Page 1
Installation Instructions
Original Instructions
Medium Voltage SMC OEM Components, 10…15 kV
Bulletin Number 7703E
Page 2
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).
Page 3
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
Page 4
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
Page 5
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
Page 6
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
Page 7
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
Page 8
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
Page 9
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)
Page 10
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.
Page 11
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
Page 12
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
Page 13
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
Page 14
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
Page 15
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
Page 16
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.
.)
Page 17
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
Page 18
Chapter 2 PowerBrick Installation
To I nter fa ce B oa rd
Ground Connections
Connect the voltage sensing board to the L1 to L3 (Line) and T1 to T3 (Load)
terminals of the power stack (see Figure 8
).
Recommended specifications for wire used on medium voltage connections: UL
style 3239, #18 AWG, 40 KVDC silicone rubber insulated wire, covered with
PCV tubing or other suitable material.
IMPORTANT The wires must be prevented from touching live or grounded metals, and low
voltage wiring, or have supplemental insulation suitable for the application.
Use the tapered features below the Lx and Tx terminals to maintain wire
spacings in this area.
The MV ratios shown above are nominal values and may be fine tuned to achieve
better accuracy on the display of the SMC-50 control module. While running
the motor in bypass mode, compare the voltage displayed on the control module
to a known accurate meter connected to the same source voltage as the motor the
MV SMC-50 is controlling. Parameter 169, MV Ratio, may be changed up or
down to match the HIM display to the external meter. A small change in ratio
can make a large change in the display, so 5 units at a time are recommended.
Increasing the ratio will decrease the displayed voltage, and visa versa.
Figure 8 - Voltage Sensing Board
18 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 19
PowerBrick Insta llation Chapter 2
Current Loop Gate Drive Power Assembly (CLGD)
The CLGD power assembly is provided as a loose component with the
PowerBricks. It should be mounted adjacent to the PowerBrick in a manner that
allows the secondary cable assembly to be correctly installed.
The CLGD power assembly consists of three parts:
1. Power supply (transformer with secondary terminal blocks and sensing
CT)
2. Current Transformer (CT) assembly (plastic tubing with two current
transformers per PowerBrick)
3. Loop Cable (white, silicone insulated, 50 kV DC, #6 AWG)
The CT assembly is mounted with hardware to the left side of the PowerBrick
stack, and can be pivoted to the left by loosening the mounting hardware to allow
removal of individual PowerBricks without removing the CT assembly. The
current transformer secondary leads plug into the gate driver board directly
behind each CT, and must all be unplugged to pivot the assembly.
Figure 9 - PowerBrick Current Loop Gate Drive Cable Assembly and Power Supply
ATT EN TI ON : Check that all CT leads are plugged into each gate driver board
before putting the SMC into service. Failure to do so may result in erratic
operation and/or equipment damage during option stop maneuvers.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 19
Page 20
Chapter 2 PowerBrick Installation
CLGD CT
Connect ion
Terminal
CLGD CTs
CLGD CT
Connection
Ter m in al
Figure 10 - Connection of CLGD CTs to Gate Driver Board
The CT assembly has a loop cable which passes through the tube and connects to
terminal blocks above and/or below the assembly (depending on how the
assembly is implemented). The three phases of loop cables are connected in series
and to the secondary of the power supply transformer. The transformer rating
and secondary voltage are selected to provide 40 or 50 amps in the loop cable.
See Ta b le 5
See Appendix C
Table 5 - Matching Loop Length to Power Supply Transformer Rating
Power Supply Transformer Rating Total Loop Length for #6 AWG Cable
50 VA, 115/230:0.6V 6.4 m ± 10 cm (21 ft ± 4 in.)
100 VA, 115/230:1.5V 15.2 m ± 20 cm (50 ft ± 8 in.)
(1) The 50 ft length is 3 x 14 ft HV wire plus 8 ft LV wire.
for matching the loop length to the power supply transformer rating.
for part numbers.
(1)
ATT EN TI ON : The loop cable length must be as specified above. The loop cable is
the load for the transformer and establishes the loop current. If it is not correct,
a longer length will not provide sufficient power to the gate driver boards, and a
shorter length will overload the cable or transformer.
20 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 21
PowerBrick Insta llation Chapter 2
To
control
power
1. Power Supply
2. Current Transformer Assembly
3. Loop Cable
4. Terminal
5. Return Cable #6 AWG (13 mm)
The total length of the three loop
cables and the return cable must be
152. m ± 20 cm (50 feet ± 8 in.).
Power Brick
assemblies
NOTE:
1. Power Supply
2. Current Transformer Assembly
3. Loop Cable
4. Terminal
5. Return Cable #6 AWG (13 mm)
The total length of the three loop
cables and the return cable must be
152. m ± 20 cm (50 feet ± 8 in.).
PowerBrick
assemblies
NOTE:
A sensing CT is supplied to monitor the current in the loop. It provides a signal
to the Interface Board to inform the SMC-50 control module that the power
supply is operating. If the current loop is not operating, option stop maneuvers
will be inhibited. An Alarm will be generated in the SMC-50 control module if
the signal is lost after control power has been applied. If control power is applied
without the signal, the controller will not provide option stop maneuvers until
the module is powered up with the signal present.
Figure 11 - Typical 12 kV Implementation for Current Loop
Figure 12 - Typical 15 kV Implementation for Current Loop
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 21
Page 22
Chapter 2 PowerBrick Installation
Notes:
22 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 23
Control Component Installation
Chapter 3
Interface Board Installation
Mount the 7703E-INTB interface board in a suitable location within a low
voltage compartment, using the appropriate hardware. Use the interface board
mounting bracket (refer to Figure 13
ATT EN TI ON : Do not touch or bend the connectors on the Interface Board when
handling it. Damage to the connectors may result in loss of communication
signals from the MV SMC™-50 to other components.
ATT EN TI ON : Do not mount the interface board in the same compartment as
high voltage components. Ensure that barriers are provided in the final
application to prevent access to any live high-voltage parts, including insulated
conductors located in enclosures with low voltage parts and wiring. Failure to
do so may result in severe burns, injury or death.
Figure 13 - Interface Board (SMC-50 Module installed)
).
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 23
Page 24
Chapter 3 Control Component Installation
231
818181
1
O
1
41
6
1
242
61
561
2
616161
+
21
13
N
2
O
N
TP32
DS15
TP10
R100
TP33
TP34
DS16
DS14
DS17
DS2
TP19
TB21
TB10
SW4
TB6
R13
R102
C31
TP5
C28
TP2
TP9
TB8
TP42
TP43
T1
TP35
MV2MV1MV3
HS1
D25
C50
R87
C53
L4
C52
C46
MOV1
TP18
DS3
TP20
TB1
DS12
DS5
DS11
TP4
TP11
TP13
DS6
TP38
DS7
TP37
TP30
DS9
DS10
R86
TP41
TP8
TP40
TP15
TP39
TP22
TP25
TP31
TP27
TP28
DS8
TP29
TP36
TP16
TP17
TP21
DS4
R84
R85
SW3
SW2
83U73U
U5
TB5
DS1
TP50
TP48
TP3
R229
C27
C115
R101
TP49
TP26
C10
C103
TP1
TP7
TB3TB2 TB4
TP44
U21
U19
C48
TB7
C49
F1
DS13
C47
C45C51
TX14TX15
TX5
TX12
RX1 TX2
TX7TX8TX13
TX3
TX10TX16
TX6
TX11TX17
RX2RX3
TX1
TX4
TX9TX18
1 32
SW1
3
4
TP6
A+
A-
A+
A -
A+
A-
B+
B-
B+
B-
B+
B-
C+
C-
C+
C-
C+
C-
SW2: When ON
(right) provides test
pulses to gate driver
circuits.
NOTE: Must be OFF
(left) for normal
operation.
LED (Red): ON when
test puls es on
SMC-50 Control Module
Ribbon connectors to
connect to SMC-50
control module
(underneath control
module)
LED (Green) is ON when Option
Stop Input Circuitry is Functioning
TB6: Option
Stop Current
Input and
Relay Status
Output
SW1: Selects CT
Current Inp ut. NOTE:
Must be on (up) for
Normal Ope ration.
Volt ag e
Feedback
Tes t Po int s
TB5: Current Transformer Connections
Module Common:
DO NOT CONNECT
to this terminal
LED (Green): ON when signal present at
temperature feedback fibre optic receivers
LED (Yellow): ON when
Phase A+ gate signal active
Phase A
Fiber Optic Transmitters send gate signals to driver boards
Phase B
Fibre Optic Transmitters
Phase C
Fibre Optic Transmitters
Tem pe r at u re
Feedbac k
Fibre Op tic
Receivers
L N G
Control Pow er
110…240V AC
L N
Power ou t to
SMC-50
SW3: detects
temperature
feedback
channels
Phase A+ gate signal
Common for Gate/Pulse
Test Points
LED (Yellow): ON when
Phase A- gate signal active
Phase A- gate signal
Common for Gate/Pulse
Test Points
LED (Yellow): ON when
Phase B+ gate signal acti ve
Phase B+ gate signal
Common for Gate/Pulse
Test Points
LED (Yellow): ON when
Phase B- gate signal active
Phase B- gate signal
Common for Gate/Pulse
Test Points
LED (Yellow): ON when
Phase C+ gate signal active
Phase C+ gate signal
Common for Gate/Pulse
Test Points
LED (Yellow): ON when
Phase C+ gate signal active
Phase C+ gate signal
Common for Gate/Pulse
Test Points
LED (Green): ON when +15V rail is present
LED (Green): ON when +5V rail is present
Power Suppl y Test Point s
Programming
Interface
SW4 Firmware
Programming
Switch
Ribbon Connector to Voltage Sensing Board
LED (Red) is ON when
in program mode
Current
Feedb ack
Tes t
Point s
LED (Green) is ON when
+12V Rail is present
LED (Green) is ON when
-12V Rail is present
LED (Green) is ON when
15V_IN Rail is present
Power
Supply
Tes t
Point s
Replacement
Part N umber
Serial
Number
Figure 14 - Connection and Test Information for Interface Board
24 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 25
IM PORTANT 10…12 kV and 12.1…15 kV
Two fiber optic devices per phase are used. One connects to the temperature
feedback in the upper PowerBrick™, and the other connects to the fiber optic
multiplexer board (see below).
Control Compon ent Installation Chapter 3
Interface Board Connections
SMC-50 Control Module
Connect control power to the interface board. Use a grounded supply source
from 110…240 +10, -15% VAC, 50/60 Hz, 15 VA.
Connect 5A current transformer (CT) secondary signals to the interface board,
noting the required CT polarity. Three-phase CTs are required.
WARNING: Do not connect to Interface Board Vcom terminal.
1. Connect the ribbon cables (5) to the back of the SMC-50 control module.
2. Align the ribbon cables (5) from the SMC-50 control module with the
connectors on the Interface Board. Push the ribbon connectors into the
mating connectors on the interface board.
3. Use the supplied screws to securely fasten the module to the board
mounting bracket.
4. Supply power to the SMC-50 control module and make the required
control connections.
Please refer to CENTERLINE Medium Voltage SMC-50 Motor Controller user
manual, publication 1560F-UM001
programming the unit.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 25
for detailed instructions on wiring and
Page 26
Chapter 3 Control Component Installation
EMC Compliance
ATT EN TI ON : This product has been designed for Class A equipment. Use of the
product in domestic environments may cause radio interference, in which case,
the installer may need to employ additional mitigation methods.
The following guidelines are provided for EMC installation compliance.
Enclosure
Install the product in a grounded metal enclosure.
Wiring
Wire in an industrial control application can be divided into three groups: power,
control, and signal. The following recommendations for physical separation
between these groups are provided to reduce the coupling effect.
• Different wire groups should cross at 90° inside an enclosure.
• Minimum spacing between different wire groups in the same tray should
be 16 cm (6 in.).
• Wire runs outside an enclosure should be run in conduit or have shielding/
armor with equivalent attenuation.
• Different wire groups should be run in separate conduits.
• Minimum spacing between conduits containing different wire groups
should be 8 cm (3 in.).
• For additional guidelines, please refer to Wiring and Ground guidelines,
publication DRIVES-IN001
• Wire earth ground to control terminal 14 of the SMC-50 control module.
• Use shielded wire for:
•PTC Input
•Ground Fault Input
• Terminate shield wires to terminal 14.
• Ground fault CT must be inside or within 3 m of metal enclosure.
• To meet product susceptibility requirements, ferrite cores need to be
added to the communication lines. All cores specified below are split core
type, so they can be added to existing connections.
• When using an external HIM (or DPI interface), a core should be
added to the HIM cable near the SMC-50 control module. The
recommended core is Fair-Rite no. 0431167281 or equivalent.
• When using DeviceNet, two cores need to be added to the DeviceNet
cable near the SMC-50 control module. The recommended cores are
TDK ZCAT2033 0930H and TDK ZCAT2035 0930 or equivalent.
.
26 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 27
Control Compon ent Installation Chapter 3
-L2
+L1
12
11
10 9
8
7
65
4
32
1
24V DC Inputs
Relay Outputs
Control Power
and Ground
(1)
Internal +24V DC
In1 DC
In2 DC
Enable I/O
Internal DC Common
Aux 2
Aux 1
Control Power
Control Voltage
The SMC-50 controller will accept a control power input of 100…240V AC,
(-15 / +10%), 1 phase, 50/60 Hz. Refer to the product nameplate to verify the
control power input voltage.
Connect control power to the controller at terminals 11 and 12. The control
power requirement for the control module is 75 VA. Depending on the specific
application, additional control circuit transformer VA capacity may be required.
Control Wiring
Ta bl e 6 provides the control terminal wire capacity and the tightening torque
requirements. Each control terminal will accept a maximum of two wires.
Table 6 - Control Wiring and Tightening Torque
Wire Size Torque
0.75…2.5 mm (#18…#14 AWG) 0.6 N•m (5 lb•in.)
Control Terminal Designations
As shown in Figure 15, the SMC-50 controller contains 12 control terminals on
the front of the controller.
Figure 15 - SMC-50 Controller Control Terminals
(1) See the controller nameplate to verify the control power ratings (120/240V AC or 24V DC).
ATTENTION: IN1 DC (terminal 11) and IN2 DC (terminal 10) are 24V DC
inputs on controllers rated 120/240V AC and on controllers rated 24V DC.
Voltages that exceed the specified input range may cause damage to the
controller.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 27
Page 28
Chapter 3 Control Component Installation
Table 7 - Terminal Descriptions
Terminal Number Description
(1) (2)
1
(1)(2)
2
3 Ground — To connect to the system/control ground point.
(1)(3)
4
(1)(3)
5
(1)(3)
6
(1)(3)
7
8 DC Internal I/O Power, DC Common
9Enable I/O
(1)(4)
10
(1)(4)
11
12 +24V DC Internal I/O Power
(1) RC snubbers are required when inductive loads are connected to terminal.
(2) See the controller nameplate to verify the control power ratings (120/240V AC or 24V DC)
(3) When set to exte rnal bypass mode, the auxiliary co ntact is used to control a properly sized extern al contactor and overload once the
motor is at full speed.
(4) Do not connect any additional loads to this terminal. Parasitic loads may cause problems with operation.
Control Power +L1
Control Power Co mmon -L2
Auxiliary Relay Contact #1—rated 3 A @ 120V AC, 1.5 A @ 240V AC
Auxiliary Relay Contact #1—rated 3 A @ 120V AC, 1.5 A @ 240V AC
Auxiliary Relay Contact #2—rated 3 A @ 120V AC, 1.5 A @ 240V AC
Auxiliary Relay Contact #2—rated 3 A @ 120V AC, 1.5 A @ 240V AC
Input #2 (24V DC) (range 15…30V DC)
Input #1 (24V DC) (range 15…30V DC)
Connecting Interface Board to Voltage Sensing Board
Note: The OFF state leakage current for a solid-state device connected to an
SMC-50 input must be less than 6 mA.
Use the wire harness provided to connect the Voltage Sensing Board and the
Interface Board. See Figure 14
board, and Figure 8 on page 18
for the location of the connector on the interface
for the connector on the voltage sensing board.
28 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 29
Control Compon ent Installation Chapter 3
+ +
+ +++ +
+ +
1
+
+
2
2 1
3
1
2
+
C11
C23
C30
R63
R40
R67
R10
R35
C15
R64
FO30
FO31
FO36
FO37
U2
FO27
FO21
C21
FO26
FO20
FO24
DS3
DS6
FO18
C9
FO25
R30
FO19
R26
C19
R27
R22
R21
FO15
FO14
R19
DS5
FO9
FO8
R20
DS2
FO12
FO13
R53
R51
C14
C1
TP2
FO39
FO38
FO33
FO32
HS2
VR1
D7
C13
DS7
C24
C27
R49
DS4
R50
R38
R59
R33
C25
D5
C29
R47
R46
R45
R34
D6
R58
C28
C26
R62
tp3
R36
C20
R31
C22
R37
C32
R32
FO35
FO34
FO28
FO29
J2
FO3
C12
FO42
D4
R66
R9
HS1
R5
R24
R56
R54
R43
R25
R44
R28
R29
R23
R55
R61
C18
U4
C16
FO23
FO17
FO16
R3
FO22
R1
R2
FO41
FO2
R65
R8
R18
R41
R15
L1
R13
R14
R52
FO6
FO7
R60
C17
FO11
FO10
FO4
FO5
RV1
FO40
FO1
F1
J1
L2
L3
R7
DS1
R48
R39
C10
R57
tp1
U5
R6
C33
T1
R4
D2
C8
D3
U1
C7
D1
C5
C6
C4
R42
C3
U3
C2
C31
R12
R11
R17
R16
TB1
127.0
[5.00]
28.6
[1.13]
4.0 [0.16]
(5) MTG HOLES
118 .4
[4.66]
52.8
[2.08]
210.0 [8.27]
201.4 [7.93]
100.7 [3.96]
Phase A
Phase B Phase C
Connecting Fiber Optic Multiplexer Board to Gate Driver Board
The 7703E-FMUXB Fiber Optic Multiplexer board accepts fiber gate drive
signals from the interface board (7703E-INTB) and splits them into the required
fiber optic gate drive signals for 10…15 kV.
Figure 16 - Fiber Optic Multiplexer Board Dimensions and Connections
Table 8 - Fiber Optic Multiplexer Board Specifications
Control Voltage 110/120V…220/240V at 50/60 Hz, 30 VA
Gate Drive (In/Out) Via Fiber Optics
1. Use the fiber optic cables (Cat. No. 7703E-XXFOXX) to connect each
fiber optic receiver from the gate driver boards to the fiber optic
multiplexer board (see Figure 16
). Ensure that the gate driver boards of
each power phase are connected to the correct terminals on the fiber optic
multiplexer board. Observe the minimum bend radius of at least 45 mm
(1.75 in.) for the fiber optic cables.
ATT EN TI ON : Do not sharply bend or strike the fiber optic cables when handling
them. A minimum bend radius of at least 45 mm (1.75 in.) should be
maintained throughout the system. Damaging the cables may result in signal
IMPORTANT Fiber optic components are color coded for easier connections. Receiver
Refer to the appropriate wiring diagram in Chapter 5
loss to the components and improper functioning of the unit.
terminals are dark blue, and transmitter terminals are grey or black. The cables
have a grey connector at one end and a blue one at the other. When connecting
to the gate driver boards, the dark blue connector must plug into the dark blue
receiver and the grey connector must plug into the grey or black transmitter.
.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 29
Page 30
Chapter 3 Control Component Installation
IMPORTANT It is acceptable to connect the fiber optic transmitter cables to any port within
a particular power phase. Note that the cables for the temperature feedback
ports should be connected to the correct phase. See Figure 14
Board layout.
2. Connect a single fiber optic cable between the interface board transmitter
(one per phase) to the corresponding receiver on the fiber optic
multiplexer board.
3. Connect the temperature feedback fiber optic receivers for each phase
from the interface board to the appropriate gate driver board transmitter.
Refer to Chapter 5
feedback fiber optic connections.
for the appropriate diagram for the temperature
for the Interface
Additional Control Components
Additional control components are required to complete the circuit, depending
on the application. Some of these control components are outlined in Chapter 4
and Appendix B
It is the responsibility of the OEM to ensure that all required power and control
components are supplied and functional.
.
30 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 31
Chapter 4
Main and Bypass Switching Device Installation
Introduction
Main Contactor or Circuit Breaker
Bypass Contactor or Circuit Breaker
The MV SMC components are designed for intermittent starting duty. A bypass
contactor or circuit breaker must be used to bypass the PowerBrick™ assemblies
once the motor is at full speed.
A line switch is required in order to isolate the power stacks from line voltage.
• If a line contactor is used, suitable short-circuit protection must be
provided in compliance with relevant standards and/or local codes (see
Standards and Codes
• If a circuit breaker is used for the line switch, it must be rated to handle
normal load and short-circuit conditions.
A bypass contactor or circuit breaker must be used in the SMC configuration to
bypass the SCRs once the motor is up to speed. The bypass must have an opening
time of 100 ms or less.
ATT EN TI ON : A bypass contactor or circuit breaker must be installed to
complete the SMC configuration. SCRs are not rated for continuous duty. The
duty cycle is limited to 60 seconds per hour. This can be a combination of
starting and stopping cycles that does not exceed 30 seconds per cycle. Failure
to install a bypass contactor or circuit breaker may result in damage to
components from overheating.
on page 7).
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 31
Page 32
Chapter 4 Main and Bypass Switching Device Installation
Notes:
32 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 33
Typical Wiring Diagrams
Chapter 5
Wiring Diagrams
The following wiring diagrams illustrate the connections between the main
components of the MV SMC OEM components.
Additional components are typically required to complete the MV SMC. See
Appendix B
implemented to form a complete solution.
for examples of how these additional components can be
ATT EN TI ON : Wires used for connecting the components must be sufficiently
insulated to withstand system voltage. Refer to the appropriate wiring diagram
for the wire insulation requirements. Failure to use adequately insulated wiring
may cause injury to personnel and/or damage to the equipment.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 33
Page 34
Chapter 5 Typ ica l Wi ri ng Dia gr ams
PHASE A PHASE B PHASE C
FO4-15 FO16-27 FO28-39
GATE TRANSMITTERS
115/230V AC
115/230V AC
G
L2/N
L1
TB1
TB6
RX1
TX17
TX18
RX2
RX3
TX10
TX16
TX15
TX5
TX6
TX11
TX12
TX14
TX13
TX9
TX4
TX3
TX8
GDPS
TX2
TX1
TX7
VSB
TB21
PHASE A PHASE C TEMP.
C-
A+
A-
B-
B+
TB5
C+
CT INPUTS
GATE TRANSMITTERS
PHASE B
POWER
IN
4
3
2
1
TB7
POWER
OUT
1
2
G
L2/N
L1
TB1
POWER
IN
SMC-50 INTERFACE BOARD
C-
A+
A-
B-
B+
C+
SMC-50 FIBER OPTIC
MULTIPLEXER BOARD
TO J1 ON VSB
NOTE: Only devices supplied by Rockwell Automation are shown.
Additional devices are required to form a complete solution
(refer to Appendix B for a typical schematic showing other
devices).
See Figure 23.
Figure 17 - Typical Power Circuit Wiring Diagram (10-15 kV)
34 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 35
Final Test Procedures
Chapter 6
Final Test Procedures
• Verify that the enclosure is properly grounded.
• Verify that phase-to-phase and phase-to-ground clearances meet the
requirements of the local electrical code.
• Visually check for sufficient electrical clearances, creepage allowances and
bend radii. Refer to the applicable local electrical codes.
• Check the tightness of all power and control connections. See Ta ble 6 on
page 27 for recommended torque values. Gently tug on all wires to ensure
that they are properly connected.
ATT EN TI ON : All hardware for electrical connections must be torqued to the
above specifications. Failure to do so may result in electrical faults causing
personal injury or damage to the equipment.
• Check for cross-threaded hardware. In addition to the regular power
connections, check the connections and wiring to the voltage sensing
board.
• The high voltage silicone-insulated wires must be identified with tube
markers. Avoid routing the wires over any components. If the wires are
routed near live parts or ground, there must be enough slack in the wire to
allow at least 15 cm (6 in.) of creep or clearance between the wire and
other parts. Tie wraps must not tightly squeeze the high voltage wires, and
must not be put on with a tie-wrap gun.
• Do not remove the plastic plugs from unused fiber optic transmitters on
the circuit boards.
• Verify that the fiber optic cables between the interface board, fiber optic
multiplexer board, and the gate driver boards are connected to the correct
power phase.
• Check the routing of the twisted pair of red and white cathode and gate
wires from the SCRs. They can safely touch the heatsink on the side of the
SCR that they are exiting; however, they must not touch the heatsink on
the other side of the SCR. The wires must be properly supported to ensure
this condition is met. See wiring diagrams in Appendix B
sequences.
• Wiring to the voltage sensing board from the power stacks must be rated
for the line voltage. Rockwell Automation recommends UL style 3239,
#18 AWG, 40 kV DC silicone rubber insulated wire covered with PVC
tubing or other suitable material for this application. These wires must not
touch live parts, grounded metal or low voltage wiring.
for the
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 35
Page 36
Chapter 6 Final Test Procedures
Jumper
• The bypass vacuum contactor or breaker (and capacitor contactor if
applicable) must have a fast drop-out time (typically 100 milliseconds or
less).
Dielectric Test
1. Remove the ribbon cable and ground wires from the voltage sensing board,
and isolate the ends to prepare for the Hi-Pot test.
2. Jumper the line and load terminals together within each phase (Figure 18
Figure 18 - Example of Jumper Positioning for Hi-pot Test
).
3. Measure the resistance between the line and load sides of each
PowerBrick™ phase assembly to make sure there is zero resistance. This
indicates that the jumpers are properly set.
4. Perform a Hi-Pot test as required by the applicable local codes and
standards. Typical levels for field testing are two times the rated voltage of
the equipment.
5. After the Hi-Pot remove the heatsink jumpers. Re-connect the feedback
board wires.
6. Perform a resistance check for each SCR. The SCR resistance can be
checked directly at the device or at the leads on the gate driver board.
a. The gate-to-cathode resistance should range from 10…40 Ω for all
styles.
b. The cathode-to-cathode resistance can also be checked and should be
between 20…32 ks per brick.
7. Check all line and load resistances to ground at the interface board voltage
feedback test points. The measurement for all voltages should be within
11…13 kΩ.
36 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 37
Final Test Procedures Chapter 6
Additional Tests
Programming
Voltage Sensing Module
Perform additional tests as outlined in the CENTERLINE Medium Voltage
SMC-50 Motor Controller user manual, publication 1560F-UM001
.
Medium Voltage SMC-50 Module
See publication 1560F-UM001 for programming procedures and default
(factory) parameter settings.
IMPORTANT The module should be programmed with an understanding of how the SMC
functions, and the characteristics of the motor and driven load. Inappropriate
settings may elicit unexpected results such as lack of acceleration torque or
full-voltage starting. For Pump Control applications, refer to Application
Considerations in publication 1560F-UM001
If the factory settings are not suitable for the application, program the module to
meet the application requirements.
The MV ratios shown above are nominal values and may be fine tuned to achieve
better accuracy on the display of the SMC-50 control module. While running the
motor in bypass mode, compare the voltage displayed on the control module to a
known accurate meter connected to the same source voltage as the motor the MV
SMC-50 is controlling. Parameter 169, MV Ratio, may be changed up or down
to match the HIM display to the external meter. A small change in ratio can make
a large change in the display, so 5 units at a time are recommended. Increasing the
ratio will decrease the displayed voltage, and visa versa.
.
Power Supply Test
Table 9 - MV Ratio
Voltage MV Ratio
12000V 126
14400V 97
ATT EN TI ON : Servicing energized industrial control equipment can be
hazardous. Severe injury or death can result from electrical shock, burn, or
unintended actuation of controlled equipment. Before proceeding, ensure that
all sources of power are isolated and locked out. Verify that all circuits are
voltage free using a hot stick or appropriate voltage measuring device. Any
covers or barriers removed during this procedure must be replaced and securely
fastened before energizing equipment. Where appropriate, the case of test
equipment should be connected to ground.
1. Isolate incoming power
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 37
Page 38
Chapter 6 Final Test Procedures
SW2 – Close (slide up) to initiate test pulse
Red LED – ON when test pulses active
2. Open the door(s) providing access to the SCR/heatsink assemblies. You
will be touching components which are connected to the high voltage
power circuit, so be sure to isolate power as stated above.
3. Apply rated control voltage to the control circuits from a separate control
source, or by plugging into the test source connector, and selecting the
TEST position of the control switch.
4. Check voltage on each gate-driver board by connecting a DC voltmeter at
TP4(+) and TP3(-). (See Figure 20
.) The voltage should be 18…22V DC.
5. Locate the SMC-50 interface board in the control section (See Figure 19
This circuit board has the control module mounted on it. Locate the
switch labeled SW2 at the upper left corner of the board. Close the switch
by sliding the toggle up. This starts a pulse generator to supply simulated
gate-pulse signals via fiber optic cables to the gate driver boards. A red
LED beside the switch, and the three yellow LEDs on the left side of the
Interface board should be lit.
Note: They may appear dim, depending on ambient light conditions.
Figure 19 - Interface PCB
).
38 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
6. With the gate pulses on, check the voltage again on each gate-driver board
as described in step 4
above. The voltage should be 4…5V DC.
7. Locate the Portable Test Power Supply that was included with the
equipment, and verify that the rating corresponds to the available power
system (i.e., 110/120V AC or 220/240V AC). Plug the unit into the
power source, and plug the green connector into J1 on each of the gate
driver boards (see Figure 20
).
Page 39
Figure 20 - Test Power Application on Gate Driver Board
Temperature signal
fiber optic
Yel low LED
Thermistor
connector
Gate signal
test point
Gate/cathode
connector
Overvoltage +20V test point
+5V test point
Gate signal
fiber optic
Plug-in test
power supply
Current loop
CT connector
ubber
Cathode
terminal
Common
test point
Final Test Procedures Chapter 6
8. The yellow LED on the upper right-hand side of the energized gate driver
circuit should be lit (it may appear dim, depending on ambient light
conditions). While the gate pulses are still on, check the voltage on each
gate driver board as described in step 4
above. The voltage should be
10…12V DC. If the voltage is less than 5V, then you have a bad gate drive
board. Do not leave the Portable Test Power Supply connected to a bad
gate driver board. The power supply adapter will burn up if the gate driver
board is shorted.
9. A more detailed check is performed by verifying the actual gate pulses by
connecting an oscilloscope between TP1 and TP3 (-) (see Figure 4 on
page 14). To check gate pulses, the pulse generator must be enabled
(i.e. SW2 toggled up) and the Portable Test Power Supply should be
connected to J1. The pulse should appear as shown in Figure 21
Figure 22
.
and
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 39
Page 40
Chapter 6 Final Test Procedures
Microseconds
Vol ts
Microseconds
Figure 21 - Gate Pulse Detail – Typical SCR (ABB)
Figure 22 - Gate Pulse Test Waveform
10. If no pulse is observed, and the yellow LED is lit, check for a shorted gate
on the SCR by removing the green plug and connecting an ohmmeter to
the gate leads. If the LED is not lit, and the circuit voltage is as specified in
step 8
(above), pinch the tab on the blue fiber-optic connector and
carefully pull it straight out of the receiver. The end of the connector
should glow red to indicate the presence of a gate signal.
ATT EN TI ON : Do not look directly into the end of the fiber optic cable.
If it does not, remove the other end of the cable from the interface board
and check that the grey transmitter is emitting red light. If it is, the fiberoptic cable must be replaced. If it isn’t, the interface board should be
replaced.
40 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 41
Final Test Procedures Chapter 6
11. When each gate driver circuit has been checked, disconnect the power
supply and remove it from the cabinet.
ATT EN TI ON : The gate-drive circuits operate at high voltage when the SMC is
energized. Failure to remove the portable test power supply will result in
equipment damage and may cause severe injury or death.
12. Open the switch SW2 on the interface board (see Figure 20
returning the unit to service. Ensure the red LED is off.
ATT EN TI ON : If the SW2 switch is not in the open position when the SMC is
energized, the motor will start in an uncontrolled manner and may cause severe
damage.
13. Check that all plugs and connectors are secure. Retrieve all hardware and
tools from the equipment. Replace and secure any barriers removed during
servicing and close all doors before applying power.
ATT EN TI ON : Servicing energized industrial control equipment can be
hazardous. Severe injury or death can result from electrical shock, burn, or
unintended actuation of controlled equipment. Recommended practice is to
disconnect and lock out control equipment from power sources, and allow any
stored energy in capacitors to dissipate. The safety related work practices of
NFPA 70E, Electrical Safety Requirements for Employee Workplaces, must be
followed if it is necessary to work in the vicinity of energized equipment.
14. Apply rated control voltage to the control circuit.
15. Using the control schematic, apply control signals to cause relays and
contactors to energize, to verify operation.
) before
Start-Up
16. Remove any jumpers used in the test and restore all circuits to normal
when finished.
1. Remove any temporary jumpers or grounding devices used during
commissioning.
2. Check that all tools are removed from the equipment. Any tools or
hardware used or dropped during installation and commissioning must be
retrieved and accounted for.
3. Check that all barriers or covers removed during installation or
commissioning have been securely mounted.
4. Close and secure all doors, and verify function of all interlocks that
prevent access to medium voltage compartments when the unit is
energized.
5. The controller is ready to power the motor.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 41
Page 42
Chapter 6 Final Test Procedures
Notes:
42 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 43
Component Deratings
Appendix A
Deratings Specifications
The components described in this publication may be applied in a wide variety of
situations. Some applications may require component derating. For example, at
altitudes above 1000 m (3300 ft), the maximum current and basic impulse level
(BIL) are reduced as shown in Tab l e 1 0
Table 10 - Component Derating Table
Altitude Rating Reduce Max. Continuous Current Rating by: B.I.L. Withstand Rating
160 A 340 A 580 A 12 kV 15 kV
0…1000 m
(0…3300 ft)
1001…2000 m
(3301…6600 ft)
2001…3000 m
(6601…9900 ft)
3001…4000 m
(9901…13,200 ft)
4001…5000 m
(13,201…16,500 ft)
— — 75 kv 95 kV
5 A 10 A 15 A 66 kV 84 kV
10 A 20 A 30 A 59 kV 74 kV
15 A 30 A 45 A 52 kV 66 kV
20 A 40 A 60 A 46 kV 58 kV
.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 43
Page 44
Appendix A Component Deratings
Notes:
44 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 45
Typical Schematic Diagrams
Appendix B
Introduction
This Appendix contains a typical schematic for a complete MV SMC-50
controller (refer to Figure 23
Refer to publication 1560F-UM001
configurations. The examples shown are not a recommendation for the correct
wiring configurations, nor is the OEM required to follow this design exactly.
The OEM must ensure that all wiring for the unit meets all performance and
safety requirements, including any applicable laws, regulations, codes and
standards.
Rockwell Automation does not assume any responsibility or liability for loss or
damages caused by failures in the unit manufactured by the OEM.
A configuration similar to Figure 23
well as main and bypass vacuum contactors.
).
for additional samples of control wiring
requires input disconnection (optional), as
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 45
Page 46
Appendix B Typical Schematic Diagrams
L1
L2
GRD
L3
24C
PHASE A PHASE B PHASE C
FO4-15 FO16-27 FO28-39
GND2GND1
J1
12345
6
GATE TRANSMITTERS
-RS 1 -RS n
TO SMC-50 CT INPUTS
-QB
-QB
-QE
SMC-50
CONTROL
MODULE
LOOP CT
FROM CURRENT
MTR
2
1
OV1
C1
S1
OV2
RR1/2
RS1/2/3
C2
S2
CS
RX1 GTX1 CT
-GP1
TEST
-BC
-+
OV S C
RX1 TX1 TCG
OV
-BC
TEST
+-
-GP2
SC
G1 G2
TT
G2
2
1
C1
S1
RS1/2/3
C2
S2
CS
G1
TT
RX1 GTX1 CT
-GP2
TEST
-BC
-+
OV S C
RX1 TX1 TCG
OV
-BC
TEST
+-
-GP1
SC
OV2 OV1
RR1/2
TO
FROM START
CONTROLLER
PHASE CTS
START CONTROLLER
BYPASS CONTROLLER
POWER CONVERTER
- CURRENT LOOP GATE DRIVER BOARD-GP
- SMC-50 INTERFACE BOARD-KF2
-BC
- SMC-50 FIBRE OPTIC BOARD-KF1
- CURRENT TRANSFORMER
- CIRCUIT BREAKER-QB
- EARTHING SWITCH (OPTIONAL EQUIPMENT)-QE
- SMC-50 POWERBRICK ASSEMBLY-RS
- VOLTAGE SENSING BOARD-BV
WIRE CONNECTIONS FOR PHASE A
CONNECTIONS SHOWN FOR PHASE C
LEGEND
WIRE CONNECTIONS FOR PHASE B
ON
THE CURRENT LOOP ASSEMBLY
CURRENT LOOP CONDUCTORS PASS THROUGH THE C.T.'S
REMOTE EQUIPMENT
VOLTAGE
NUMBER OF
10-12kV 5
12.1-14.4kV 6
INCOMING
LINE UNIT
NCOMING LINE
CUSTOMER'S
L3
L2
L1
1
-BC2
-BC1
-BC3
-BC2
-BC1
-BC3
-BV
T3
T2
T1
115/230V AC
115/230V AC
G
L2/N
L1
TB1
TB6
RX1
TX17
TX18
RX2
RX3
TX10
TX16
TX15
TX5
TX6
TX11
TX12
TX14
TX13
TX9
TX4
TX3
TX8
GDPS
TX2
TX1
TX7
VSB
TB21
PHASE A PHASE C TEMP.
C-
A+
A-
B-
B+
TB5
C+
CT INPUTS
GATE TRANSMITTERS
PHASE B
POWER
IN
432
1
TB7
POWER
OUT
1
2
G
L2/N
L1
TB1
POWER
IN
SMC-50 INTERFACE BOARD
C-
A+
A-
B-
B+
C+
SMC-50 FIBER OPTIC
MULTIPLEXER BOARD
Figure 23 - Typical Power System Diagram (10…15 kV)
46 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 47
Figure 24 - Typical Control Circuit, Standard Module (10-15 kV)
123456789101112
+L1
-L2
GND
Aux1Aux2
COM
Enable
Input 1 DC
Input 2 DC
+24V DC
A1A2A3A4A5A6A7A8A9A10A11A12
Aux A1
Input A1
Input A2
Input A3
Input A4
COM
Aux A2Aux A3
NC
SLOT 7
150-SM4
SLOT 8 SLOT 9
DPI COMM
SMC 50
EXT.
BYPASS
NORMAL
START
STOP
OPTION
COAST
Emer.
Byp.
FAULT
3 4
SMC 50IB_TB6
CL_FLT
MC
SS
BC
SS
From SMC 50IB
TB7
CR
CL_FLT
CR
CR
CR
CL_FLT
ESTOP
STOP
MC CR
CONTROL RELAY (CR
)
FAULT RELAY
Typ ica l Sch ema tic Diag ram s Appendix B
Note: Requires optional Main and Bypass control panels, as well as control relays
and pilot devices.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 47
Page 48
Appendix B Typical Schematic Diagrams
Notes:
48 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 49
Spare Parts
Appendix C
PowerBricks
Table 11 - PowerBrick Replacements
Part Number Description Match Designator PowerBrick Current
Rating
81020-232-51-R Heatsink Assembly only W 160 A
81020-753-51-R IJ
81020-230-51-R Complete PowerBrick W
81020-752-51-R IJ
81020-232-57-R Heatsink Assembly only Y 340 A
81020-232-58-R Z
81020-230-57-R Complete PowerBrick Y
81020-230-58-R Z
81020-753-85-R Heatsink Assembly only DM 580 A
81020-753-86-R DN
81020-752-85-R Complete PowerBrick DM
81020-752-86-R DN
Table 12 - Snubber Capacitor / Snubber Resistor
Snubber Capacitor Part Number
200/400 Amp
All voltages 80026-508-02 (0.68 µF)
Snubber Resistor
3 per PowerBrick 80026-561-02-R (20 Ω, 120 W)
(1) All parts are ceramic, wirewound, non-inductive winding.
(2) Resistors are series connected for a total of 60 per snubber for 180/360A assemblies and 30 per snubbe r for 600A assemblies. A
PowerBrick has one snubber per pair of SCRs.
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 49
(1)
Part Number
200/400 Amp
(2)
Page 50
Appendix C Spare Parts
Table 13 - Common Parts
Part Number Description Quantity
80026-562-01-R Sharing resistor 16.25 kS, 112W, 2.5 k, tap 2 per SCR pair
80190-519-02-R Current loop self-powered gate driver board (CLGD) 1 per SCR
81020-237-52-R Voltage Sensing Board
81020-237-53-R 12.1-15 kV
(VSB)
10-12 kV 1 per controller
PN-545832 160 A, Interface Board, 10…15 kV 1 per controller
PN-545833 340 A, Interface Board, 10…15 kV 1 per controller
PN-545835 580 A, Interface Board, 10…15 kV 1 per controller
80190-679-01-R Fiber optic multiplexer Board 1 per controller
80025-549-03-R Fiber Optic Cable 2.5 m (8.2 ft) (1 per SCR) + 6
80025-549-01 5 m (16.4 ft)
80187-051-51-R Test Power Supply 120V AC for North America 1 per controller
80187-245-51-R Universal
80022-133-01 Current loop transformer 50 VA, 115/230 : 0.6V 1 per controller
80022-133-02 100 VA, 115/230:1.5V
80018-246-56 Current loop cable (4.3 m) 14 ft
80018-246-57 (6.4 m) 21 ft
80022-163-01 Current loop sense CT 1 per controller
80026-146-56 Ribbon cable from VSB to Interface Board 1 per controller
80174-201-01 Ribbon cable from control
80174-201-02 8-pin 3 per controller
module to Interface board
6-pin 2 per controller
(1)
(2)
(1)
(1)
(1) See Tab le 11 for an explanation of the number of SCRs per controller, which is voltage dependent.
(2) Different lengths may be used for various configurations. The current loop total length must conform to the requirements outlined
in Current Loop Gate Drive Power Assembly (CLGD)
on page 19.
Table 14 - Accessories
Part Number Description Quantity
PN-281287 Control Module (Standard) 1
350325-A06 HIM (Bezel Mounted) 1
PN-71481 SMC-50 Digital I/O Module 1
PN-71480 SMC-50 Ground Fault, PTC Module 1
80144-491-02 Fuse Extractor
50 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Page 51
Index
A
additional test procedures 37
B
bypass switching device
installation
31
C
catalog numbers
PowerBricks
voltage sensing boards
CLGD (current loop gate drive power
codes
CEC
CSA 7
ICS1
ICS3
IEC 7
NEC
OSHA
UL 7
control components
control power
derating
EMC compliance 26
installation
interface board
SMC-50 control module
control power
control components
control terminal designations 27
current loop gate drive power assembly
9
10
assembly)
19
7
7
7
7
7
27
voltage
27
wiring 27
wiring, torque requirements
43
23
connections
installation 23
layout
mounting
control terminal designations
installation
25
24
23
25
27
voltage
27
wiring
27
(CLGD)
19
27
27
D
derating
control components
diagrams
schematic
10...15 kV control circuit 47
10...15 kV power system
wiring
dielectric test procedure 36
33
jumper positioning
43
45
46
36
dimensions
PowerBricks
voltage sensing board
10, 12, 13, 14
17
E
electrostatic sensitive devices
handling procedures
EMC compliance
control components
ESD (Electrostatic Sensitive Devices)
handling procedures
7
26
7
F
fiber optic multiplexer board
connec to gate driver board
29
G
gate driver board
connect to fiber optic multiplexer board
H
handling procedures
ESD (electrostatic sensitive devices)
I
identification, PowerBricks 9
installation
bypass switching device
control bomponents
interface boards
control components
SMC-50 control module
main switching device 31
PowerBricks
interface board
connect to voltage sensing board
connections 25
layout
mounting
9
24
23
31
23
23
25
L
layout
interface board
loop length
power supply transformer rating
24
M
main switching device
installation
31
29
7
28
20
Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 51
Page 52
Index
mounting
interface boards
PowerBricks
voltage sensing boards
23
11, 13, 14
17
O
operating restrictions
PowerBricks
options
PowerBricks
voltage sensing boards
16
9
10
P
power connections
PowerBricks
voltage sensing boards
power supply test procedure 37
power supply transformer rating
loop length
PowerBrick
catalog numbers
current loop gate drive power assembly
dimensions
identification
installation 9
mounting
operating restrictions
options 9
power connections
spare parts 49
specifications
torque requirements
programming 37
SMC-50 control module
15
grounding
20
(CLGD)
10, 12, 13, 14
9
11, 13, 14
grounding
10
16
17
9
19
16
15
16
11
37
T
test procedures 35
additional
dielectric
power supply
start-up
torque requirements
control components
PowerBricks
37
36
jumper positioning
37
41
wiring
27
11
V
voltage ratios
voltage sensing module
voltage sensing board
catalog numbers
connect to interface board
dimensions 17
mounting
options
power connections 17
voltage sensing module
voltage ratios
10
17
10
37
W
wiring diagrams 33
36
37
28
R
receving
overview
7
S
schematic diagrams 45
10...15 kV control circuit
10...15 kV power system
SMC-50 control module
control terminal designations
installation 25
programming
spare parts
PowerBricks
specifications
PowerBricks
standards and codes
start-up test procedure
52 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
37
49
49
10
47
46
27
7
41
Page 53
Page 54
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Publication 7703E-IN001F-EN-P - July 2019
Supersedes Publication 7703E-IN001E-EN-P - August 2014 Copyright © 2019 Rockwell Automation, Inc. All rights reserved. Printed in Canada.
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