Medium Voltage SMC™ OEM Components (10…15 kV)
Contents
1. CONTROL POWER lt 230V HH SCH OR 115V La QT 1 X om 10 SMCFLEXIB TB6 Q lt 6 AWG 600V co j 1 28 p 2 START STO e a o Q 2 CR MC CR 55 BC CR T FROM SMCFLEXIB 4 12 13 1 15 17 19 2 21 2 SMC FLEX TO BE PROGRAMMED BY THE CUSTOMER NS BEFORE START JP EXTERNAL BYPASS DPI AUX2 AUX3 AUX4 FAULT ALARM NORMAL PTC TACH GROUND INPUT INPUT FAULT 22 2 5 2 2 2 2 3 32 33 34 Key SMCFLEXIB INPUT POWER FIBER OPTIC BOARD INPUT POWER L1 N LEGEND EU CURRENT LOOP CONDUCTORS PASS THROUGH THE CURRENT LOOP DRIVE CURRENT TRANSFORMER ASSEMBLY 2 NOTINCLUDED WITH MV SMC FLEX OEM KITS Rockwell Automation Publication 7703E INOO1E EN P July 2014 Appendix B 2 CONTROL RELAY 2 BYPASS CONTACTOR CIRCUIT BREAKER 2 MAIN CONTACTOR CIRCUIT BREAKER Note Requires optional Main and Bypass control panels as well as control relays and pilot devices 51 AppendixB Typical Schematic Diagrams Notes 52 Rockwell Automation Publication 7703E INOO1E2. gt To Interface Board ground Connections VOLTAGE FEEDBACK Eb ELLA GND1 2 TETTE P NEL al Ta al a 2 a a 8 E 2 8 1 1 1 1 1 1 1 2 4 5 6 L1 T L2 T2 13 T3 22 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Current Loop Gate Drive Power Assembly CLGD PowerBrick Installation Chapter 3 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 see below The CLGD power assembly consists of three parts 1 Power supply transformer with secondary terminal blocks and sensing 2 Current Transformer CT assembly plastic tubing with two current transformers per PowerBrick 3 Loop Cable white silicone insulated 50 kV DC 46 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 Cu
3. TEN mE XN ay IN Rockwell Automation Publication 7703E INOO1E EN P July 2014 lt lt Non conductive mounting plate Insulator supplied by OEM PowerBrick Installation Chapter 3 Figure 6 Photo of Typical Single Phase PowerBrick Assembly Front View Rockwell Automation Publication 7703E INOO1E EN P July 2014 19 Chapter3 PowerBrick Installation Grounding PowerBrick Operating Restrictions 20 is suitably bonded to ground and that provisions for grounding are made ATTENTION It is the responsibility of the OEM to ensure that the final enclosure according to local electrical codes and standards 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 40 C Refer to Table 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 Donotoperate the power stacks for at least five minutes between a start or a stop cycle e For repeated hourly operation forced ventilation is required Note It may be possible to exceed so
4. Me A gt Ben 9 Fy TP8 Common for 24 power supply 3 Gate Pulse TPs m sensor input PhaseB Fiber Optic Transmitter LED Yellow ON Ej when Phase B a gate signal active hee ON TB5 Current u when current loop Transformer ME IE TP11 Phase B Connections is presen z Q gate sign B LED Yellow ON m Phase C 2 E E when Phase C Fiber Optic Transmitter a gate signal active 3T Phase C LED Green ON gate signal aiu Ig when power is present M A I TP15 Common for yum 19 20 c 19 20 Gate Pulse TPs O Power Supply EN LEDs Green ON when Lon test points SW3 Used to TEMP signal present at temperature defeat temperature Pe feedback fiber optic receivers feedback channels Temperature Feedback pl 5 Fiber Optic Receivers 3 C Ee x x aaO os Ul 1 LNG LN Serial Replacement Control Power Power out Number Part Number 110 240V AC to SMC Flex Notes 1 ICOM is the common connection for Gate and Pulse test points 28 2 VCOM is the common connection for Current and Voltage feedback test points Do not connect to earth ground Do not connect ICOM and VCOM together either directly or through test probes meter or scope common Rockwell Automation Publication 7703E
5. D 2 End i m D 0 ba 0 52 og HB L 1 22i le mim L Front View Side View Rockwell Automation Publication 7703E INOO1E EN P July 2014 15 Chapter3 PowerBrick Installation Typical Mou nting Figure 4 Typical PowerBrick arrangement for 12 1 14 4 kV Arrangement 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 16 Rockwell Automation Publication 7703E INOO1E EN P July 2014 PowerBrick Installation Chapter 3 Power Connections when completing connections Failure to do so may result in severe burns ATTENTION To avoid shock hazard lock out incoming power to power cables injury or death IMPORTANT Itis the responsibility ofthe 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 co
6. the gate driver boards and a Shorter length will overload the cable or transformer ATTENTION The loop cable length must be as specified above The loop cable is 24 Rockwell Automation Publication 7703E INOO1E EN P July 2014 PowerBrick Installation Chapter 3 A sensing CT is supplied to monitor the current in the loop It provides a signal to the Interface Board to inform the SMC Flex 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 Flex 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 1 To control 3 power 1 Power Supply NOTE 2 Current Transformer Assembly 3 Loop Cable 4 Terminal 5 Return Cable 6 AWG 13 mm Rockwell Automation Publication 7703E INOO1E EN P July 2014 PowerBrick assemblies The total length ofthe three loop cables and the return cable must be 50 feet 8 in 152 m 20 25 Chapter3 PowerBrick Installation Figure 12 Typical 15 kV Implementation for Current Loop lt PowerBrick assemblies 1 Power Supply NOTE The total length of the three loo
7. 12 000V 7703E VSN Use the data in Table 3 to assist in calculating the enclosure size 12 001 14 400V ATTENTION 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 Table 3 PowerBrick Specifications Description 160 A 340A 10 000 12 000V e Pm 12 001 14 400V 3 phase 10 15 Ambient Temperature 0 C 40 C 32 F 104 F Power Section 30SCRat 10 12 kV for 3 phases 36 SCR at 12 1 14 4 kV Repetitive Peak Inverse Voltage Rating 10 012 kV 32 500 PIV 12 1 14 4 kV 39 000 PIV Thermal Capacity 600 of FLA 10 seconds 450 of FLA 30 seconds dv dt Protection R C Snubber Network Start or Stop Cycle at 450 FLA 2 Maximum Heat 160A 340A 580A Continuous Dissipation kW 10 000 12 000V 27 57 98 05 12 001 14 400V 32 69 117 0 5 Altitude 0 1000 m 0 3 300 ft See Controller Deratings Table on page 6 Publication 1503 BR010F EN P Net Shipping Weight 3 phases Rating kV 10 12 12 1 144 Weight kg lbs 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 12 Rockw
8. 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 21 Figure 21 Test Power Application on Gate Driver Board Gate signal Temperature signal fiber optic receiver fiber optictransmitter Yellow LED Plug in test power Current loop Thermistor CT connector supply connector TEST POWER Ort Ty Ie e THERM GAS AB R4 GATE Snubb S 3 _ a m nur 2160 e m terminal m pe an fo Gate signal T u n um c RIS gi li test point Cathode SCRI m RI9 R21 R24 D9 terminal T Pe zi EL ur fr e ari Gate cathode Di m ES T e connector Common test point 20V test point 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 voltag
9. Automation Publication 7703E INOO1E EN P July 2014 53 AppendixC Spare Parts 80025 549 03 R Fiber Optic Cable 2 5 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 Q 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 module to 6 pin 2 per controller 80174 201 02 8 3 per controller 1 Referto table C 1 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 of Section 3 Current Loop Gate Drive Power Assembly Table 14 Accessories Part Number Description Control Module Standard 41391 454 01 B1FX Control Module Pump Control Quantity 41391 454 01 S1FX Notes 1 Reference only 2 7703E For OEM products refer to OEM supplied documentation for specific spare parts list 54 Rockwell Automation Publication 7703E INOO1E EN P July 2014 additional test procedures 41 Bypass Swi
10. EN P July 2014 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 160A 81020 753 51 R 81020 230 51 R Complete PowerBrick W 81020 752 51 R IJ 81020 232 57 R Heatsink Assembly only 340A 81020 232 58 R 1 81020 230 57 R Complete PowerBrick Y 81020 230 58 R 1 81020 753 85 R Heatsink Assembly only DM 580A 81020 753 86 R DN 81020 752 85 R Complete PowerBrick DM 81020 752 86 R DN Table 12 Snubber Capacitor Snubber Resistor Part Number Snubber Capacitor 200 400 Amp All voltages 80026 508 02 0 68 uF Part Number Snubber Resistor 200 400 Amp 3 per PowerBrick 80026 561 02 R 20 Q 120 W Part Number 80026 562 01 R 1 All parts are ceramic wirewound non inductive winding 2 Resistors are series connected for a total of 60 2 per snubber for 180 360A assemblies and 30 2 per snubber for 600A assemblies A PowerBrick has one snubber per pair of SCRs Table 13 Common Parts Description Sharing resistor 16 25 kS 112W 2 5 tap Quantity 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 VSB 10 12 kV 1 per controller 81020 237 53 R 12 1 15 kV 80190 440 03 R Interface Board 1 per controller Rockwell
11. controller Figure 15 SMC Flex Controller Control Terminals CY TET Rockwell Automation Publication 7703E INOO1E EN P July 2014 31 Chapter4 Control Component Installation Table 7 Terminal Descriptions Terminal Number Description Terminal Number Description 11 Control Power Input C 23 PTC Input 12 Control Power Common C 24 PTC Input 13 Control Enable Input 25 Tach Input 14 Control Module Ground 26 Tach Input 15 Option Input 2 27 Ground Fault Transformer Input 16 Option Input 1 28 Ground Fault Transformer Input 17 Start Input 29 Aux Contact 2 18 Stop Input 30 Aux Contact 2 19 Aux Contact 1 Ext Bypass 31 Aux Contact 3 20 Aux Contact 1 Ext Bypass 32 Aux Contact 3 21 Not Used 33 Aux Contact 4 Normal 4 22 Not Used 34 Aux Contact 4 Normal 1 Do not connect any additional loads to these terminals These parasitic loads may cause problems with operation which may result in false starting and stopping 2 Aux Contact 1 is always programmed for Ext Bypass N 0 to control the bypass contactor in MV applications 3 Aux Contact 4 is always programmed for Normal N 0 to control the isolation contactor in MV applications 4 RCsnubbers are required on inductive loads connected to auxiliary Connecting Interface Board to Voltage Sensing Board 32 Note The OFF state leakage current for a solid state devic
12. optic receivers for each phase from the interface board to the appropriate gate driver board transmitter Refer to Chapter 6 for the appropriate diagram for the temperature feedback fiber optic connections Addition al Control Additional control components are required to complete the circuit depending on the application Some of these control components are outlined in Chapter 5 Components and Appendix B It is the responsibility of the OEM to ensure that all required power and control components are supplied and functional 34 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Chapter 5 Main and Bypass Switching Device Installation Introduction 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 Main Contactor or Circuit line switch is required in order to isolate the power stacks from line voltage Breaker Ifa line contactor is used suitable short circuit protection must be provided in compliance with relevant standards and or local codes refer to Section 2 e Ifa circuit breaker is used for the line switch it must be rated to handle normal load and short circuit conditions Bypa ss Contactor or Circuit bypass contactor or circuit breaker must be used in the SMC configuration to Breaker bypass the SCRs once the motor is up to speed The bypass must have an opening time
13. 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 refer to Figure 3 and Figure 4 Rockwell Automation Publication 7703E INOO1E EN P July 2014 13 Chapter3 PowerBrick Installation 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 ATTENTION Maintain sufficient clearance between the power phases and Figure 2 Single PowerBrick Dimensions 1000 2400V am RLR ha h URH 2 3 06 Mounting holes for M8 5 16 hardware 4 places Front View Side View 14 Rockwell Automation Publication 7703E INOO1E EN P July 2014 PowerBrick Installation Chapter 3 Typical Mounting Figure 3 Typical PowerBrick arrangement for 10 12 kV Arrangement 10 12 kV PowerBrick System Typical spacing to ground metallic enclosure components Spacing may be reduced through the full use of suitable insulation systems 27 iml E x d ii y U
14. standards and codes and any additional local codes that a medium voltage controller must comply with CEC Canadian Electrical Code CSA 22 2 No 253 Canadian Standards Association Medium Voltage AC Contactors Controllers and Control Centers NEC National Electrical Code Rockwell Automation Publication 7703E INOO1E EN P July 2014 9 Chapter 2 Receiving and General Information NEMA ICS Standards National Electrical Manufacturers Association 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 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 Rockwell Automation Publication 7703E INOO1E EN P July 2014 PowerBrick Installati
15. FACE BOARD UNE A hax on co VOLTAGE us 1 5 POWERBRICK1 GNDI 2 SENSING PHASE A PHASE BOARD 4 N CABLES lg GATE TRANSMITTERS i i SMCFIBER OPTICS NIE THERMISTOR lo MULTIPLEXER qe BOARD S 5 CLGD1 ay N b 1 ale 9 1 2 3 4 5 8 u uf SMCINTERFACE BOARD PNG SMCFLEXIB sj T TEN TXI TB21 C2 8 CLGD2 6 vsB TO LINE AND LOAD TERMINALS el E TG i v2 na as ly A Vom Oa Um L d BE T86 hx Lt De amp E GDPS X
16. INOO1E EN P July 2014 Interface Board Connections SMC Flex Control Module EMC Compliance Control Component Installation Chapter 4 IMPORTANT 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 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 N WARNING Do not connect to Interface Board Vcom terminal 1 Connect the ribbon cables 5 to the back of the SMC Flex control module 2 Align the ribbon cables 5 from the SMC Flex 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 Supply power to the SMC Flex control module and make the required control connections Please refer to User Manual MV SMC Flex Motor Controller Bulletins 1503E 1560E and 1562E Publication 1560E UMO051 EN P for detailed instructions on wiring and programming the unit product in domestic environments may cause radio interference in which case ATTENTION This product has been designed for C
17. Installation Instructions Allen Bradley Medium Voltage OEM Components 10 15 kV Publication 7703E INOO1E EN P Allen Bradley Rockwell Software Automation 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
18. 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 fiber optic cable must be replaced it isn t the interface board should be replaced 44 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Final Test Procedures Chapter 7 11 When each gate driver circuit has been checked disconnect the power supply and remove it from the cabinet energized Failure to remove the portable test power supply will result in ATTENTION The gate drive circuits operate at high voltage when the SMC is equipment damage and may cause severe injury or death 12 Open the switch SW2 on the interface board see Figure 21 before returning the unit to service Ensure the red LED is off energized the motor will start in an uncontrolled manner and may cause severe ATTENTION If the SW2 switch is not in the open position when the SMC is damage 13 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 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 energ
19. Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt Allen Bradley Rockwell Software Rockwell Automation PowerFlex and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information Changes throughout this revision are marked by change bars as shown to the right of this paragraph New and Updated This table contains the changes made to this revision Information Topic Page Migrated manual to FrameMaker Updated PowerBrick catalog numbers and removed footnotes about them 1 Added 580 A to PowerBrick specifications table 12 Updated PowerBrick dimension and arrangement diagrams 14 15 16 Removed 160 340 A description from power circuit wiring diagram 38 Added 580 A to component derating table 47 Added 580 A to PowerBrick replacements table 53 Added Index 55 Rockwell Automation Publication 7703E INOO1E EN P July 2014 3 Summary of Changes Notes 4 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Introduction Receiving and General Information PowerBrick Installation Control Component Installation Main and Bypass Switching Device Installation Table of Contents Chapter 1 SCOPE ri etus see etes 7 Additional Pu
20. SE PHASE PHASE zor CATE TRANSMITTERS SMCFLEX Fros FIRER OPTIC ESH BOARD am C N 88 m SMC FLEX INTERFACE BOARD VOLTAGE FEEDBACK SMC FLEX XIE VB i TX1 1821 1 24 Ein DQ 8 re on 21 75 CAUTION 798 7 Far MAXIMUM TWO STARTS PER HOUR WITH A MINIMUM OF FIVE Era IL MINUTES BETWEEN STARTS m enod _ s 15 LEGEND mp X WIRE CONNECTIONS FOR PHASE A mes ana X WIRE CONNECTIONS FOR PHASE B 50 5 RC S2 ica xj WIRE CONNECTIONS SHOWN FOR PHASE C xj DON T CONNECT Tx En CURRENT LOOP CONDUCTORS PASS THROUGH THE CURRENT KE LOOP GATE DRIVE CURRENT TRANSFORMER ASSEMBLY REMOTE EQUIPMENT 75 4 USED ONLY FOR 4 OR MORE POWERBRICKS IN SERIES B z NOT INCLUDED WITH MV SMC FLEX OEM KITS m amp SHORT CIRCUIT PROTECTIVE DEVICE SCPD MAY BE A CIRCUIT BREAKER OR FUSED CONTRACTOR WITH DISCONNECT e A VONE PONERERICKS A 10 1207 5 FROM B 12 1 144 6 CONTROL ui i 84 s E TO SMC FLEX CONTROL MODULE Note Requires input disconnection optional as well as main and bypass vacuum contactors Rockwell Automation Publication 7703E INOO1E EN P July 2014 Typical Schematic Diagrams Figure 25 Typical Control Circuit Standard Module 10 15 kV
21. X T 2 TX12 mi POWERBRICK n LJ M HS2 E TX13 4 At RS RS IRB TX15 B TX16 B m mJ EL Us Sel Fr E ve d Hovi um re Rama S 3 amp TERM ZI DN Ps las 5 Bude Fa ES t S 2 off m 4 xD c2 e PHASEB PHASEC E CURRENT LOOP TRANSFORMER LM E PRU CURRENT LOOP CT se 8 82 S Bau H4 x2 NOTE Only devices supplied by Rockwell Automation are shown LEGEND Additional devices are required to form a complete solution CONNECTIONS SHOWN FOR PHASE A refer to Appendix B for a typical schematic showing other EJ 9 e gt WIRE CONNECTIONS FOR PHASE B WIRE CONNECTIONS SHOWN FOR PHASE C DON T CONNECT USED ONLY FOR 4 OR MORE POWERBRICKS IN SERIES VOLTAGE NUMBEROF POWERBRICKS 96 4 10 120 5 124 144 kV 6 SEE CHAPTER 3 Current Loop Gate Drive Power Assembly CLGD on 23 FOR CABLE REQUIREMENTS devices Rockwell Automation Publication 7703E INOO1E EN P July 2014 Final Test Procedures Chapter 7 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 rad
22. blications vri LR Reis 7 Chapter 2 Receiving T 9 Handling Procedures for Electrostatic Sensitive Devices 9 Standards and Codes sa 9 Chapter 3 te Inch ttes ctetu ta doe 11 Sizing the Enclosute ses esse soa Rese 12 Dimensions as iii OF anes 13 Torque Requirements as Heu 13 PowerBrick Mounting ua er 13 Typical Mounting Arrangement 10 12 PowerBrick System 15 Typical Mounting Arrangement 12 1 14 4 kV PowerBrick System 16 Power Connections 17 Grounding M m 20 PowerBtick Operating Resttictions een se ea 20 Voltage Sensing Board 21 Mounting and Connecting the Voltage Sensing Board 21 Current Loop Gate Drive Power Assembly CLGD 23 Chapter 4 Interface Board Installation 255 em C CILE eate ete 27 Interface Board Connections sa OE Sen EE qa 29 SMG Flex Control Module nu ra 29 EMC Compliance caster pete CE a La ds eie 29 sre ttd utate ec de UD on 29 ee Rad ete ON ot 30 POWER S a CIEN aM eee 30 Control Voss 30 Conto Win ra des RR quen ad NE Re NEN E 31 Control Terminal Designations i un een 31 Connecting Interface Board to Voltage Sensing Board 32 Connecting Fiber Optic Multiplexer Board to Gate Driver Board 33 Additional Control Components 1 2 34 Chapt
23. c Sensitive Devices Standards and Codes Chapter 2 Receiving and General Information Refer to Getting Started General Handling Procedures for Medium Voltage Controllers Publication 05050 EN P This document is included with your shipment and contains information regarding receiving unpacking initial inspection handling storage and site preparation 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 ATTENTION Printed circuit boards contain components that can be damaged To guard against electrostatic damage ESD to equipment the following precautions should be observed when handling electrostatic sensitive devices 1 Usea 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 These precautions are the minimum requirements for guarding against ESD For more information refer to Guarding Against Electrostatic Damage Publication ICCG 4 3 See che Additional Publications section for information on obtaining this document IMPORTANT Itis recommended that the user be familiar with the following safety and design
24. ds Rockwell Automation does not assume any responsibility or liability for loss or damages caused by failures in the unit manufactured by the OEM For more information see the Warranty section in General Terms and Conditions of Sale Publication 6500 CO001_ EN P Rockwell Automation Publication 7703E INOO1E EN P July 2014 49 Appendix B Typical Schematic Diagrams 50 Figure 24 Typical Power System Diagram 10 15 kV 8 2 2 3 m SCPD 2200 n u 222 4 S 2 er 2 t 1 22 f wn 13 p 7 RRI POWERBRICK 1 RRI POWERBRICKn 2 am a o2 s MAG tS Ha E ELIs 5 5 lt 5 TEST TEST TEST TEST aa aco aco c D D D Reel lt Rime 6 7 1 1 ge 4 324 4 2 c gt p B 2 u A c nx2 l nX2 nx2 4 FO4 TO FO16TO F028 TO F015 F039 PHA
25. e connected to an SMC Flex input must be less than 6 mA board Rockwell Automation Publication 7703E INOO1E EN P July 2014 Use the wire harness provided to connect the Voltage Sensing Board and the Interface Board Refer to Figure 14 for the location of the connector on the interface board and Figure 8 on page 22 for the connector on the voltage sensing Control Component Installation Chapter 4 Connecting Fiber Optic bi ee iem S ud ho e gate ur rom the interface board 7703E and splits them into the required fiber pa to Gate optic gate drive signals for 10 15 kV river boar Figure 16 Fiber Optic Multiplexer Board To Gate Driver Boards Su m SO Phase gate drive fiber optic signals from Interface Board Figure 17 Fiber Optic Multiplexer Board Dimensions and Connections 4 0 0 16 5 MTG holes 1184 4 66 127 0 5 00 AMA 100 7 3 96 gt gt 28 6 1 13 201 4 7 93 210 0 8 27 Rockwell Automation Publication 7703E INOO1E EN P July 2014 33 Chapter4 Control Component Installation Table 8 Fiber Optic Multiplexer Board Specifications Control Voltage 110 120V 220 240V at 50 60 Hz 30 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
26. e 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 16 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 22 and Figure 23 Rockwell Automation Publication 7703E INOO1E EN P July 2014 43 Chapter7 Final Test Procedures Figure 22 Gate Pulse Detail Typical SCR ABB 6 00 5 00 4 4 00 4 Volts 3 00 2 00 1 00 0 00 2 00 1 00 0 00 1 00 2 00 3 00 4 00 5 00 6 00 7 00 Microseconds Figure 23 Gate Pulse Test Waveform T 1 1 1 T T T en 2 0 1 5 1 0 0 5 0 0 0 5 1 0 1 5 2 0 2 5 3 0 Microseconds 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 N ATTENTI
27. ell Automation Publication 7703E INOO1E EN P July 2014 Dimensions Torque Requirements PowerBrick Mounting PowerBrick Installation Chapter 3 Refer to Figure 2 Figure 3 and Figure 4 for PowerBrick dimensions and mounting All electrical connections must be torqued to the specifications shown in Table 4 specification Failure to do so may result in damage to the equipment and or ATTENTION Ensure that all electrical connections torqued to the correct injury to personnel Table 4 Torque Requirements Hardware Recommended Torque 74 20 thread cutting housing assembly screws 7 62 Ib in M5 3 4 30 Ib in Control Wire Terminals 0 2 0 4 2 0 3 3 Ibein CLGD Power Assembly Terminals 5 6 Nem 50 Ib in SMC Flex Control Module Terminals 0 6 5in Ib M8 Capacitor Lugs 7 5 66 Ib in 8 All others 14 120 Ib in M10 29 N m 250 Ib 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 refer to 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
28. er some of the devices described are not provided These must be acquired separately 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 11 Each form of PowerBrick assembly is applied with other Bulletin 7703E control components and power devices in forming a complete solution Please refer to Medium Voltage SMC Flex Motor Controller Bulletin 1503E 1560 1562E User Manual 1560E UMO51_ EN P for additional information about the functionality of some of the Bulletin 7703E products This document contains the following information for the MV SMC Flex e Commissioning Maintenance and Troubleshooting e Parameter List To order additional copies of Instruction Manuals for all Rockwell Automation medium voltage products please contact a Rockwell Automation sales office or your local distributor Chapter1 Introduction Notes 8 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Receiving Handling Procedures for Electrostati
29. er 5 Introductions elle N EEE 35 Main Contactor or Circuit 35 Bypass Contactor or Circuit 35 Rockwell Automation Publication 7703E INOO1E EN P July 2014 5 Table of Contents Typical Wiring Diagrams Final Test Procedures Component Deratings Typical Schematic Diagrams Spare Parts Index Chapter 6 ee 37 Chapter 7 Final Test Proc due re 39 Dielectric Tests E RE CEA A 40 Additional Fests etse sete te dus POE INTO RN Ped e ee TC 41 Programming se en Rene 41 SMC Flex Module asien ea 41 Voltage Sensing Module ai nn qd e ate pb pce ev aeta 41 Power Supply Lest nu arg 42 Start De ee 46 Spare RE 46 Appendix resta swt bed bestie Ha UA Seda 47 Appendix B Introduction Tui soa VA cse fal iud onu e reato pe dera 49 Appendix C arena esi do ys memes 53 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Scope Additional Publications Rockwell Automation Publication 7703E INOO1E EN P July 2014 Chapter 1 Introduction 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 howev
30. ii Refer to the applicable local electrical codes Check the tightness of all power and control connections Refer to Table 4 on page 13 for recommended torque values Gently tug on all wires to ensure that they are properly connected above specifications Failure to do so may result in electrical faults causing personal injury or damage to the equipment ATTENTION All hardware for electrical connections must be torqued to the 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
31. 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 Table 10 Table 10 Component Derating Table Reduce Max Continuous Current Rating by B I L Withstand Rating Altitude Rating 160Ac 340A 580A 12 kV 15kV 0 1000 m 75 kv 95 kV 0 3300 ft 1001 2000 m 5A 10A 15A 66 kV 84 kV 3301 6600 ft 2001 3000 m 10A 20A 30A 59 74 kV 6601 9900 ft 3001 4000 m 15A 30A 45A 52kV 66 kV 9901 13 200 ft 4001 5000 m 20 40 60 46 kV 58 kV 13 201 16 500 ft Rockwell Automation Publication 7703E INOO1E EN P July 2014 47 Component Deratings Notes 48 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Introduction Appendix B Typical Schematic Diagrams This Appendix contains a typical schematic for a complete MV SMC Flex controller refer to Figure 24 Refer to publication 1560E UM051_ EN P for additional samples of control wiring 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 standar
32. lass A equipment Use of the 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 Rockwell Automation Publication 7703E IN001E EN P July 2014 29 Chapter4 Control Component Installation 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 IN001M EN P Wire earth ground to control terminal 14 of the SMC Hex control module Use shielded wire for PTC Input Tach Input e 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 line
33. lication requirements The MV ratios shown above are nominal values and may be fine tuned to achieve better accuracy on the display of the SMC Flex 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 SMC Flex is controlling Parameter 106 MV Ratio may be changed up or down to match the Flex 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 Table 9 MV Ratio Voltage MV Ratio 12000V 126 14400V 97 1 References apply to publication 1560E UM051_ EN P Rockwell Automation Publication 7703E INOO1E EN P July 2014 41 Chapter7 Final Test Procedures Power Supply Test 42 hazardous Severe injury or death can result from electrical shock burn 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 ATTENTION Servicing energized industrial control equipment can be Is
34. me 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 to observe the recommended precautions may result in injury to personnel or ATTENTION The operating restrictions for the SMC must be adhered to Failure damage to the equipment Rockwell Automation Publication 7703E IN001E EN P July 2014 Voltage Sensing Board Dimensions Mounting and Connecting the Voltage Sensing Board PowerBrick Installation Chapter 3 Figure 7 Voltage Sensing Board Dimension Diagram 289 4 11 39 og 58 5 134 0 N 5 28 7 k en A 28 9 0 35 4 holes 92 7 19 40 E 345 0 10 e 0 ec eG eG 13 58 1 Approximate dimensions mm inches Includes features to secure HV wire for maintained spacings The voltage sensing board VSB for the relevant voltage range see table below should be mounted adjacent to the PowerBrick refer to Figure 7 for dimensions All connection points are to be made accessible Description Line Voltage Catalog Number 3 phase 50 60 Hz 10 000 12 000V 126 7703E VSM Voltage Sensing Board 12 001 14 400V 97 7703E VSN Connec
35. nnector on the top of each PowerBrick is attached to the fixed connector on the bottom of the PowerBrick above 2 Thetop 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 Refer to Figure 5 for the terminal location Torque the fastening hardware to the specifications shown in Table 4 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 Table 4 Referto Chapter 5 and Chapter 6 for a typical wiring diagram to determine the required connections Appendix B includes a typical schematic for a complete soft starter unit Rockwell Automation Publication 7703E INOO1E EN P July 2014 17 Chapter 3 18 PowerBrick Installation Figure 5 Typical Single Phase 15 kV PowerBrick Assembly side view Terminal Flexible bus link 11 mm clearance hole for M10 hardware 7 supplied OEM provided flexible link 175 mm i 2 supplied IN INN 0 0 V 0 0 NH vs ANEA
36. ntrol Module 29 Main Switching Device 35 PowerBricks 11 Interface Board connecting to Voltage Sensing Board 32 connections 29 layout 28 mounting 27 L layout Interface Boards 28 loop length Power Supply Transformer rating 24 M Main Switching Device installation 35 55 Index 56 mounting Interface Boards 27 PowerBricks 13 15 16 Voltage Sensing Boards 21 0 operating restrictions PowerBricks 20 options PowerBricks 11 Voltage Sensing Boards 12 P power connections PowerBricks 17 grounding 20 Voltage Sensing Boards 21 power supply test procedure 42 Power Supply Transformer rating loop length 24 PowerBrick catalog numbers 11 Current Loop Gate Drive Power Assembly CLGD 23 dimensions 13 14 15 16 identification 11 installation 11 mounting 13 15 16 operating restrictions 20 options 11 power connections 17 grounding 20 spare parts 53 specifications 12 torque requirements 13 programming 41 SMC Flex Control Module 41 receving overview 9 5 schematic diagrams 49 10 15 kV control circuit 51 10 15 kV power system 50 SMCFlex Control Module Control Terminal designations 31 installation 29 programming 41 spare parts 53 PowerBricks 53 specifications PowerBricks 12 standards and codes 9 start up test procedure 46 Rockwell Automation Publication 7703E INOO1E EN P July 2014 T test procedures 39 additional 41 dielectric 40 jumper positioning 40 power supply 42 start up 46 torq
37. of 100 ms or less complete the SMC configuration SCRs are not rated for continuous duty The duty cyde 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 ATTENTION bypass contactor or circuit breaker must be installed to Rockwell Automation Publication 7703E INOO1E EN P July 2014 35 Chapter5 Main and Bypass Switching Device Installation Notes 36 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Chapter 6 Typical Wiring Diagrams Wiring Diagra ms 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 Refer to Appendix B for examples of how these additional components can be implemented to form a complete solution 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 ATTENTION Wires used for connecting the components must be sufficiently Rockwell Automation Publication 7703E INOO1E EN P July 2014 37 Chapter 6 38 Typical Wiring Diagrams Figure 18 Typical Power Circuit Wiring Diagram 10 15 kV TO INTER
38. olate incoming power 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 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 Check voltage on each gate driver board by connecting a DC voltmeter at TP4 and TP3 See Figure 21 The voltage should be 18 22V DC Locate the SMC Flex Interface board in the control section See Figure 20 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 20 Interface PCB SW2 Close slide up to initiate test pulse Red LED ON when test pulses active Rockwell Automation Publication 7703E INOO1E EN P July 2014 Final Test Procedures Chapter 7 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
39. olutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 7703E INOOTE EN P July 2014 Supersedes Publication 7703E INO01D EN P June 2013 Copyright O 2014 Rockwell Automation Inc All rights reserved Printed in Canada
40. on Identification A PowerBrick is shown in Figure 1 Figure 1 Single phase PowerBrick Chapter 3 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 Table 1 Table 1 PowerBrick Options and Catalog Numbers Catalog Number 7703E PPMT Voltage 7703E PPMA 12000V 7703E PPMC 7703E PPNT 7703E PPNA 13800V 7703E PPNC 3 phase 50 60 Hz Current Amps 160 340 580 160 340 580 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 INO08 EN P 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 INOO1E EN P July 2014 11 Chapter 3 PowerBrick Installation Sizing the Enclosure In addition to the PowerBricks a voltage sensing board is to be connected in the power circuit Table 2 lists the voltage sensing board catalog numbers Table 2 Voltage Sensing Board Catalog Number Catalog Number 7703E VSM Voltage Sensing Board Input 3 phase 50 60 Hz 10 000
41. 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 for the 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 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 Rockwell Automation Publication 7703E INOO1E EN P July 2014 39 Chapter7 Final Test Procedures 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 as shown in Figure 19 Figure 19 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 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 c
42. onnect 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 ohms for all styles b The cathode to cathode resistance can also be checked and should be between 20 32 ks per brick 40 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Additional Tests Programming Voltage Sensing Module Final Test Procedures Chapter 7 7 Check allline and load resistances to ground at the interface board voltage feedback test points The measurement for all voltages should be within 11 13 Perform additional tests as outlined in Chapter 3 of User Manual SMC Flex Motor Controller Bulletins 1503E 1560E and 1562E Publication 1560E UMO51 MV SMC Flex Module Refer to Chapter 40 for programming procedures The default factory parameter settings are as shown in Appendix BY IMPORTANT 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 1560E UMO51 EN p If the factory settings are not suitable for the application program the module to meet the app
43. p 2 Current Transformer Assembly cables and the return cable must be 3 Loop Cable 50 feet 8 in 4 Terminal 152 m 20 cm 5 Return Cable 6 AWG 13 mm 26 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Chapter 4 Control Component Installation 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 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 ATTENTION Do not mount the interface board in the same compartment as Figure 13 Mounting the Interface Board nn 25620 09 gt e 241 3 9 50 gt lt IE Top mounting holes for SMC Flex 285 8 Control Module 11 25 241 3 19 50 U 10002 o gt Mounting holes 4 7 14 mm 0 281 in dia 00000 00 000000 0000 O 00000000 0 of 0900 0000 00000 0000 0 0000000070 Oho 00 0G ad ad ad Bottom mounting holes for SMC Flex Control Module Side View Front View Approximate dimensions in mm inches Rockwell A
44. r Canada 1 440 646 3434 Outside United States Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www ab com mvb Allen Bradley Rockwell Software Rockwell Automation PowerFlex and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information S
45. refer to Figure 16 and Figure 17 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 them minimum bend radius of at least 45 mm 1 75 in should be maintained throughout the system Damaging the cables may result in signal loss to the components and improper functioning of the unit ATTENTION Do not sharply bend or strike the fiber optic cables when handling IMPORTANT Fiber optic components are color coded for easier connections Receiver 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 Refer to the appropriate wiring diagram in Chapter 6 IMPORTANT Itis 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 Refer to Figure 14 for the Interface 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
46. rrent Loop Gate Drive Cable Assembly and Power Supply before putting the SMC into service Failure to do so may result in erratic ATTENTION Check that all CT leads are plugged into each gate driver board operation and or equipment damage during option stop maneuvers Rockwell Automation Publication 7703E INOO1E EN P July 2014 23 Chapter3 PowerBrick Installation Figure 10 Connection of CLGD CTs to Gate Driver Board CLGD CT Connection Terminal CLGD CTs CLGD CT Connection Terminal 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 Table 5 for matching the loop length to the power supply transformer rating See Appendix C for part numbers 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 21 feet 4 in 6 4 m 10 cm 100 VA 115 230 1 5V 50 feet 8 in 15 2 m 20 cm 0 1 The 50 foot length is 3 x 14 ft HV wire plus 8 ft LV wire the load for the transformer and establishes the loop current If it is not correct a longer length will not provide sufficient power
47. s All cores specified below are split core type so they can be added to existing connections e When using an external HIM or DPI interface a core should be added to the HIM cable near the SMC Flex 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 Flex control module The recommended cores are TDK ZCAT2033 0930H and TDK ZCAT2035 0930 or equivalent Control Power Control Voltage The SMC Flex 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 30 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Control Terminal Designations Control Component Installation Chapter 4 Control Wiring Table 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 0 75 2 5 mm 18 14 AWG Torque 0 6 Nem 5 Ib in As shown in Figure 15 the SMC Flex controller contains 24 control terminals on the front of the
48. t the voltage sensing board to the L1 to L3 Line and T1 to T3 Load terminals of the power stack refer to Figure 8 and Chapter 6 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 Rockwell Automation Publication 7703E INOO1E EN P July 2014 21 Chapter3 PowerBrick Installation The MV ratios shown above are nominal values and may be fine tuned to achieve better accuracy on the display of the SMC Flex 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 Flex is controlling Parameter 106 MV Ratio may be changed up or down to match the Flex 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
49. tching Device installation 35 C catalog numbers PowerBricks 11 Voltage Sensing Boards 12 CLGD Current Loop Gate Drive Power Assembly 23 codes 9 CSA 9 ICS1 9 ICS3 9 IEC 9 NEC 9 OSHA 9 UL9 Control Components control power 30 voltage 30 wiring 31 wiring torque requirements 31 derating 47 EMC compliance 29 installation 27 Interface Board connections 29 installation 27 layout 28 mounting 27 SMC Flex Control Module Control Terminal designations 31 installation 29 control power Control Components 30 voltage 30 wiring 31 Control Terminal designations 31 Current Loop Gate Drive Power Assembly CLGD 23 D derating Control Components 47 diagrams schematic 49 10 15 KV control circuit 51 10 15 kV power system 50 wiring 37 dielectric test procedure 40 jumper positioning 40 Rockwell Automation Publication 7703E INOO1E EN P July 2014 Index dimensions PowerBricks 13 14 15 16 Voltage Sensing Board 21 Electrostatic Sensitive Devices handling procedures 9 EMC Compliance Control Components 29 ESD Electrostatic Sensitive Devices handling procedures 9 F Fiber Optic Multiplexer Board connecting to Gate Driver Board 33 G Gate Driver Board connecting to Fiber Optic Multiplexer Board 33 handling procedures ESD Electrostatic Sensitive Devices 9 identification PowerBricks 11 installation Bypass Switching Device 35 Control Components 27 Interface Boards 27 SMCFlex Co
50. ue requirements Control Components wiring 31 PowerBricks 13 V voltage ratios Voltage Sensing Module 41 Voltage Sensing Board catalog numbers 12 connecting to Interface Board 32 dimensions 21 mounting 21 options 12 power connections 21 Voltage Sensing Module voltage ratios 41 wiring diagrams 37 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States o
51. 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 gt gt 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
52. utomation Publication 7703E INOO1E EN P July 2014 27 Chapter4 Control Component Installation ATTENTION 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 Flex to other components Figure 14 Interface Board Layout SMC Flex Control Module SW2 When ON up provides LED Red ON Ribh test pulses to gate driver circuits when test pulses on ibbon connectors to connect to Current feedback mum Must be OFF down SMC Flex Control Module test points A for normal operation underneath control module EI ROCKWELL Q Phase A lt lt LED Yellow ON Fiber Optic Transmitter oc when Phase A Voltage feedback Ribbon connector sends gate signals gate signal active testp oints to Voltage to multiplexer GATE LINEA Sensing Board TP4 Phase A gate signal Module common IL A No connection es A VCOM Current loop
53. y 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 ATTENTION Servicing energized industrial control equipment can be 1 Apply rated control voltage to the control circuit 2 Using the control schematic apply control signals to cause relays and contactors to energize to verify operation 3 Remove any jumpers used in the test and restore all circuits to normal when finished Rockwell Automation Publication 7703E INOO1E EN P July 2014 45 Chapter7 Final Test Procedures Start Up Spare Parts 46 Remove any temporary jumpers or grounding devices used during commissioning 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 Check that all barriers or covers removed during installation or commissioning have been securely mounted Close and secure all doors and verify function ofall interlocks that prevent access to medium voltage compartments when the unit is energized The controller is ready to power the motor For a complete listing of spare parts refer to Appendix C Rockwell Automation Publication 7703E INOO1E EN P July 2014 Deratings Specifications Component Deratings Appendix A The components described
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