OneGear OEM Products -...

BULLETIN 7703E

www.klinkmann.com6 / 2011

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

Important User Information

Table of Contents

7703E SMC OEM Components

Description ....................................................................................................1

Standard Control Module ............................................................................. 1

Optional Control Module .............................................................................. 1

Features ...................................................................................................... 1

Optional Communication Modules ............................................................... 1

Product Selection Guide – 10-15 kV ............................................................ 1

Typical Power System Diagram – 10-15 kV ................................................ 2

Typical Power Circuit – Standard Module (10-15 kV) .................................. 3

Functional Design Specifications ................................................................. 4

7703E OEM Component Kits

PowerBrick™ ............................................................................................... 5

Description ........................................................................................... 5

Specifications ....................................................................................... 5

Options and Catalog Numbers ............................................................. 6

Typical Mounting Arrangement for 10-12 kV PowerBrick System ........ 8

Voltage Sensing Board ................................................................................ 9

Description ........................................................................................... 9

Catalog Number ................................................................................... 9

Interface Board .......................................................................................... 10

Description ......................................................................................... 10

Specifications ..................................................................................... 10

Catalog Number ................................................................................. 10

Fiber Optic Multiplexer Board .................................................................... 11

Description ......................................................................................... 11

Specifications ..................................................................................... 11

Catalog Number ................................................................................. 11

SMC Flex Control Module .......................................................................... 12

Description ......................................................................................... 12

Starting and Stopping Options ............................................................ 12

Specifications ..................................................................................... 12

Dimensions ......................................................................................... 13

Options and Catalog Numbers ........................................................... 13

Fiber Optics ............................................................................................... 14

Description ......................................................................................... 14

Specifications ..................................................................................... 14


Gate Driver Test Power Supply ................................................................. 15

Description ......................................................................................... 15

Specifications ..................................................................................... 15


Overview

Rockwell Automation has produced quality Medium Voltage products to meet the

requirements of all types of industries for well over six decades.

From the original oil-immersed contactor to air break and vacuum contactors, to solid-state

controllers such as Smart Motor Controllers and AC Variable Frequency Drives, Rockwell

Automation has developed and built a medium voltage product line that satisfies industries who

are demanding more safety, less maintenance, longer life and reliability in motor control equipment.

Added to those demands is the need for smaller, more flexible medium voltage products that

are more efficient and reduce building and expansion costs.

OEM frames and components leverage the existing family of motor controllers built by

Rockwell Automation. They also incorporate some of the most fundamental, high volume

components available in our OEM product line for Original Equipment Manufacturers and

electrical equipment companies.

Bulletin 1502 vacuum contactors are a comprehensive line of vacuum contactors used as

isolating contactors or as bypass contactors. Light weight and maintainability are but two of

the features of this fixed-mounted design.

Bulletin 1503F OEM components are a series of medium voltage frame-mounted

components designed to mount into new or existing structures or enclosures. These

assemblies can also be used to retrofit existing motor controllers. These products are

available as a complete OEM frame or sold individually as components.

Bulletin 1503E MV SMC™ Flex OEM kits are a series of solid-state reduced voltage

components designed to mount into new or existing structures or enclosures. These

assemblies can also be used to retrofit existing motor controllers. These products are

available as an OEM frame and components.

Bulletin 857 is a motor/feeder protection relay that includes all the essential functions

needed to protect motors and feeders in diverse industrial applications. The programmable

857 includes the optional arc protection feature, thermal, trip circuit supervision and circuit

breaker protection. The device can include numerous communication protocols, as well as a

twelve-channel RTD scanner.

Bulletin 865 is a differential protection relay that includes the necessary functions to protect

transformers for distribution networks of utilities, industry power plants and offshore

applications, as well as motor and generator differential protection. The device’s

programmable functions include thermal and circuit breaker protection, and numerous

communications protocols. An optional arc flash protection is available.

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.

1

Description

The Bulletin 7703E SMC OEM components are used to create a medium voltage soft starter. The voltage range currently supported is 10 to 15 kV, up to 340 amps.

Standard Control Module

The SMC Flex controller provides microprocessor controlled starting for standard three-phase, squirrel-cage induction motors. Several standard modes of operation are available within a single controller:

• Soft Start – with selectable kickstart • Soft Stop• Current Limit Start – with selectable kickstart• Linear Acceleration* – with selectable kickstart• Linear Deceleration* • Dual Ramp – with selectable kickstart • Full Voltage• Preset Slow Speed

* requires motor tachometer

Optional Control Module

• Pump Control (eliminates water hammer) – separate start and stop profi les

Features

• Electronic motor overload protection• Metering (MW, MWh, Power Factor, V, I)• Build-in DPI communication• Three-line, 16-character backlit LCD display• Keypad programming• Four programmable auxiliary contacts• Advanced SCR power circuit design using PowerBrick™

technology (Patent pending)• Fiber optic SCR gate fi ring• Self-powered current loop gate driver boards (Patented design)

Optional Communication Modules

The following communication boards mount within the control module:• DeviceNet (20COMM-D)• ControlNet (20COMM-C)• Ethernet/IP (20COMM-E)• Profi bus DP (20COMM-P)• Remote I/O (20COMM-R)• RS485 (DFI) (20COMM-S)• RS485 HVAC (Modbus RTU/Metasys N2/Siemens P1) (20COMM-H)• Modbus/TCP (20COMM-M)

SMC Flex Control Module

Product Selection Guide, 10-15 kV, 160/340 Amp Description � Component Selection

PowerBrick Assembly (7703E-PP__) One Required Control Module (7703E-__1FX) One Required Interface Board (7703E-INTB) One Required Voltage Sensing Board (7703E-VS__) One Required Fiber Optic Cables (7703E-__FO__) One Required Fiber Optic Multiplexer Board (7703E-MUXB) One Required Main Line Switching Device and Short Circuit Protection One Required ��

Bypass Switching Device One Required ��Gate Drive Test Power Supply (7703E-PS__) Optional �� Required for testing, commissioning, and troubleshooting gate-firing circuits. � Can be either a circuit breaker or a contactor with main switch and fuses. � Can be either a circuit breaker or contactor. � Provided by others. � For complete catalog number, refer to publication 7703E-PL030E-EN-E.


2

Typical Power System Diagram – 10-15 kV (Requires short circuit protection, as well as Start and Bypass switching devices)

L1

L2

GRD

L3

24C

PHAS

E A

PHAS

E B

PHAS

E C

FO3

FO2

FO1

FO4-

15FO

16-2

7FO

28-3

9

GND2

GND1

J1

1 2 3 4 5 6

POWERIN

GNL1TB1

GATE

TRA

NSMI

TTER

S TB6

ØA

U16

U18

U20

TEMP.GATE TRANSMITTERS

ØBTX

7

GDPS

TX1

VSB

TB21

GL2/NL1

POWERIN

TB1

ØCTX

13

-RS

1-R

S n

TO S

MC F

LEX

CT IN

PUTS

CT INPUTS

C+A- A+ B+B-TB5

C-J3

-QB

-QB

-QE

FROM

CONT

ROL

CIRC

UIT

SMC

FLEX

CONT

ROL

MODU

LELOOP

CT

FROM

CUR

RENT

MTR

FROM

CONT

ROL

CIRC

UIT

2

1

OV1

C1S1

OV2

RR1/2

RS1/2

/3

C2S2

CS

RX1

GTX

1C

T

-GP1

TEST

-BC

-+

OVS

C

RX1

TX1

TC

GOV

-BC

TEST

+-

-GP2S

C

G1G2

TT

G2

2

1

C1S1

RS1/2

/3

C2S2

CS

G1

TT

RX1

GTX

1C

T

-GP2

TEST

-BC

-+

OVS

C

RX1

TX1

TC

GOV

-BC

TEST

+-

-GP1S

C

OV2

OV1

RR1/2

RX

-KF1

-KF2

TO

FROM

STA

RTCO

NTRO

LLER

PHAS

E CT

S

STAR

T CO

NTRO

LLER

BYPA

SS C

ONTR

OLLE

R

POW

ER C

ONVE

RTER

- CUR

RENT

LOOP

GAT

E DR

IVER

BOA

RD-G

P

- SMC

FLE

X IN

TERF

ACE

BOAR

D-K

F2-BC

- SMC

FLE

X FI

BRE

OPTI

C BO

ARD

-KF1

- CUR

RENT

TRA

NSFO

RMER

- CIR

CUIT

BRE

AKER

-QB

- EAR

THIN

G SW

ITCH

(OPT

IONA

L EQU

IPME

NT)

-QE

- SMC

FLE

X PO

WER

BRIC

K AS

SEMB

LY-R

S

- VOL

TAGE

SEN

SING

BOA

RD-B

V

WIR

E CO

NNEC

TION

S FO

R PH

ASE

A

CONN

ECTI

ONS

SHOW

N FO

R PH

ASE

C

LEGE

ND

WIR

E CO

NNEC

TION

S FO

R PH

ASE

B

ON T

HE C

URRE

NT LO

OP A

SSEM

BLY

CURR

ENT

LOOP

CON

DUCT

ORS

PASS

THR

OUGH

THE

C.T

.'S

REMO

TE E

QUIP

MENT

VOLT

AGE

NUMB

ER O

F

10-1

2kV

512

.1-14

.4kV

6

INCO

MING

LINE

UNIT

INCO

MING

LINE

CUST

OMER

'S

L3L2L1

1

-BC2

-BC1

-BC3

-BC2

-BC1

-BC3

-BV

T3T2T1

POWEROUT


3

Typical Control Circuit – Standard Module (10-15 kV)(Requires a Start and Bypass switching device, control panels, as well as control relays and pilot devices)

-BC4

LEGEND

CURRENT LOOP CONDUCTORS PASS THROUGH THE C.T.'S

ØA ØB ØC

TO SMC FLEXINTERFACE

INTERFACE BOARD

STOPSTART

H1 H3 H2 H4

230V

OR

CONTROL POWER

START/STOP SIGNAL

BYPASS CONTROLLERPILOT CONTROL RELAY

START CONTROLLER

- CURRENT LOOP TRANSFORMER-TT1

- MINIATURE CIRCUIT BREAKER OR CONTROL FUSE-FB

29 3028272524 2623 33 34

201918171514 161311 12

SMCTM FLEX

DPI

21 22

31 32

CONTROL TERMINALS

GROUNDFAULT

TACHINPUT

PTCINPUT

-FB

-FB

-TT1

H1 H3 H2 H4

X1 X2

115V

BOARD -TB6-BC4

FROM SMC FLEX

CONTROL RELAY

PILOT CONTROL RELAY

-KG1

-KG1

-KG3

AUX.1UP-TO-SPEED

AUX.4NORMAL

AUX.2FAULT

AUX.3ALARM

SMC FLEX TO BE PROGRAMMED BYTHE CUSTOMERBEFORE START-UP

- BYPASS CONTROLLER PILOT CONTROL RELAY-KG2

- START/STOP SIGNAL CONTROL RELAY-KG1

- START CONTROLLER PILOT CONTROL RELAY-KG3

-KG3

- CURRENT LOOP CURRENT SENSORON THE CURRENT LOOP ASSEMBLY

SMC FLEX FIBER OPTIC BOARDPOWER IN

-KG3

-KG2

-KG1

SMC FLEX INTERFACE BOARDPOWER IN

R


4

Functional Design Specifications Features Description

Power Wiring The MV SMC Flex 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. Installation

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

Keypad The MV SMC Flex Controller is configured with the front keypad and backlit LCD display.

Set-up Software

Parameter values can be downloaded to the MV SMC Flex Controller with Drive Tools programming software and an optional (20COMM-x) 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 Flex control module)

Starting Modes Soft Start with selectable kickstart, Soft Stop, Current Limit Start with selectable kickstart, Linear Acceleration with selectable kickstart, Linear Deceleration, Dual Ramp with selectable kickstart, Full Voltage, Preset Slow Speed

Protection and Diagnostics Power 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 110/120 V AC to 220/240 V AC; 50/60 Hz

Fibre Optic Cables Available in two lengths (2.5 m and 5.0 m). Provides isolation between interface board and power stacks.

Standard Features

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

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

Features Communication Modules DeviceNet, ControlNet, Ethernet/IP, Profibus DP, Remote I/O, RS485 (DF1),

RS485 (Modbus RTU, Metasys N2, Siemens P1), Modbus/TCP � Thermal capacity limits must not be exceeded.

The combined maximum ratings for MV SMC Flex units are as follows: • 30 second Start/Stop • 40°C Ambient temperature • 2 Start/Stop in an hour • 450% FLC (average during starting) If any of the above maximums are not required, it is generally possible to exceed some of the other ratings. Please consult factory for details.


5

PowerBrick™ Description

The Bulletin 7703E MV PowerBrick module (patent pending) is a two-device power stack that pro-vides excellent mounting fl exibility. 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 Flex control module on the interface board and connect interface board to the voltage

sensing board and the gate driver boards with fi ber 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 Flex 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

• Installation Manual

SpecificationsDescription 160 A, 340 A

Input Voltages (50/60 Hz)

10,000 to 12,000 volts 12,001 to 14,400 volts 3 phase, +10%, -15%

Ambient Temperature 0°C to 40°C (32°F to 104°F) Power Section (for 3 phases)

30 SCR at 10 to 12 kV 36 SCR at 12.1 to 14.4 kV

Repetitive Peak Inverse Voltage Rating

10 to12 kV – 32500 PIV 12.1 to 14.4 kV – 39000 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 500% FLA)

160A 340A Continuous 10,000 – 12,000 35 65 0.25

Maximum Heat Dissipation (kW)

12,001 – 14,400 42 78 0.25

Altitude 0 to 1000 m (0 to 3,300 ft.) (See Controller Deratings Table on page 7, Publication 1503-BR010F-EN-P)

Rating (kV) 10 – 12 12.1 – 14.4 Net Shipping Weight (3 phases) Weight

kg (lbs) 285 (630) 342 (756)


6

PowerBrick - 3D View

PowerBrick2400V, 200/400 A

PowerBrick™ Options and Catalog Numbers ��

Line Voltage � Size (Amps) � Catalog Number �160 7703E-PPMT 12 kV 340 7703E-PPMA 160 7703E-PPNT 15 kV 340 7703E-PPNA

� Includes transformer for current loop gate driver system. Wiring to be supplied by OEM. � 3 phase, 50/60 Hz. – 12 kV can be used for motor voltage from 10 to 12 kV, includes 5 PowerBrick units per phase – 15 kV can be used for motor voltage from 12.1 to 14.4 kV, includes 6 PowerBrick units per phase � Nominal motor full load current. May require derating depending on enclosure type, ambient

and application conditions. � The following components are also required to complete one unit kit:

– One of 7703E-S1FX or 7703E-B1FX – One 7703E-INTB – One 7703E-MUXB – One 7703E-VSM or 7703E-VSN

– One of 7703E-xxFOxx � Additional hardware is required for main and bypass switching and circuit protection (not

supplied by Rockwell Automation). PowerBrick units are rated for starting duty only, and must be bypassed after the motor reaches full speed.

� Current loop CT assembly included.


7

Front View Side View

Current Loop Gate Drive Cable(mounts on PowerBricks)




8

Typical Mounting Arrangementfor 10-12 kV PowerBrick System

Note: For 12-15 kV PowerBrick system, an additional PowerBrick is required per phase. This will add 250 mm (9.84 in.) to the height of each phase assembly.

160,0[6.30]

160,0[6.30]

65465.1]

80,0 [3.15] 25,0 [0.98]

1326 [52.2]

627 [24.7]

160,0[6.30]

90,0[3.54]

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



9

Voltage Sensing Board Description

The 15 kV Voltage Sensing Board steps the voltage down from the system voltage to a voltage level compatible with the SMC Flex control module. Includes mounting instructions.

Catalog Number Description Line Voltage (3 phase, 50/60 Hz) Catalog Number

10,000 to 12,000 V 7703E-VSM Voltage Sensing Board

12,001 to 14,400 V 7703E-VSN

Approximate dimensions in mm [inches]

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 secureHV wire for maintained spacings.


10

Interface Board Description

Converts digital signals from the SMC Flex control module to drive the gate driver boards via fi ber optics. It also provides voltage, current and temperature feedback to the control module. Includes mounting instructions.

Note: Dimensions shown include mounting bracket assembly which is included with the interface board.

Interface Board and Mounting Brackets27.6

[1.09]


Front View

Mounting holes (4)7.14 mm [0.281 in.) dia.

Top mounting holes for SMC Flex Control Module

Bottom mounting holes for SMC Flex Control Module Side View

27.6[1.09]

.

256.2 [10.09]

241.3 [9.50]

241.3[9.50]

285.8[11.25]

SpecificationsControl Voltage 110/120 to 220/240 V – 50/60 Hz, 15 VA

Gate Drive Via Fiber Optics

SCR Overtemperature Via Fiber Optics

Catalog NumberInterface Board Catalog Number

110/120 to 220/240 V AC – 50/60 Hz 7703E-INTB


11

Fiber Optic Multiplexer DescriptionBoard Accepts fi ber optic gate drive signals from the interface board (7703E-INTB) and splits them into the

required fi ber optic gate drive signals for 10-15 kV.

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]

127.0[5.00]

28.6[1.13]

Phase A Phase B Phase C

SpecificationsControl Voltage 110/120 to 220/240 V – 50/60 Hz, 30 VA

Gate Drive (In/Out) Via Fiber Optics

Catalog Number Fiber Optic Multiplexer Board Catalog Number

110/120 to 220/240 VAC – 50/60 Hz 7703E-MUXB


12

SMC Flex Control Module Description

The SMC Flex control module provides microprocessor controlled starting for standard three-phase, squirrel-cage induction motors. The SMC Flex control module provides the following modes of operation as standard:

• Soft Start – with selectable kickstart • Soft Stop

• Current Limit Start – with selectable kickstart• Linear Acceleration* – with selectable kickstart

• Linear Deceleration*• Dual Ramp – with selectable kickstart • Full Voltage• Preset Slow Speed

* requires motor tachometer

The SMC Flex control module provides motor protection, including overload, underload, stall, jam, etc., during starting and while the bypass contactor is energized.

Starting and Stopping Options

The following control option is available:

• Pump Control


13

Options and Catalog Numbers Control Module Options Catalog Number

Standard Module 7703E-S1FX

Pump Control 7703E-B1FX


240.7[9.5]

127.1 [5.0]70.5[2.78]



240.7[9.5]

127.1 [5.0]70.5[2.78]


NET B

NET A

MOD

PORT

Allen-Bradley SMC Flex

Esc Sel

23 24 25 26 27 28 29 30 31 32 33 34

11 12 13 14 15 16 17 18 19 20 21 22


14

Fiber Optics Description

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 retrofi t into an existing enclosure. Includes mounting instructions.

SpecificationsNo. of Cables Voltage Range 2.5 m (8.2 ft) 5.0 m (16.4 ft)

12000 V 36 3613800 V 42 42

Options and Catalog Numbers Fiber Optic System Voltage Length of Cable Catalog Number

2.5 m (8.2 ft) 7703E-25FO30 12000 V 5.0 m (16.4 ft) 7703E-50FO30 2.5 m (8.2 ft) 7703E-25FO36 13800 V 5.0 m (16.4 ft) 7703E-50FO36


Gate Driver Test Power DescriptionSupply

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

Options and Catalog Numbers Test Power Supply Options Catalog Number

120 V AC, 60 Hz 7703E-PSD Universal (requires power cord) 7703E-PSU

Specifications

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

AC Power Cord North American (Cord supplied)

Universal (Cord supplied by OEM)

Publication 7703E-BR001A-EN-P – May 2011 Copyright © 2011 Rockwell Automation, Inc. All rights reserved. Printed in Canada.

Rockwell_Medium_Voltage_7703E_OneGear_Brochure_en_0611.pdf

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www.klinkmann.com

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