricks are provided as a set of components used to create a three-phase
assembly (refer to Figure 1 on page 11
applied with other Bulletin 7703E control components and power devices, in
forming a complete solution.
Please refer to Medium Voltage SMC Flex Motor Controller, Bulletin 1503E,
1560E, 1562E User Manual 1560E-UM051_-EN-P
about the functionality of some of the Bulletin 7703E products. This document
contains the following information for the MV SMC Flex:
• Commissioning
• Maintenance and Troubleshooting
• Parameter List
). Each form of PowerBrick assembly is
for additional information
To order additional copies of Instruction Manuals for all Rockwell Automation
medium voltage products, please contact a Rockwell Automation sales office or
your local distributor.
Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014 7
Chapter 1 Introduction
Notes:
8 Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014
Receiving and General Information
IMPORTANT
Chapter 2
Receiving
Handling Procedures for Electrostatic Sensitive Devices
Refer to Getting Started, General Handling Procedures for Medium Voltage
Controllers – Publication MV-QS050_-EN-P
your shipment and contains information regarding receiving, unpacking, initial
inspection, handling, storage, and site preparation.
ATT EN TI ON : Printed circuit boards contain components that can be damaged
by electrostatic charges that build up on personnel during normal activities.
Exercise the following precautions when handling electrostatic sensitive
devices. Failure to do so may damage the device and render it inoperable.
To guard against electrostatic damage (ESD) to equipment, the following
precautions should be observed when handling electrostatic sensitive devices.
1. Use a grounding wrist strap to minimize the build up of static charges on
personnel.
2. Handle the module by the edges and avoid touching components or
printed circuit paths.
3. Store devices with sensitive components in the conductive packaging that
the module is shipped in.
. This document is included with
These precautions are the minimum requirements for guarding against ESD. For
more information refer to Guarding Against Electrostatic Damage –
Publication ICCG-4.3. See the Additional Publications section for information
on obtaining this document.
Standards and Codes
It is recommended that the user be familiar with the following safety and
design standards and codes, and any additional local codes that a medium
voltage controller must comply with:
• CEC (Canadian Electrical Code)
• CSA 22.2 No. 253 (Canadian Standards Association) – Medium Voltage
AC Contactors, Controllers and Control Centers
• NEC (National Electrical Code)
Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014 9
Chapter 2 Receiving and General Information
• NEMA ICS Standards (National Electrical Manufacturers’ Association)
• OSHA (Occupational Safety and Health Administration)
• UL 50 (Underwriters Laboratories) – Enclosures for Electrical Equipment
• UL 347B (Underwriters Laboratories) – Medium Voltage Motor
Controllers
• UL 508 (Underwriters Laboratories) – Industrial Control Equipment
• IEC 60204-1 – Safety of Machinery – Electrical Equipment of Machines,
Part 1: General Requirements
• IEC 62271-200 – AC Metal Enclosed Switchgear and Control Gear for
Rated Voltages Above 1kV and up to 52 kV (formerly IEC 60298)
• IEC 62271-106 – High Voltage Alternating Current Contactors (formerly
IEC 604701
• IEC 60529 – Degrees of Protection Provided by Enclosures (IP Code)
• IEC 62271-1 – Common Clauses for High Voltage Switchgear and
Control Gear Standards
• ICS1– Industrial Control and Systems General Requirements
• ICS3 Part 2 – Industrial Control and Systems - Medium Voltage
Controllers Rated 2001-7200V AC
10 Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014
PowerBrick™ Installation
Chapter 3
Identification
A PowerBrick is shown in Figure 1.
Figure 1 - Single-phase PowerBrick
Several PowerBricks are supplied as a loose set of components to service a
particular voltage and current. Verify the voltage and current rating of the OEM
power stacks by examining the shipping label and referencing it to the
information in Ta b l e 1
.
Table 1 - PowerBrick Options and Catalog Numbers
Catalog Number
7703E-PPMT
7703E-PPMA 340
7703E-PPMC 580
7703E-PPNT
7703E-PPNA 340
7703E-PPNC 580
(1) The OEM is responsible for ordering and installing the correct format for the current loop gate drive conductor conduit/CT assembly
(refer to the Installation Instructions, publication 7703E-IN008_-EN-P
(2) Voltage ranges: 12000 = 10000…12000V (5 PowerBricks in series per phase)
Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014 11
(1)
13800 = 12001…14400V (6 PowerBricks in series per phase)
Voltag e
12000V
13800V
(2)
3 phase, 50/60 Hz
for additional details.)
Current (Amps)
160
160
Chapter 3 PowerBrick™ Installation
In addition to the PowerBricks, a voltage sensing board is to be connected in the
power circuit. Ta b l e 2
Table 2 - Voltage Sensing Board Catalog Number
Catalog Number Voltage Sensing Board Input (3 phase, 50/60 Hz)
7703E-VSM 10,000…12,000V
7703E-VSN 12,001…14,400V
lists the voltage sensing board catalog numbers.
Sizing the Enclosure
Description 160 A, 340 A
Input Voltages
(50/60 Hz)
Ambient Temperature 0 °C…40 °C (32 °F…104 °F)
Power Sec tion
(for 3 phases)
Repetitive Peak Inverse
Volt age R ating
Thermal Capacity
dv/dt Protection R.C. Snubber Network
Maximum Heat
Dissipation (kW)
Altitude
Net Shipping Weight
(3 phases)
Weig ht
kg (lbs)
(1)
10,000…12,000V
12,001…14,400V
3 phase, +10%, -15%
30 SCR at 10…12 kV
36 SCR at 12.1…14.4 kV
10 to12 kV…32,500 PIV
12.1…14.4 kV…39,000 PIV
600% of FLA, 10 seconds
450% of FLA, 30 seconds
Start or Stop Cycle (at 450% FLA)
10,000…12,000V 27 57 98 0.5
12,001…14,400V 32 69 117 0.5
0…1000 m (0…3,300 ft)
(See Controller Deratings Table on page 6, Publication 1503-BR010F-EN-P
Rating (kV) 10…12 12.1…14.4
570 (1260) 684 (1512)
ATT EN TI ON : The enclosure for the power stack assemblies must be adequately
sized to provide sufficient airflow to cool the units. Failure to provide adequate
cooling may result in reduced duty cycles or component failure.
Use the data in Ta b l e 3 to assist in calculating the enclosure size.
Table 3 - PowerBrick Specifications
160 A 340 A 580 A Continuous
)
(2)
(1) It may be possible to offer extended start times at reduced current or ambient temperature. Please consult Rockwell Automation factory for assistance.
(2) After bypass contactor/breaker is closed.
12 Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014
PowerBrick™ Installation Chapter 3
Dimensions
Torque Requirements
Refer to Figure 2, Figure 3, and Figure 4 for PowerBrick dimensions and
mounting.
All electrical connections must be torqued to the specifications shown in Ta b l e 4 .
ATT EN TI ON : Ensure that all electrical connections are torqued to the correct
specification. Failure to do so may result in damage to the equipment and/or
injury to personnel.
Table 4 - Torque Requirements
Hardware Recommended Torque
¼-20 thread cutting housing assembly screws 7 N•m [62 lb•in]
M5 3.4 N•m [30 lb•in]
Control Wire Terminals 0.2…0.4 N•m [2.0…3.3 lb•in]
CLGD Power Assembly Terminals 5.6 N•m [50 lb•in]
SMC Flex Control Module Terminals 0.6 N•m [5in•lb]
M8, Capacitor Lugs
M8, All others
M10 29 N•m [250 lb•in]
7.5 N•m [66 lb•in]
14 N•m [120 lb•in]
PowerBrick Mounting
PowerBricks are to be mounted in a vertical orientation in order to provide
adequate component cooling. Mount the PowerBricks in a suitable location using
the mounting holes provided in the assembly (refer to Figure 2
). Use
M8 (5/16 in.) or similar hardware for the mounting hole dimensions of
10.7 x 15.9 mm (0.421 x 0.625 in.).
PowerBricks are provided with two methods for mounting (as shown in
Figure 2
). The PowerBricks can be mounted to a vertical surface using the four
mounting locations on the rear face, or they can be mounted to a horizontal
surface using the four mounting locations on the base.
Note: Using either mounting option requires space above and below each phase
assembly (refer to Figure 3
and Figure 4).
Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014 13
Chapter 3 PowerBrick™ Installation
Top View
Front View
Side View
Mounting holes for
M8 [5/16] hardware
(4) places
ATT EN TI ON : Maintain sufficient clearance between the power phases and
between phases and grounded surfaces. Refer to local electrical codes to
determine the required clearance. Failure to do so may result in injury to
personnel or damage to the equipment.
Figure 2 - Single PowerBrick Dimensions (1000/2400V)
14 Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014
PowerBrick™ Installation Chapter 3
Front View
Typical spacing to ground metallic enclosure
components. Spacing may be reduced through the
full use of suitable insulation systems.
Side View
Typical Mounting Arrangement, 10…12 kV PowerBrick System
Figure 3 - Typical PowerBrick arrangement for 10…12 kV
Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014 15
Chapter 3 PowerBrick™ Installation
Front View
Typical spacing to ground metallic enclosure
components. Spacing may be reduced through the
full use of suitable insulation systems.
Side View
Typical Mounting
Arrangement,
12.1…14.4 kV
PowerBrick System
Figure 4 - Typical PowerBrick arrangement for 12.1…14.4 kV
16 Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014
PowerBrick™ Installation Chapter 3
IMPORTANT
Power Connections
ATT EN TI ON : To avoid shock hazard, lock out incoming power to power cables
when completing connections. Failure to do so may result in severe burns,
injury or death.
It is the responsibility of the OEM to ensure that suitable line and load cables
are used to satisfy the requirements of the equipment and meet local electrical
codes.
1. The PowerBrick units are connected to each other in order to create a
complete phase assembly. The flexible connector on the top of each
PowerBrick is attached to the fixed connector on the bottom of the
PowerBrick above.
2. The top PowerBrick should be connected to a suitable fixed terminal
location. Use appropriate cable lugs to attach suitable line cables to the line
cable terminal. Each PowerBrick can use M10 (3/8 in.) hardware. Refer to
Figure 5
specifications shown in Tab l e 4
3. Use cable lugs to attach suitable load cables to the load cable terminal
(lower). Refer to Figure 5
hardware to the specifications shown in Ta b l e 4
for the terminal location. Torque the fastening hardware to the
.
for the terminal location. Torque the fastening
.
4. Refer to Chapter 5
determine the required connections. Appendix B
schematic for a complete soft starter unit.
and Chapter 6 for a typical wiring diagram to
includes a typical
Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014 17
Chapter 3 PowerBrick™ Installation
Non-conductive mounting plate
(supplied by OEM)
Insulator
(supplied by OEM)
Flexible bus link
11 mm clearance hole
for M10 hardware
(supplied)
OEM provided
flexible link
Ter m i na l
Figure 5 - Typical Single Phase 15 kV PowerBrick Assembly (side view)
18 Rockwell Automation Publication 7703E-IN001E-EN-P - July 2014
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