Rockwell Automation 7763 User Manual
Installation Instructions
OneGear™ MV SMC Flex Solid-State Motor Controller
Publication Number 7760-IN001B-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, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Equipment Overview
Transportation and Handling
Equipment Installation
Table of Contents
Chapter 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2
Unpacking and Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cabinet Handling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overhead Lifting Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rod or Pipe Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fork Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shipping Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 3
Removal of Overhead Lifting Brackets and Channels . . . . . . . . . . . . . . . . . 9
Opening the Front Medium Voltage Doors of the Converter Cabinet . . 9
Remove Medium Voltage Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . 10
Disconnect Fiber Optic Cables to Converter Roll-out Modules . . . . . . 10
Disconnect Flexible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disconnect Current Loop Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disconnect Mechanical Fastening of Converter Modules . . . . . . . . 13
Install Converter Roll-out Module Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install Converter Roll-out Module Pull Handle. . . . . . . . . . . . . . . . . . . . . 15
Removal of Lifting Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install the Converter Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
With Back Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Without Back Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inter-Cabinet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Floor Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation of Power Bus Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install Power Bus Bushing Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Connect Power Bus to Switchgear Risers . . . . . . . . . . . . . . . . . . . . . . . 23
Install Lower Bus Links in the Converter Cabinet. . . . . . . . . . . . . . . 24
Installation of Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Ground Bus Linking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electromechanical Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OneGear Standard Plenum
General Reference
Chapter 4
Assemble Standard Plenum to Cabinetry. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Appendix A
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rockwell Automation Publication 7760-IN001B-EN-P - June 2013 1
Table of Contents
Notes:
2 Rockwell Automation Publication 7760-IN001B-EN-P - June 2013
Equipment Overview
Incoming Line Unit
Main Unit
Converter Cabinet
Bypass Unit
650 mm
650 mm
1500 mm
650 mm
Chapter 1
Overview
The OneGear™ MV SMC controller family consists of the following
configurations:
• Bul. 7760 – Retrofit Controller
• Bul. 7761 – OEM Controller (converter cabinet)
• Bul. 7762 – Complete Controller utilizing vacuum contactors
• Bul. 7763 – Complete Controller utilizing vacuum breakers.
Figure 1
shows an overview of a typical Bulletin 7762/7763 controller complete
with incoming line unit. Refer to project documentation for specific
configuration details and dimensions.
Figure 1 - Typical Bulletin 7762/7763 OneGear MC SMC Controller
The Incoming Line Cabinet, Main Cabinet, and Bypass Cabinet are switch-gear
cabinets and are referred to as such throughout the remainder of this document.
All cabinets are shipped individually. This document describes the handling and
installation of the converter cabinet and the interconnections with the adjacent
switchgear cabinets.
Installation and connection instructions for switchgear cabinets, that are adjacent
to each other is covered by the respective manufacturer’s documentation and is
not included in this document.
Rockwell Automation Publication 7760-IN001B-EN-P - June 2013 3
Chapter 1 Equipment Overview
Notes:
4 Rockwell Automation Publication 7760-IN001B-EN-P - June 2013
Transportation and Handling
IMPORTANT
IMPORTANT
Chapter 2
Unpacking and Inspecting
Before leaving the factory, the controller has been tested mechanically and
electrically. Immediately upon receiving the controller, remove the packing and
check for possible shipping damage. Report any damage immediately to the
claims office of the carrier.
After unpacking, check the items received against the Bill of Lading to ensure
that the nameplate description of each item agrees with the material ordered.
Inspect the controller for physical damage as stated in the Rockwell Automation
Conditions of Sale.
All claims for breakage and damage, whether concealed or obvious, must be
made to the carrier by the customer as soon as possible after receipt of the
shipment. Rockwell Automation will render reasonable assistance in the
securing of adjustment for such damage claims.
Remove all packing material, wedges or braces from within the controller. If any
part of the equipment will not be installed when it is unpacked, it should be
stored in a clean dry place. The storage temperature must be between
-20...75 °C(-4...167° F) with a maximum humidity of 95% non-condensing.
The controller sections are shipped on wooden skids bolted to the cabinetry.
Lifting brackets are installed at the top corners of the cabinetry. The controller
sections must be maintained in the upright position during any handling.
ATT EN TI ON : Ensure that the load rating of all lifting equipment is sufficient to
safely raise the controller sections. Refer to the packing slip for shipping
weights.
Round rollers can be used to assist in moving the equipment to the installation
site. Once at the final site, rollers can be used to place the sections in their desired
position.
ATT EN TI ON : Use either a forklift or the pipe rolling technique for positioning
purposes to ensure that the equipment is not scratched, dented or damaged.
Stabilize the controller during handling to guard against tipping and injury to
personnel.
Customer installation duties must be performed correctly. Errors can cause
delays in commissioning or damage to the equipment.
Rockwell Automation Publication 7760-IN001B-EN-P - June 2013 5
Chapter 2 Transportation and Handling
Cabinet Handling Instructions
When lifting the 1500 mm wide converter cabinet, the lifting instructions
specified below must be followed.
WARNING: Do not pass cables or ropes through support holes. Always use
load-rated shackles or safety hooks in support holes. The legs of swing must not
exceed 45° from vertical.
Overhead Lifting Method
1. Verify that the front/back lifting channels and the middle cosmetic
channels are all installed and that the connecting hardware is tightened to
the cabinet.
2. Verify that the four lifting clips have corresponding internal lifting clips
installed and connected. Lifting clip holes are 30 mm.
3. Figure 2
different depending on customers’ decision and availability of the lifting
hardware. Verify shipping weight and capacity of lifting equipment.
4. The angle between the slings (Figure 2
more (70° is ideal).
is only for lifting demonstration purpose. The lifting parts may be
) and horizontal must be 45° or
5. The centre to centre distance of the two lifting points of the lifting angle or
beam is to be 1500 mm +/- 150 mm (60” +/- 6.0”).
6 Rockwell Automation Publication 7760-IN001B-EN-P - June 2013
Figure 2 - Overhead Lifting of Converter Cabinet
Transportation and Handling Chapter 2
Rockwell Automation Publication 7760-IN001B-EN-P - June 2013 7
Chapter 2 Transportation and Handling
2 x 6 in. minimum (50.8 x 152.4 mm)
Rod or Pipe Rollers
This method is only suitable when there are no inclines and the controller is
being moved on level floor. Boards 50 x 152 mm (2 x 6”) or equivalent and at
least 300 mm longer than the controller must be placed under the shipping skid,
as shown in Figure 3
Carefully ease the shipping skid over the rollers until the equipment weight is
borne on the rollers. The controller can be rolled to its desired location. Steady
the load to prevent tipping.
Figure 3 - Rod or Pipe Rollers
.
ATT EN TI ON : Ensure that the load rating of all lifting equipment is sufficient to
safely raise the controller sections. Refer to the packing slip for shipping
weights.
Fork Lift Truck
A single fork lift truck may be used, extreme caution must be exercised.
1. Insert the forks into openings of the shipping skid from the rear of the
controller.
2. Carefully balance the controller on the forks and apply safety straps.
Shipping Skid Removal
Internal access is not required to remove the wooden shipping skid from the
converter cabinet. External angle brackets attached to the enclosure are used to
attach the enclosure to the wooden skid.
Remove the angle brackets and the associated hardware. When the enclosure is
lifted by overhead means, the wooden skid can be removed.
8 Rockwell Automation Publication 7760-IN001B-EN-P - June 2013
Equipment Installation
Chapter 3
Removal of Overhead Lifting Brackets and Channels
Before joining to adjacent equipment, the lifting brackets and exterior vertical
lifting channels from the converter cabinet must be removed.
Removing of the lifting brackets requires access to the interior of the enclosure
where corresponding internal brackets are located and require removal. Please
refer to page 16
It will be necessary to remove the converter roll-out modules from the enclosure
to install power connections to the adjacent equipment and to install hardware to
secure the enclosure to its floor.
To remove converter modules from the cabinet, the following operations are
necessary:
1. Open the Medium Voltage Doors (see below)
2. Remove the Medium Voltage Front Cover (page 10
3. Disconnect Fiber Optic Cables (page 10
4. Disconnect Flexible Braided Links (page 12
5. Disconnect Current Loop Wire (page 12
6. Disconnect Mechanical Fastening of Converter Module (page 13
for hardware removal details.
)
)
)
)
)
Opening the Front Medium Voltage Doors of the Converter Cabinet
7. Installation of converter roll-out module ramp (page 14
8. Installation of Pull Handle (page 15
Access to the medium voltage converter section is attained by opening the three
lower doors. The left door is generally equipped with interlocking with upstream
equipment. The specifics of this interlocking depends on customer requirements
and is provided in the customer drawings.
Rotating the door handle unlatches the door allowing it to be opened. DO NOT
force open the doors.
The middle and right medium voltage doors are mechanically interlocked with
the left medium voltage door such that the left door must be opened before the
middle and right doors can be opened. Similarly, the left door cannot be closed
until both the middle and right doors are closed and latched.
Rockwell Automation Publication 7760-IN001B-EN-P - June 2013 9
)
)
Chapter 3 Equipment Installation
Medium Voltage
Front Cover
Remove Medium Voltage Front Cover
Access to the medium voltage area above the middle and right doors is attained
by removing the bolts that hold the cover in place (Figure 4
ATT EN TI ON : Ensure that power to the unit has been shut down and locked out
before accessing medium voltage areas. Failure to do so may result in severe
injury or death.
Figure 4 - Medium Voltage Front Cover Identification
).
Disconnect Fiber Optic Cables to Converter Roll-out Modules
ATT EN TI ON : Fiber optic cables can be damaged by bending the cables with a
radius of less than 50 mm (2 in.).
To disconnect the fiber optic cables on each of the converter modules, it is
necessary to remove the Front Medium Voltage front cover located over the
middle and right medium voltage doors. Removal of this panel provides access to
the multi-channel fiber optic circuit board.
10 Rockwell Automation Publication 7760-IN001B-EN-P - June 2013
IMPORTANT
Multi-channel Fiber
Optic Board location
Equipment Installation Chapter 3
Note the locations of the fiber optics from the fiber optic circuit board before
disconnecting them.
The fiber optic cables are individually identified. Fiber optic cables are
disconnected from the circuit by squeezing the latch lever of each fiber optic
terminal and pulling the fiber optic line out of the multi-channel fiber optic
circuit board (Figure 5
Figure 5 - Multi-channel Fiber Optic Circuit Board Location
)
The cables should be carefully coiled on top of the PowerBricks, so they will not
be damaged when the cart is removed
Reconnection of fiber optic cables requires that the fiber optic cables, for each
phase of converter module, must be connected to the transmitter terminals of the
appropriate phase location on the fiber optic multiplexer circuit board. Within
each phase of fiber optic connectors the order of connection is not critical.
Figure 6
shows a close-up view of the fiber optic multiplexer board and the
grouping of fiber optic connections per phase.
Rockwell Automation Publication 7760-IN001B-EN-P - June 2013 11
Chapter 3 Equipment Installation
IMPORTANT
Figure 6 - Fiber Optic Multiplexer Board
Disconnect Flexible Links
At the top of each roll-out converter module, two flexible links are provided to
connect power to the converter module. A 13 mm hex tool is needed to remove
the hardware at the upper end of the flexible link. The location of the top flexible
link connections to the converter bus are shown in Figure 7
The cable from the rear of the cart must be freed from the clamps that secure it to
the structure.
The cable must be re-attached to these clamps when the cart is re-installed.
.
Disconnect Current Loop Wires
Power for the gate driver circuit boards is provided by current transformers that
derive power from a low voltage loop of wire that is visible at the front of the rollout converter modules. The current loop wire terminations are accessible at the
front and can be disconnected at terminal blocks located above each of the
converter modules, as shown in Figure 7
.
12 Rockwell Automation Publication 7760-IN001B-EN-P - June 2013
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