Rockwell Automation Allen-Bradley OneGear User Manual
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Rockwell Automation Allen-Bradley OneGear User Manual

Rockwell Automation Allen-Bradley OneGear User Manual

7.2 kv motor controller - full-voltage non-reversing
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User Manual
Original Instructions
OneGear 7.2 kV Motor Controller — Full-voltage,
Non-reversing
Bulletin Number 7712

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Summary of Contents for Rockwell Automation Allen-Bradley OneGear

  • Page 1 User Manual Original Instructions OneGear 7.2 kV Motor Controller — Full-voltage, Non-reversing Bulletin Number 7712...
  • 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

    Shutter Position Indicator........33 Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 4 Transfer Block ..........70 Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 5 To open Output Cabinet ........71 Interlock Operation Sequence (Two Motors) ....71 Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 6 Table of Contents Notes: Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 7: Introduction

    Preface Introduction This user manual provides installation instructions and maintenance procedures for the Rockwell Automation Bulletin 7712 ArcShield™ arc flash resistant enclosure, medium voltage controller. The Bulletin 7712 structure provides one complete MV controller unit. Summary of Changes This manual contains new and updated information as indicated in the following table.

  • Page 8: Controller Unit Identification

    Figure 1 - Typical Structure Nameplate A nameplate is also found in the low voltage compartment (see Figure 2) with specific unit and motor application information. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 9: Additional Resources

    Preface Figure 2 - Typical Unit/Motor Nameplate Refer to these nameplates whenever you contact Rockwell Automation for assistance. Be prepared to provide information such as series number, structure series, unit series, diagram schematic, and catalog number. Additional Resources The following table lists publications that provide related information.
  • Page 10 Preface Notes: Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 11: Environmental Conditions

    Rockwell Automation products use materials that comply with Class 1: Industrial Clean Air sulphur environments as defined in IEC Standard 60654- 4 (Operating Conditions for Industrial-Process Measurement and Control Equipment), and G1 as defined in ISA-S71.04-1985 (Environmental...

  • Page 12: Product Dimensions And Weights

    (1) The height dimension does not include the plenum (574 mm [22.60 in.]), which is removed for shipping and installed by the customer. The total height of the unit including an installed plenum is 2674 mm (105.27 in.). Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 13: Arcshield Components Installation Requirements

    • The medium voltage power cell doors must be properly secured, using the handle mechanism (refer to instruction label on the power cell door and page 16). Failure to do so voids the arc flash resistance integrity. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 14 Chapter 1 General Information Notes: Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 15: Recommended Torque Values

    48 ft•lb (65 N•m) ATTENTION: Some components of this product incorporate Imperial hardware. Rockwell Automation recommends the use of the appropriate tools to successfully complete the maintenance procedures on these components. If you cannot obtain such tools, contact your area Rockwell Automation sales office for assistance.

  • Page 16: Open The Enclosure Doors

    Close and secure the low voltage door in the reverse order of opening. Figure 4 - Enclosure Compartments ArecShield Plenum 1/4-turn Fasteners Low Voltage Door Medium Voltage Door Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 17: Opening The Medium Voltage Door

    3. Ensure the earthing switch is closed (page 30). 4. Lift the release handle and swing the door to the left. Close and secure the medium voltage door in the reverse order of opening. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 18 Chapter 2 Safety Interlock and Accessibility Requirements Notes: Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 19: Contactor Inspection

    • Mechanical interlocks function properly • Contactor cart functions properly • Earthing switch functions properly • Microprocessor-based protection relay is correctly programmed • Enclosure interior is free from dirt, metal chips, loose hardware, and or tools Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 20: Testing Contactor Operation

    Failure to lockout incoming power will result in a live bus cell. Once the shutter between power cell and bus cell is open, it may cause severe burns, injury or death. Rockwell Automation does not assume any responsibility for injuries to personnel who have not completed the following safety procedure prior to servicing the equipment.

  • Page 21: Test Power Supply

    To avoid shock hazards, the MV and LV doors must be closed. Failure to do so may result in severe burns, injury, or death. Rockwell Automation assumes no responsibility for injuries to personnel who do not follow the safety procedures prior to servicing or operating the equipment.
  • Page 22 Inspect the area around the magnetic cores of the vacuum contactor and remove any metal filings, if present. This type of debris is attracted to the coil once it is energized and could prevent the contactor from closing properly. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 23 Start-up Procedure Chapter 3 Figure 6 - Typical Wiring Diagram: Electrically Held Vacuum Contactor (with IntelliVAC Control) Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 24 Chapter 3 Start-up Procedure Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 25 Start-up Procedure Chapter 3 Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 26 Chapter 3 Start-up Procedure Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 27: Power Lockout Procedure

    Low Voltage Section can also be powered by a temporary LV test power supply. 1. Turn the selection switch to Off. 2. Unplug the temporary test power supply. 3. Disconnect any customer supplied power supply using standard lockout/tagout procedures. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 28: Selecting Power Source

    • the contactor status must read OPEN. ATTENTION: The contactor cart must be racked out using tools supplied by Rockwell Automation only. Failure to do so can cause damage to equipment, personal injury, or death. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 29 8). From test to service position requires 11 complete rotations (a mechanism stops the screw rotation after 11 turns). The last turns require more torque to overcome the cart engagement resistance. Figure 8 - Position Speed Wrench Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 30: Operation Of Motor Controller

    IMPORTANT Before closing the earthing switch, ensure: • the contactor cart is in test/withdrawn position (if the cart is in the operating position, the earthing switch will not close); and, • the door is closed and latched. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 31: Earthing Switch Positioning Indicators

    Earthing switch OPEN Unearthed Earthing switch CLOSED Earthed Open/Closed Position Indicator Decal In the closed position (Figure 11), the arrow points toward “I” (red background). Figure 11 - Switch indicator - Off Closed position Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 32: Contactor Cart

    1. Orient the LV plug aligning the guide pins on the cart with the openings in the plug. 2. Push down the plug and secure the connection with the locking arm mounted on the cart (Figure 13). Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 33: Shutter Position Indicator

    The color of the indicator will change to red even if the shutter door is partially open. Figure 14 - Shutter position Indicator Indicator Close position (Green) Open position (Red) Viewing Window Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 34 TIP If the shutter door is partially or fully open, an interlock prevents the MV door from opening. A viewing window (Figure 15) shows the position of the contactor cart. Figure 15 - Viewing Window Viewing Window Indicator Figure 16 - Shutter closed Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 35 Equipment Operation Chapter 4 Figure 17 - Shutter open Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 36 Chapter 4 Equipment Operation Notes: Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 37: Required Tools

    Association NEMA) Standard No. ICS 1.3, Preventive Maintenance of Industrial Control and Systems Equipment, for general guidelines for setting- up a periodic maintenance program. Some specific guidelines for Rockwell Automation products are listed below. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 38: Contamination

    (EMI). Check the tightness of all terminals and bus bar connections and tighten securely any loose connections. Replace any parts or wiring damaged by overheating, and any broken wires or bonding straps. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 39: Coils

    Lubricate the Contactor Cart Earthing Switch Maintenance Inspect and Lubricate Earthing Switch Mechanism Ground Connection Inspection Toggle Assembly Inspection Earthing Switch Auxiliary Maintenance Auxiliary Contacts Replacement Auxiliary Contacts Adjustment Earthing Switch Auxiliary Contacts Inspection Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 40: Remove Contactor Cart

    Figure 18 - Securing Service Cart to the front of the Cabinet 3. Insert cart latch key into the cart latch disengagement and turn the key approximately a quarter turn clockwise (Figure 19). Ensure latch is disengaged from the rail. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 41 Figure 20 - Contactor Cart Removal Handle 5. Once the contactor cart is extracted from the cabinet, secure the cart using the latch and the service cart wheels to prevent movement. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 42 Chapter 5 Maintenance Figure 21 - Contactor Cart removed from enclosure Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 43: Remove And Replace Fuses

    Maintenance Chapter 5 Remove and Replace Fuses 1. Unscrew eight M8 bolts to remove the red Glastic cover (Figure 22). Figure 22 - Remove Glastic cover Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 44 Chapter 5 Maintenance 2. Replace each fuse by removing four M10 nuts (Figure 23). Figure 23 - Fuse Removal 3. Replace the M10 nuts and reattach the Glastic cover using the M8 bolts. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 45: Contactor Cart Maintenance

    To access the vacuum bottles, the glastic cover must be removed. See page 43. 1. Unscrew eleven M8 bolts to remove the fuse mounting mold (Figure 25). Figure 25 - Remove Fuse Mounting Mold Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 46 3. Remove the load terminal retaining bolt at the rear of the contactor, and the vacuum bottle mounting bolt at the top of the contactor (Figure 27). Figure 27 - Mounting and Retaining bolt removal Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 47 This gap is precisely calibrated later in this section. The wear indicator line on the bottom of the bottle's movable shaft must be visible from the front of the contactor. Repeat this step for the remaining two bottles. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 48: Calibrate The Overtravel And Contact Gap

    2. Rotate the insulator until the gap is correct. Repeat for the two remaining bottles. IMPORTANT This establishes synchronization between the three vacuum bottles. Figure 30 - Establishing Overtravel Overtravel Gap 0.065 in. [1.65 mm] Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 49 9. Position the stop bracket lightly against the armature plate and tighten the bolts securing the stop in position. Ensure that the actuator plate contacts the gap adjustment screw and the armature plate contacts the stop bracket (Figure 32). Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 50: Lubricate The Contactor Cart

    10. Reconnect the lower terminal connections at the rear of the contactor, and replace eleven M8 bolts to install the fuse mounting mold. Lubricate the Contactor Cart 1. Grease the contactor interlock rod using Aeroshell No.7 (Figure 33). Figure 33 - Lubricate interlock rod Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 51 2. Grease the front assembly guide rod on both side of the cart using Aeroshell No.7 (Figure 34). Figure 34 - Lubricate guide rod 3. Grease door to cart interlock sliding bracket Using Aeroshell No.7 (Figure 35). Figure 35 - Lubricate the sliding bracket Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 52 Chapter 5 Maintenance 4. Grease the tulip fingers Using Nye lubricant (Nyogel 759G) (Figure 36). Figure 36 - Lubricate the Tulip Fingers Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 53: Earthing Switch Maintenance

    1. Inspect the lubrication between the ground stab and the earthing switch blades. 2. Apply Nye lubricant (Nyogel 759G) to the ground stab (Figure 37) as needed. Figure 37 - Lubricate Earthing Switch Mechanism Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 54 Chapter 5 Maintenance 3. Grease (Aeroshell No. 7) the main shaft, mating surface of cam and gear, mating surface of shaft and gear housing (Figure 38). Figure 38 - Lubricate Earthing Switch Mechanism Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 55: Ground Connection Inspection

    1. Inspect the torque seal of the shoulder bolt for the toggle assembly. 2. If seal is broken, apply 4.4 lb•ft (6.0 N•m) to secure the shoulder bolt and apply torque seal. Figure 40 - Toggle Assembly Inspection Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 56: Earthing Switch Auxiliary Maintenance

    Horizontal Adjustment 1. Loosen the auxiliary mounting hardware (two M3.5 hex nuts). 2. Adjust the auxiliary as required. 3. Secure the adjusted position of auxiliary by tightening the nut. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 57: Earthing Switch Auxiliary Contacts Inspection

    Operation of electrical auxiliaries must be validated on a yearly basis. IMPORTANT Auxiliaries must be tested electrically with control power off. Refer to the unit electrical drawing to determine the test locations on the terminals located in the low voltage compartment. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 58 Chapter 5 Maintenance Notes: Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 59: Typical Bulletin 7712 Parts

    Appendix Spare Parts Typical Bulletin 7712 Parts Contact your local Rockwell Automation office to verify that the following part numbers are available. Table 3 - IntelliVAC Description Part Number IntelliVAC Contactor Control Module 1503VC-BMC5 IntelliVAC Internal Fuse 80174-902-14-R Table 4 - Fuses...
  • Page 60 Ground Fault Ct, 100:1 PN-317009 (1) Select from Project Spare Parts List. Table 10 - Accessories Description Part Number Cart racking crank PN-256639 Earthing switch operating tool PN-256678 Cart latching key 80026-855-01 Service cart PN-438186 Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 61: Test Summary

    Alternating current disconnectors and earthing switches. • IEC 62271-200, High-voltage switchgear and control gear - Part 200: AC metal-enclosed switchgear and control gear for rated voltages above 1 kV and up to and including 52 kV. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 62 External surface IP4X IEC 60470/5/13 ER-070-2012 Rockwell Automation IEC 62271-1/5.13 Internal barriers IP2X ER-070-2012 Rockwell Automation Arc Tests 7712 Starter 31.5 kA/0.5 s line side IEC 62271-200/ Annex A, AFLR 20158-2, 08/16-18/2010 Powertech Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 63: Door Interlock Circumvention

    1. Open the LV door. 2. In order to circumvent the earthing switch to door interlock, remove three M6 flat head screws located on the door (Figure 43). Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 64 Figure 43 - Circumvent Earthing Switch to Door Interlock 3. Push the top edge of the interlock mounting bracket downward using a flathead screwdriver. Open the door. 4. Reverse steps 1 through 2 to reassemble the mounting bracket to the door. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 65: Door To Isolation Shutter

    • Earthing switch must be closed. 1. Open the LV door. 2. Remove the four M6 bolts located on the compartment floor (Figure 44). Figure 44 - Circumvent Door to Isolation Shutter, Removing the bolts Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 66 (Figure 45). Figure 45 - Circumvent Door to Isolation Shutter 4. Reverse steps 1 through 2 to reassemble the lever arm to roof of the MV compartment. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 67 Figure 46 - PowerFlex drive with bypass using OneGear 7712 controllers Incomer 7791 Bypass 7712 MB Drive Input 7712 D Drive Output 7712 DO Output Cables 7791 F Figure 47 - Transfer Block KC KC KC KC KC Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 68 Drive Input Drive Output Output Cables Output Cables Incomer Bypass M1 7712 D 7712 7712 DO 7712 MO 7712 MO 7791 7712 MB Figure 49 - Transfer Block KC KC KC KC KC Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 69: Keys

    • 1 Key in Output Cables Cabinet door. Prevent the door to open when key is removed. KD and KE Key for Output Cables Cabinet Door • Keys in the Output Cables Cabinet door. • Prevent the door to open when key is removed. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...

  • Page 70: Transfer Block

    • Place all KC keys in transfer block • Take KA and KB keys and place in Drive Input and Drive Output doors • Turn keys to unlock carts • Rack-in Drive Input and Drive Output carts. • Run drive Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 71 The only difference is that the Output Cables Cabinets do not require a KC Key. To open the Output Cables Cabinet the appropriate earthing switch interlock key is required. Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 72 Appendix D Mechanical Interlock for 7712 and PowerFlex 7000 Drive Notes: Rockwell Automation Publication 7712-UM001D-EN-P - October 2017...
  • Page 74 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, ArcShield, IntelliVAC, OneGear, PowerFlex, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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Allen-bradley 7712

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