Installation Instructions
Original Instructions
Medium Voltage SMC OEM Components, 10…15 kV
Bulletin Number 7703E
Important User Information
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.
IMPORTANT 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).
Table of Contents
Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1
Receiving and General
Information
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Handling Procedures for Electrostatic Sensitive Devices . . . . . . . . . . . 7
Standards and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 2
PowerBrick Installation Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sizing the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PowerBrick Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Typical Mounting, 10…12 kV PowerBrick System . . . . . . . . . . . . . . . 13
Typical Mounting, 12.1…14.4 kV PowerBrick System. . . . . . . . . . . . 14
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PowerBrick Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Voltage Sensing Board Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mounting and Connecting the Voltage Sensing Board. . . . . . . . . . . . 17
Current Loop Gate Drive Power Assembly (CLGD) . . . . . . . . . . . . . 19
Chapter 3
Control Component Installation Interface Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Interface Board Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SMC-50 Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
EMC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting Interface Board to Voltage Sensing Board. . . . . . . . . . . . 28
Connecting Fiber Optic Multiplexer Board to Gate Driver Board . 29
Additional Control Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main and Bypass Switching
Device Installation
Chapter 4
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Main Contactor or Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bypass Contactor or Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 3
Table of Contents
Chapter 5
Typical Wiring Diagrams Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 6
Final Test Procedures Final Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dielectric Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Additional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Medium Voltage SMC-50 Module. . . . . . . . . . . . . . . . . . . . . . . . . . 37
Voltage Sensing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Appendix A
Component Deratings Deratings Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Appendix B
Typical Schematic Diagrams Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix C
Spare Parts PowerBricks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Preface
Summary of Changes
Scope
Topic Page
Replace d all reference s from SMC Flex to SMC-50 Throughout
Changed MV Ratio parameter number to 169 18, 37
Replaced dimensions graphic to show updated SMC-50 board 23
Replaced SMC Flex interface board graphic with SMC-50 24
Updated control terminal designations and descriptions 27
Replaced multiplexer board graphic 29
Replaced typical power circuit wiring diagram to reflect SMC-50 interface board 34
Replaced typical power system diagram to reflect SMC-50 interface board 46
replace d typical co ntrol circuit graphic to reflect S MC-50 inter face board 47
This document pertains to the Bulletin 7703E SMC OEM components for
10…15 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 9
). Each form of PowerBrick assembly is
applied with other Bulletin 7703E control components and power devices, in
forming a complete solution.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 5
Preface
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
CENTERLINE Medium Voltage SMC-50 Motor Controller
user manual, publication 1560F-UM001
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Product Certifications website: rok.auto/certifications Provides declarations of conformity, certificates, and
Provides information on installing, commissioning,
operation, programming, troubleshooting, and
parameter information for MV SMC-50 controllers
Provides general guidelines for installing a Rockwell
Automation industrial system.
other certification details.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page
.
6 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Receiving and General Information
Chapter 1
Receiving
Handling Procedures for Electrostatic Sensitive Devices
See Getting Started, General Handling Procedures for Medium Voltage
Controllers, publication
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.
MV-QS050. This document is included with your
Standards and Codes
These precautions are the minimum requirements for guarding against ESD. For
more information, see Guarding Against Electrostatic Damage, publication
8000-4.5.2
IMPORTANT It is recommended that the user be familiar with the following safety and
•CEC (Canadian Electrical Code)
• CSA 22.2 No. 253 (Canadian Standards Association) – Medium Voltage
• NEC (National Electrical Code)
• NEMA ICS Standards (National Electrical Manufacturers’ Association)
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 7
.
design standards and codes, and any additional local codes that a medium
voltage controller must comply with:
AC Contactors, Controllers and Control Centers
Chapter 1 Receiving and General Information
• 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
8 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
PowerBrick Installation
Chapter 2
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 bl e 1
.
Table 1 - PowerBrick Options and Catalog Numbers
Catalog Number
7703E-PPMT 12,000V 3 PH, 50/60 Hz 160
7703E-PPMA 340
7703E-PPMC 580
7703E-PPNT 13,800V 160
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
(2) Voltage ranges: 12000 = 10000…12000V (5 PowerBricks in series per phase)
13800 = 12001…14400V (6 PowerBricks in series per phase)
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 9
(1)
Voltag e
(2)
for additional details.)
Current (A)
Chapter 2 PowerBrick Installation
Sizing the Enclosure
In addition to the PowerBricks, a voltage sensing board is to be connected in the
power circuit. Ta bl e 2
Table 2 - Voltage Sensing Board Catalog Number
Catalog Number Voltage Sensing Board Input (3 PH, 50/60 Hz)
7703E-VSM 10,000…12,000V
7703E-VSN 12,001…14,400V
lists the voltage sensing board catalog numbers.
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
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 0…1000 m (0…3,300 ft)
Net Shipping Weight
(3 PH)
Weight kg (lb) 570 (1260) 684 (1512)
(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.
(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 s
450% of FLA, 30 s
Start or Stop Cycle (at 450% FLA)
160 A 340 A 580 A Continuous
10,000…12,000V 27 57 98 0.5
12,001…14,400V 32 69 117 0.5
(See Controller Deratings Table on page 6, publication 1503-BR010F
Rating (kV) 10…12 12.1…14.4
)
(2)
Dimensions
10 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
See Figure 2, Figure 3, and Figure 4 for PowerBrick dimensions and mounting.
PowerBrick Insta llation Chapter 2
Torque Requirements
PowerBrick 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 Recommende d Torq ue
¼-20 thread cutting housing assembly screws 7 N•m [62 lb•in]
M5 3.4 N•m [30 lb•in]
Control Wi re 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-50 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]
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 (see 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 (see Figure 3
and Figure 4).
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.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 11
Chapter 2 PowerBrick Installation
Top View
Front View
Side View
Mounting holes for
M8 [5/16] hardware
(4) places
Figure 2 - Single PowerBrick Dimensions (1000/2400V)
12 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
PowerBrick Insta llation Chapter 2
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, 10…12 kV PowerBrick System
Figure 3 - Typical PowerBrick arrangement for 10…12 kV
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 13
Chapter 2 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,
12.1…14.4 kV PowerBrick
System
Figure 4 - Typical PowerBrick Arrangement for 12.1…14.4 kV
14 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Power Connections
Non-conductive mounting plate
(supplied by OEM)
Insulator
(supplied by OEM)
Flexible bus link
11 mm clearance hole
for M10 hardware
(supplied)
Ter m in al
PowerBrick Insta llation Chapter 2
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.
IMPORTANT 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. See
Figure 5
specifications shown in Tab l e 4
for the terminal location. Torque the fastening hardware to the
.
3. Use cable lugs to attach suitable load cables to the load cable terminal
(lower). Refer to Figure 5
for the terminal location. Torque the fastening
hardware to the specifications shown in Ta b l e 4
4. Refer to Chapter 5
connections. Appendix B
for a typical wiring diagram to determine the required
includes a typical schematic for a complete soft
starter unit.
Figure 5 - Typical Single Phase 15 kV PowerBrick Assembly (side view)
.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 15
Chapter 2 PowerBrick Installation
Figure 6 - Photo of Typical Single Phase PowerBrick Assembly (Front View)
Grounding
ATT EN TI ON : It is the responsibility of the OEM to ensure that the final enclosure
is suitably bonded to ground, and that provisions for grounding are made
according to local electrical codes and standards.
PowerBrick Operating Restrictions
16 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
The SCRs in the power stacks are not intended for continuous operation.
Observe the following operating restrictions for the SMC when operating at the
thermal capacity limit and maximum ambient temperature (see Ta bl e 3
• Power stacks must be bypassed using a separate contactor or circuit breaker
when the motor is up to speed.
• Do not operate the power stacks for more than 60 seconds in one hour.
• Do not exceed 30 seconds for any individual duty cycle of the power
stacks.
.)
PowerBrick Insta llation Chapter 2
8.9 [0.35]
4 holes
Includes features to secure
HV wire for maintained spacings.
Approximate dimensions in mm [inches]
• Do not operate the power stacks for at least five minutes between a start or
a stop cycle.
• For repeated hourly operation, forced ventilation is required.
Note: It may be possible to exceed some of the above restrictions if all maximum
ratings are not attained. For example, higher ambient conditions can be
supported when the % FLC and/or start time are reduced. Please consult factory
for details.
ATT EN TI ON : The operating restrictions for the SMC must be adhered to. Failure
to observe the recommended precautions may result in injury to personnel or
damage to the equipment.
Voltage Sensing Board Dimensions
Figure 7 - Voltage Sensing Board Dimension Diagram
Mounting and Connecting the Voltage Sensing Board
The voltage sensing board (VSB) for the relevant voltage range (see table below)
should be mounted adjacent to the PowerBrick (see Figure 7
for dimensions). All
connection points are to be made accessible.
Description Line Voltage
(3 phase, 50/60 Hz)
Voltage Sensing Board 10,000…12,000V 126 7703E-VSM
12,001…14,400V 97 7703E-VSN
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 17
MV Ratio Catalog Number
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