Medium Voltage SMC OEM Components – 10…15 kV Specifications · 2020. 4. 16. · 6 Rockwell...

Technical DataOriginal Instructions

Medium Voltage SMC OEM Components – 10…15 kV Specifications Bulletin Number 7703E

Topic Page

7703E Soft Starter Components 2

PowerBrick 7

SMC-50 Control Module 10

Voltage Sensing Board 12

Interface Board 13

Fiber-optic Multiplexer Board 14

Fiber-optic Cables 15

Gate Driver Test Power Supply 15

Medium Voltage SMC OEM Components – 10…15 kV Specifications

Overview

Our Bulletin 7703E Reduced Voltage Starters with SMC-50™ controllers provide microprocessor-controlled starting for standard three-phase, squirrel-cage induction motors. These assemblies can also be used to retrofit existing motor controllers and are available as OEM components.

Most of the components described in this publication are provided in various 7703E kits; however, some of the devices that are described are not provided. These must be acquired separately.

A key part of the Bulletin 7703E components is the power stack assembly, which uses PowerBrick™ technology. PowerBricks are a superior means of packaging SCRs, heatsinks, passive devices (for circuit protection), and gate driver 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.

Rockwell Automation also offers standard motor controllers, solid-state reduced voltage starters, and variable speed drives with standard, yet flexible, product configurations for all product lines.

Rockwell Automation offers several OEM programs, such as customer-specific program (custom engineered options and configurations with a standard quick-ship delivery). Contact your local Rockwell Automation office for more information on these programs and other OEM products.

7703E Soft Starter Components

This document pertains to the Bulletin 7703E SMC OEM components for 10…15 kV, up to 580 A. These components allow you to fabricate a medium voltage soft starting solution. See publication 7703E-IN001 for detailed instruction on component installation.

Table 1 - Product Selection, 10…15 kV, 160/340/580 Amp

Description Component Selection Part No.

PowerBrick Assembly One Required 7703E-PPxx

Control Module One Required 7703E-FS1FX

Interface Board One Required 7703E-FINTB-xx

Voltage Sensing Board One Required 7703E-VSxx

Fiber-optic Cables One Required 7703E-xxFOxx

Fiber-optic Multiplexer Board One Required 7703E-FMUXB

Main Line Switching Device and Short Circuit Protection One Required(1) (2)

(1) Can be either a circuit breaker or a contactor with main switch and fuses.(2) Provided by others.

—

Bypass Switching Device One Required(3)

(3) Can be either a circuit breaker or contactor.

—

Gate Drive Test Power Supply Optional(4)

(4) Required for testing, commissioning, and troubleshooting gate-firing circuits.

7703E-PSxx

2 Rockwell Automation Publication 7703E-TD001A-EN-P - April 2020

https://literature.rockwellautomation.com/idc/groups/literature/documents/in/7703e-in001_-en-p.pdf


Typical Power System Diagram

Figure 1 - Typical Power System Diagram (10…15 kV)L1

L2

GRD

L3

24C

PHAS

E A

PHAS

E B

PHAS

E C

FO4-

15FO

16-2

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28-3

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GND2

GND1

J1

1 2 3 4 5 6

GATE

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NSMI

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S

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RX1

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UNIT

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CUST

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'S

L3L2L1

1

-BC2

-BC1

-BC3

-BC2

-BC1

-BC3

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T3T2T1

115/230V AC

115/230V AC

GL2/NL1TB1

TB6

RX1

TX17

TX18

RX2

RX3

TX10

TX16

TX15

TX5

TX6

TX11

TX12

TX14

TX13

TX9

TX4

TX3

TX8

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TX2

TX1

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PHASE A PHASE C TEMP.

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PTIC

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Rockwell Automation Publication 7703E-TD001A-EN-P - April 2020 3


Figure 2 - Typical Control Circuit, Standard Module (10…15 kV)

123456789101112

+L1

-L2

GND

Aux1Aux2COM

Enab

le

Inpu

t

1

DC

Inpu

t 2

DC

+24V

DC

A1A2A3A4A5A6A7A8A9A10A11A12

Aux A1

Inpu

tA1

Inpu

tA2

Inpu

tA3

Inpu

tA4

COM

Aux A2Aux A3

NC

SLOT 7 150-SM4

SLOT 8 SLOT 9

DPI COMMSMC 50

EXT.BYPASSNORMAL

STAR

T

STOP

OPT

ION

COAS

T

Emer.

Byp.

FAULT

3 4

SMC 50IB_TB6

CL_FLT

MC

SS

BC

SS

From SMC 50IBTB7

CR

CL_FLT

CR

CR

CR

CL_FLT

ESTOP

STOP

MC CR

CONTROL RELAY (CR)

FAULT RELAY

SMC-50 IBInput Power

Fiber-optic Multiplexer BoardInput Power

L1

L1 N

L2/N



Functional Design Specifications

Table 2 - Functional Design Specifications

Features Description

Standard Features

InstallationPower Wiring

The MV SMC-50 controller must be wired with a start contactor or circuit breaker as per local/regional codes. A bypass contactor or circuit breaker must be employed after the controller has brought the motor to full speed.

Control Wiring 2- and 3-wire control for a wide variety of applications.

Set-up

Keypad The MV SMC-50 controller is configured with the front keypad and back-lit LCD display.

SoftwareParameter values can be downloaded to the MV SMC-50 controller with DriveTools™ (or Connected Components Workbench™ software) programming software and an optional (20COMMx) communication module.

Communications (two ports) One serial (DPI) port provided for connection to optional human interface. One serial (DPI) port provided for optional 20-COMMx modules (mounted within SMC-50 control module)

Starting ModesSoft Start with selectable kick-start, Soft Stop, Current Limit Start with selectable kick-start, Linear Acceleration with selectable kick-start, Linear Deceleration, Dual Ramp with selectable kick-start, full-voltage

Protection and DiagnosticsPower loss, line fault, voltage unbalance, current unbalance, excessive starts/hour, phase reversal, undervoltage, overvoltage, controller temperature, stall, jam, open gate, overload, underload, communication fault, ground fault

Metering Amps, volts, elapsed time, motor thermal capacity usage, power (MW, MWh, PF)

Status Indication Stopped, ramping, stopping, at speed, and fault.

Auxiliary Contacts One single-pole, double-throw contact programmable as normal or external bypass one contact programmable as normal or fault.

Control Voltage 110/120V AC to 220/240V AC; 50/60 Hz

Fiber-optic Cables Available in two lengths (2.5 m and 5.0 m). Provides isolation between interface board and power stacks.

Soft Stop Extended coast-to-rest to minimize load shifting. Ramp down time may be adjusted.

Optional FeaturesPump Control

Helps reduce fluid surges in centrifugal pumping systems during starting and stopping period. Starting time is adjustable from 0…30 seconds. Depending on the application, stopping time may be adjusted.

Communication Modules DeviceNet®, ControlNet®, EtherNet/IP™, PROFIBUS DP, Remote I/O, RS-485 (DF1), RS-485 (Modbus RTU, Metasys N2, Siemens P1), Modbus-TCP



Thermal Capacity

Thermal capacity limits must not be exceeded. The combined maximum ratings for medium voltage SMC-50 units are as follows:

• 30 second Start/Stop• 40 °C (104 °F) ambient temperature• 2 Start/Stop sequences in an hour• 450% FLC (average during starting)

If any of the above maximums are not required, it is possible to exceed some of the other ratings. Please consult the factory for details.

Component Deratings

The components that are described in this publication may be applied in a wide variety of situations. Some applications may require component derating depending on enclosure type, ambient and application conditions. For example, at altitudes above 1000 m (3300 ft), the maximum current and basic impulse level (BIL) are reduced as shown in Table 3.

Table 3 - Component Deratings

Altitude Rating Reduce Max. Continuous Current Rating by: B.I.L. Withstand Rating

160 A 340 A 580 A 12 kV 15 kV

0…1000 m (0…3300 ft) — — — 75 kV 95 kV

1001…2000 m (3301…6600 ft) 5 A 10 A 15 A 66 kV 84 kV

2001…3000 m (6601…9900 ft) 10 A 20 A 30 A 59 kV 74 kV

3001…4000 m (9901…13,200 ft) 15 A 30 A 45 A 52 kV 66 kV

4001…5000 m (13,201…16,500 ft) 20 A 40 A 60 A 46 kV 58 kV



PowerBrick

The Bulletin 7703E medium voltage PowerBrick™ module is a two-device power stack that provides excellent mounting flexibility. Each PowerBrick has a voltage rating of 2.4 kV, so higher voltage ratings are achieved by connecting PowerBrick units in series.

To fully install the PowerBrick modules, the OEM must complete the following:

• Mount PowerBrick modules and link in series.• Connect power cables from the power stacks to the input start

controller, bypass device, and motor;• Mount the SMC-50 control module on the interface board and

connect interface board to the voltage sensing board and the gate driver boards with fiber optic cables;

• Mount voltage sensing board and connect to the line and load terminals;

• Connect the interface board to OEM-supplied current transformers.

The vacuum bypass device (contactor or circuit breaker) is connected in parallel with the SCRs and is controlled by a contact on the SMC-50 control module that opens and closes the bypass device.

The PowerBrick system includes:• Three-phase PowerBrick system comprised of heatsinks, SCRs, snubber caps and resistors• Gate driver boards and mounting hardware• Gate drive power supply and cables• Medium Voltage SMC OEM Components, 10…15 kV installation manual, publication 7703E-IN001

Product Selection

PowerBricks include a transformer for the current loop gate driver system. The wiring is to be supplied by the OEM. Additional hardware is required for main and bypass switching and circuit protection. All PowerBrick units are rated for starting duty only, and must be bypassed after the motor reaches full speed.

All line voltages are 3-phase, 50/60 Hz. • 12 kV is used for motor voltage from 10…12 kV (5 PowerBrick units per phase)• 13.8 kV is used for motor voltage from 12.1…14.4 kV (6 PowerBrick units per phase)• It is possible to use fewer PowerBricks for lower voltages (for example, 7.2 kV). In this case, consult the factory.

Table 4 - PowerBrick Options and Catalog Numbers

Voltage Current (A) Cat. No.

12,000V 3 PH, 50/60 Hz 160 7703E-PPMT

340 7703E-PPMA

580 7703E-PPMC

13,800V 160 7703E-PPNT

340 7703E-PPNA

580 7703E-PPNC


https://literature.rockwellautomation.com/idc/groups/literature/documents/in/7703e-in001_-en-p.pdf


Dimensions

Figure 3 - PowerBrick Dimensions372 (15)

300 (12)

230 (9)

Current Loop GateDrive Cable(Mounts on

PowerBrick Unit)

Mounting Holes for M8 (5/16) Hardware, 8 places

230 (9)

290 (11)356 (14)

377 (15)

250 (10)


PowerBrick Unit)

Mounting Holes for M8 (5/16) Hardware, 4 places


PowerBrick Unit)

Top View

Front View

Side View

Dimensions are shown in mm (in.)



Figure 4 - Typical Mounting Arrangement for 3-Phase 10…12 kV PowerBrick System

Specifications

Table 5 - PowerBrick Specifications

Description 160 A, 340 A, 580 A

Input Voltages (50/60 Hz)10,000…12,000V, 12,001…14,400V3 PH, +10%, -15%

Ambient Temperature 0…40°C (32…104°F)

Power Section (for 3 PH) 30 SCR at 10…12 kV, 36 SCR at 12.1…14.4 kV

Repetitive Peak Inverse Voltage Rating 10…12 kV – 32500 PIV12.1…14.4 kV – 39000 PIV

Thermal Capacity 600% of FLA, 10 seconds450% of FLA, 30 seconds

dv/dt Protection R.C. Snubber Network

Maximum Heat Dissipation (kW)

Start or Stop Cycle (at 500% FLA)

160 A 340 A Continuous

10,000…12,000 35 65 0.25

12,001…14,400 42 78 0.25

Altitude 0…1000 m (0…3300 ft). See Component Deratings on page 6.

Net Shipping Weight (3 PH)Rating (kV) 10…12 12.1…14.4

Weight kg (lb) 285 (630) 342 (756)

627 (25)

160 (6) 90 (4)

160 (6)

160 (6)

654 (65)

25 (1)80 (3)

1326(52)

Front View Side View

Typical spacing to ground metallic enclosure parts. Spacing may be reduced through the full use of suitable insulation systems

For 12…15 kV PowerBrick systems, an additional PowerBrick is required per phase. This adds 250 mm (9.84 in.) to the height of each phase assembly.



SMC-50 Control Module

The SMC-50 control module provides microprocessor controlled starting for standard 3-phase, squirrel-cage induction motors.

The SMC-50 control module provides the following modes of operation as standard:

• Soft start with selectable kick-start• Soft stop• Pump control start/stop• Torque control• Current limit start with selectable kick-start• Sensorless linear acceleration with selectable kick-start• Sensorless linear deceleration• Dual ramp with selectable kick-start• Emergency run (full-voltage)

Product Selection

The SMC-50 control module provides motor protection, including overload, underload, stall, jam, and so on during starting and while the bypass contactor is energized.

Table 6 - SMC-50 Control Module Options and Catalog Number

Control Module Cat. No.

Standard SMC-50 control module 7703E-FS1FX

Communication Modules Cat. No.

DeviceNet (20COMM-D)

ControlNet (20COMM-C)

EtherNet/IP (20COMM-E)

PROFIBUS DP (20COMM-P)

Remote I/O (20COMM-R)

RS-485 (DFI) (20COMM-S)

RS-485 HVAC (Modbus RTU/Metasys N2/Siemens P1) (20COMM-H)

Modbus/TCP (20COMM-M)



Dimensions

Specifications

Table 7 - SMC-50 Control Module Specifications

Electrical Ratings UL/CSA/NEMA IEC

Control Circuit

Rated Operational Voltage 100…240V AC 100…240V AC

Rated Insulation Voltage — 240V

Rated Impulse Voltage — 3000V

Dielectric Withstand 1600V AC 2000V

Operating Frequency 50/60 Hz 50/60 Hz

Protection Against Electric Shock Finger-safe IP20

Power Requirement Control Module 75VA

Auxiliary Contacts (Relay Contacts)

Rated Operational Voltage 20…265V AC, 5…30V DC (resistive)

Number of Contacts (Programmable N.O./N.C., held closed electrically) 2 Form A, (3 additional with 150-SM4 option module)

Rated Current 3 A @ 120V AC, 1.5 A @ 240V AC

Operating Frequency 50/60 Hz

Utilization Category AC-15/B300

Make/Break VA 3600/360

Environmental UL/CSA/NEMA IEC

Operating Temperature Range (Enclosed) 0…40 °C (32…104 °F)

Storage and Transportation Temperature Range -20…+75 °C (-4…+167 °F)

Altitude 2000 m (6500 ft)

Humidity 5…95%, noncondensing

Pollution Degree 2

284.2(11.19)

115.1(4.53)

166.6(6.56)

72.4(2.92)



Voltage Sensing Board

The 15 kV voltage sensing board steps the voltage down from the system voltage to a voltage level compatible with the SMC-50 control module.

This component includes mounting instructions.

Product Selection

Dimensions

Table 8 - Voltage Sensing Board Product Selection

Description Line Voltage (3 PH, 50/60 Hz) Cat. No.

Voltage Sensing Board10,000…12,000V 7703E-VSM

12,001…14,400V 7703E-VSK

289.4 [11.39]

0.0 [0.00

]

270.0

[10.63

]

0.0 [0.00]

134.0[5.28]

8.9 [0.35]4 Holes

345.0[13.58]

492.7[19.40]

Includes features to secure HV wire for maintained spacings.



Interface Board

Converts digital signals from the SMC-50 control module to drive the gate driver boards via fiber-optic cables. The interface board also provides voltage, current, and temperature feedback to the control module.


Product Selection

Dimensions

Specifications

Interface Board Catalog Number

System Voltage Controller Current Rating Cat. No.

10…15 kV

160 A 7703E-FINTB-2

340 A 7703E-FINTB-4

580 A 7703E-FINTB-6

Table 9 - Interface Board Specifications

Control Circuit Voltage and Frequency 110/120…220/240V AC, 50/60 Hz

Gate Drive Via Fiber Optics

SCR Overtemperature Via Fiber Optics



Fiber-optic Multiplexer Board

The fiber-optic multiplexer board accepts fiber-optic gate drive signals from the interface board and splits them into the required fiber-optic gate drive signals for 10…15 kV.


Product Selection

Dimensions

Specifications

Interface Board Catalog Number

Fiber-optic Multiplexer Board Cat. No.

110/120…220/240 VAC – 50/60 Hz 7703E-FMUXB

Table 10 - Multiplexer Board Specifications

Control Circuit Voltage and Frequency 110/120…220/240V AC, 50/60 Hz, 30VA

Gate Drive (In/Out) Via Fiber Optics

+ +

+ +

+ + +

+ +

1

+

+

2

2 13

1

2

+

C11

C23

C30

R63

R40

R67

R10

R35

C15

R64

FO30

FO31

FO36

FO37

U2

FO27

FO21

C21

FO26

FO20

FO24

DS3

DS6

FO18

C9

FO25

R30

FO19

R26

C19

R27

R22

R21

FO15

FO14

R19 DS

5

FO9

FO8

R20 DS

2

FO12

FO13

R53

R51

C14 C1

TP2

FO39

FO38

FO33

FO32

HS2

VR1

D7 C13

DS7

C24

C27

R49

DS4

R50

R38

R59 R3

3 C25

D5

C29

R47R4

6

R45

R34

D6

R58

C28

C26R62

tp3

R36

C20

R31

C22

R37 C3

2

R32

FO35

FO34

FO28

FO29

J2

FO3

C12

FO42 D4

R66 R9 HS1

R5

R24

R56

R54 R4

3

R25

R44

R28

R29

R23

R55

R61

C18

U4

C16

FO23

FO17

FO16

R3FO22

R1 R2

FO41 FO

2

R65 R8

R18

R41 R15

L1

R13

R14

R52

FO6

FO7

R60

C17

FO11

FO10 FO

4

FO5 RV1

FO40 FO

1

F1

J1

L2 L3

R7

DS1

R48

R39

C10

R57 tp1

U5 R6

C33

T1R4

D2 C8

D3

U1C7

D1C5 C6

C4

R42

C3

U3 C2

C31

R12

R11

R17

R16

TB1

++

++

++

+

++

1

+

+

2

21

3

1

2

+

C11

C23

C30

R63

R40

R67

R10

R35

C15

R64

FO30

FO31

FO36

FO37

U2

FO27

FO21

C21

FO26

FO20

FO24

DS3

DS6

FO18

C9

FO25

R30

FO19

R26

C19

R27

R22

R21

FO15

FO14R19

DS5

FO9

FO8

R20

DS2

FO12

FO13

R53

R51

C14

C1

TP2

FO39

FO38

FO33

FO32

HS2

VR1

D7

C13

DS7

C24

C27

R49

DS4

R50

R38

R59

R33

C25

D5

C29

R47

R46

R45

R34

D6

R58

C28

C26

R62

tp3

R36

C20

R31

C22

R37

C32

R32

FO35

FO34

FO28

FO29

J2

FO3

C12

FO42

D4

R66

R9

HS1

R5

R24

R56

R54

R43

R25

R44

R28

R29

R23

R55

R61

C18

U4

C16

FO23

FO17

FO16

R3

FO22

R1

R2

FO41

FO2

R65

R8

R18

R41

R15

L1

R13

R14

R52

FO6

FO7

R60C17

FO11

FO10

FO4

FO5

RV1

FO40

FO1

F1

J1

L2

L3

R7

DS1

R48

R39

C10

R57

tp1

U5

R6

C33

T1R4D2

C8

D3

U1C7

D1C5

C6

C4

R42

C3

U3

C2

C31

R12

R11

R17

R16

TB1

4.0 [0.16](5) MTG HOLES

118.4[4.66]

52.8[2.08]

210.0 [8.27]

201.4 [7.93]

100.7 [3.96]

Phase A Phase B Phase C

127.0[5.00]

28.6[1.13]



Fiber-optic Cables

Fiber-optic cables connect the interface board to gate driver boards mounted on power stacks. They are also used to connect thermistors in the power stacks to interface boards. Two lengths are available to aid the design and manufacture of a new controller, or to retrofit into an existing enclosure.

Fiber-optic cables include mounting instructions.

Product Selection

Specifications

Gate Driver Test Power Supply

The gate driver test power supply is used to provide power for the gate driver board during commissioning and/or troubleshooting.

Gate driver test power supplies include mounting instructions.

Product Selection

Specifications

Fiber-optic System Voltage Length of Cable Cat. No.

12,000V2.5 m (8.2 ft) 7703E-25FO30

5.0 m (16.4 ft) 7703E-50FO30

13,800V2.5 m (8.2 ft) 7703E-25FO36

5.0 m (16.4 ft) 7703E-50FO36

Voltage RangeNumber of Cables

2.5 m (8.2 ft) 5.0 m (16.4 ft)

12,000V 36 36

13,800V 42 42

Test Power Supply Options Cat. No.

120V AC, 60 Hz 7703E-PSD

Universal (requires power cord) 7703E-PSU

Voltage Range 120V AC, 60 Hz 110/220V AC, 50/60 Hz

AC Power Cord North American (cord supplied) Universal (cord supplied by OEM)


Allen-Bradley, DriveTools, LISTEN. THINK. SOLVE., PowerBrick, Rockwell Automation, Rockwell Software, and SMC-50 are trademarks of Rockwell Automation, Inc.ControlNet, DeviceNet, and EtherNet/IP are trademarks of ODVA, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication 7703E-TD001A-EN-P - April 2020

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Medium Voltage SMC OEM Components – 10…15 kV Specifications · 2020. 4. 16. · 6 Rockwell...

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