Rockwell Automation Allen-Bradley 7703E Installation Instructions Manual
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Rockwell Automation Allen-Bradley 7703E Installation Instructions Manual

Rockwell Automation Allen-Bradley 7703E Installation Instructions Manual

Medium voltage smc oem components, 10...15 kv
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Installation Instructions
Original Instructions
Medium Voltage SMC OEM Components, 10...15 kV
Bulletin Number 7703E

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Summary of Contents for Rockwell Automation Allen-Bradley 7703E

  • Page 1 Installation Instructions Original Instructions Medium Voltage SMC OEM Components, 10…15 kV Bulletin Number 7703E...
  • Page 2 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.

  • Page 3: Table Of Contents

    Bypass Contactor or Circuit Breaker......31 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 4 ............51 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 5: Preface

    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...

  • Page 6: Additional Resources

    Provides general guidelines for installing a Rockwell publication 1770-4.1 Automation industrial system. Product Certifications website: rok.auto/certifications Provides declarations of conformity, certificates, and other certification details. You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 7: Receiving

    • CEC (Canadian Electrical Code) • CSA 22.2 No. 253 (Canadian Standards Association) – Medium Voltage AC Contactors, Controllers and Control Centers • NEC (National Electrical Code) • NEMA ICS Standards (National Electrical Manufacturers’ Association) Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 8 • 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 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 9: Identification

    (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 for additional details.) (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...

  • Page 10: Sizing The Enclosure

    (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. Dimensions Figure...

  • Page 11: Torque Requirements

    ATTENTION: 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...
  • Page 12 Chapter 2 PowerBrick Installation Figure 2 - Single PowerBrick Dimensions (1000/2400V) Top View Mounting holes for M8 [5/16] hardware (4) places Front View Side View Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 13: Typical Mounting, 10

    Figure 3 - Typical PowerBrick arrangement for 10…12 kV 10…12 kV PowerBrick System Typical spacing to ground metallic enclosure components. Spacing may be reduced through the full use of suitable insulation systems. Front View Side View Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 14: Typical Mounting, 12.1

    Figure 4 - Typical PowerBrick Arrangement for 12.1…14.4 kV 12.1…14.4 kV PowerBrick System Typical spacing to ground metallic enclosure components. Spacing may be reduced through the full use of suitable insulation systems. Front View Side View Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 15: Power Connections

    Figure 5 - Typical Single Phase 15 kV PowerBrick Assembly (side view) Terminal Non-conductive mounting plate (supplied by OEM) Flexible bus link 11 mm clearance hole Insulator for M10 hardware (supplied by OEM) (supplied) Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 16: Grounding

    • 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. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 17: Voltage Sensing Board Dimensions

    Figure 7 for dimensions). All the Voltage Sensing Board connection points are to be made accessible. Description Line Voltage MV Ratio Catalog Number (3 phase, 50/60 Hz) Voltage Sensing Board 10,000…12,000V 7703E-VSM 12,001…14,400V 7703E-VSN Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 18 5 units at a time are recommended. Increasing the ratio will decrease the displayed voltage, and visa versa. Figure 8 - Voltage Sensing Board Ground Connections To Interface Board Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 19: Current Loop Gate Drive Power Assembly (Clgd)

    ATTENTION: 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...
  • Page 20 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. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 21 2. Current Transformer Assembly 152. m ± 20 cm (50 feet ± 8 in.). 3. Loop Cable 4. Terminal 5. Return Cable #6 AWG (13 mm2) Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 22 Chapter 2 PowerBrick Installation Notes: Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 23: Interface Board Installation

    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...
  • Page 24 Replacement LED (Red) is ON when Part Number in program mode MOV1 DS17 R229 Serial Number Programming L N G SW4 Firmware Interface Control Power Power out to Programming 110…240V AC SMC-50 Switch Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 25: Interface Board Connections

    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 for detailed instructions on wiring and programming the unit. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 26: Emc Compliance

    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. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 27: Control Power

    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...

  • Page 28: Connecting Interface Board To Voltage Sensing Board

    Interface Board. See Figure 14 for the location of the connector on the interface to Voltage Sensing Board board, and Figure 8 on page 18 for the connector on the voltage sensing board. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 29: Connecting Fiber Optic Multiplexer Board To Gate Driver Board

    Refer to the appropriate wiring diagram in Chapter Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 30: Additional Control Components

    Some of these control components are outlined in Chapter 4 Components Appendix It is the responsibility of the OEM to ensure that all required power and control components are supplied and functional. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 31: Introduction

    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. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 32 Chapter 4 Main and Bypass Switching Device Installation Notes: Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 33: Wiring Diagrams

    ATTENTION: 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...
  • Page 34 TX11 TX12 TX17 TX18 L2/N 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). Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 35: Final Test Procedures

    • 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.

  • Page 36: Dielectric Test

    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. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 37: Additional Tests

    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...
  • Page 38 (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). Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 39 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 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 40 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 fiber- optic cable must be replaced. If it isn’t, the interface board should be replaced. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 41: Start-Up

    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...
  • Page 42 Chapter 6 Final Test Procedures Notes: Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 43: Deratings Specifications

    59 kV 74 kV (6601…9900 ft) 3001…4000 m 15 A 30 A 45 A 52 kV 66 kV (9901…13,200 ft) 4001…5000 m 20 A 40 A 60 A 46 kV 58 kV (13,201…16,500 ft) Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 44 Appendix A Component Deratings Notes: Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 45: Introduction

    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...
  • Page 46 Appendix B Typical Schematic Diagrams Figure 23 - Typical Power System Diagram (10…15 kV) POWER CT INPUTS GATE TRANSMITTERS POWER POWER PHASE A PHASE B PHASE C TEMP. 115/230V AC 115/230V AC Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 47 Aux A1 EXT. FAULT NORMAL BYPASS SLOT 7 150-SM4 SMC 50 DPI COMM SLOT 8 SLOT 9 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...
  • Page 48 Appendix B Typical Schematic Diagrams Notes: Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 49: Powerbricks

    (2) Resistors are series connected for a total of 60 Ω per snubber for 180/360A assemblies and 30 Ω per snubber for 600A assemblies. A PowerBrick has one snubber per pair of SCRs. Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 50 Current Loop Gate Drive Power Assembly (CLGD) on page Table 14 - Accessories Part Number Description Quantity PN-281287 Control Module (Standard) 350325-A06 HIM (Bezel Mounted) PN-71481 SMC-50 Digital I/O Module PN-71480 SMC-50 Ground Fault, PTC Module 80144-491-02 Fuse Extractor Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 51: Index

    20 control components 43 diagrams schematic 45 10...15 kV control circuit 47 main switching device 10...15 kV power system 46 installation 31 wiring 33 dielectric test procedure 36 jumper positioning 36 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...

  • Page 52: Rockwell Automation Publication 7703E-In001F-En-P - July

    10...15 kV control circuit 47 10...15 kV power system 46 SMC-50 control module control terminal designations 27 installation 25 programming 37 spare parts 49 PowerBricks 49 specifications PowerBricks 10 standards and codes 7 start-up test procedure 41 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019...
  • Page 54 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, CENTERLINE, PowerBrick, Rockwell Automation, Rockwell Software, and SMC-50 are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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