Rockwell Automation Allen-Bradley OneGear User manual

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

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 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.
Labels may also be on or inside the equipment to provide specific precautions.
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
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 Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 7712-UM001D-EN-P - October 2017 3
Table of Contents
Preface
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ArcShield Arc Flash Resistant Enclosure Features . . . . . . . . . . . . . . . . . 7
Controller Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
General Information Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Product Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ArcShield Components Installation Requirements . . . . . . . . . . . . . . . 13
Chapter 2
Safety Interlock and Accessibility
Requirements
Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Open the Enclosure Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Opening the Low Voltage Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Opening the Medium Voltage Door. . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 3
Start-up Procedure Contactor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Testing Contactor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Test Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operating Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 4
Equipment Operation Power Lockout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Open Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Power Down Low Voltage Section . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Selecting Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connecting Test Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Racking Contactor Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operation of Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Earthing Switch Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Earthing Switch Positioning Indicators. . . . . . . . . . . . . . . . . . . . . . 31
Contactor Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Connect LV Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Shutter Position Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Chapter 5
Maintenance Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Maintenance of Industrial Control Equipment . . . . . . . . . . . . . . . . . . 37
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Contamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operating Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Annual Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Remove Contactor Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Remove and Replace Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Contactor Cart Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Replace the Vacuum Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Calibrate the Overtravel and Contact Gap. . . . . . . . . . . . . . . . . . . 48
Lubricate the Contactor Cart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Earthing Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect and Lubricate Earthing Switch Mechanism . . . . . . . . . . . 53
Ground Connection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Toggle Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Earthing Switch Auxiliary Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 56
Auxiliary Contacts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Auxiliary Contacts Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Earthing Switch Auxiliary Contacts Inspection . . . . . . . . . . . . . . 57
Appendix A
Spare Parts Typical Bulletin 7712 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Appendix B
Certification Data Test Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
High Voltage Controlgear Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Appendix C
Troubleshooting Door Interlock Circumvention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Earthing Switch to Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Door to Isolation Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Appendix D
Mechanical Interlock for 7712 and
PowerFlex 7000 Drive
Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
KD and KE Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
KC Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
KA and KB Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
KC Keys for doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
KD and KE Key for Output Cables Cabinet Door . . . . . . . . . . . 69
Transfer Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Rockwell Automation Publication 7712-UM001D-EN-P - October 2017 5
Table of Contents
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Motor Connection from 7791. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Motor Connection from 7712. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Interlock Operation Sequence (One Motor). . . . . . . . . . . . . . . . . . . . . 70
Initial Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
To Run Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
To Run Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
To open Drive for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
To open Output Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Interlock Operation Sequence (Two Motors) . . . . . . . . . . . . . . . . 71

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Rockwell Automation Publication 7712-UM001D-EN-P - October 2017 7
Preface
Introduction This user manual provides installation instructions and maintenance
procedures for the Rockwell Automation Bulletin 7712 ArcShield™ arc flash
resistant enclosure, medium voltage controller. The Bulletin 7712 structure
provides one complete MV controller unit.
Summary of Changes This manual contains new and updated information as indicated in the
following table.
Who Should Use this Manual This manual is intended for qualified service personnel responsible for
installing and maintaining medium voltage controllers. You should have
previous experience with, and an understanding of, electrical terminology,
procedures, required troubleshooting equipment, equipment protection
procedures and methods, and safety precautions. See safety related practices
contained in publication NFPA 70E, Standard for Electrical Safety in the
Work Place.
Service and Maintenance For your convenience, Rockwell Automation Customer Support and
Maintenance (CSM), provides an efficient and convenient method of servicing
medium voltage products. Contact your local area support office to make
arrangements to have a qualified service representative come to your facility. A
complete listing of Area Support Offices may be obtained by calling your local
Rockwell Automation Distributor or Sales Office.
For Medium Voltage technical support on start-up or existing installations,
contact your Rockwell Automation representative. You can also call 1-519-
740-4790 for assistance Monday through Friday from 9:00 a.m. to 5:00 p.m.
(Eastern Time zone).
ArcShield Arc Flash Resistant
Enclosure Features
Built to minimize exposure to electrical hazards, the OneGear 7.2 kV motor
controller includes an optional earthing switch and fully interlocked
compartment doors to isolate the power source when an apparatus cell door is
open. The controller features ArcShield arc flash-resistant enclosures, which
provide arc-flash protection in accordance with the IEC 62271-200 Annex A
standard.
The controller is designed, manufactured and tested to meet or exceed the
applicable requirements of the latest standards published by the following
organizations:
• IEC 60470: High-voltage Alternating Current Contactors and
Contactor Based Motor-Starters.
Topic Page
Replaced Spare Parts List 59

8Rockwell Automation Publication 7712-UM001D-EN-P - October 2017
Preface
• IEC 62271-100: High-voltage Switchgear and Control Gear, Circuit
Breakers
• IEC 62271-1: High-voltage Switchgear and Control Gear, Common
Specifications
• IEC 62271-200: High-voltage Switchgear and Control Gear
• IEC 62271-102: High-voltage Switchgear and Control Gear,
Disconnectors and Earthing Switches
• European Directives for Safety and EMC
•RoHS
Note: It is the responsibility of the customer and/or installer to know and meet
all local codes, standards, and OSHA requirements.
Controller Unit Identification A nameplate is attached to the front door of the structure (see Figure 1). Refer
to the nameplate for information such as series number, section number,
enclosure type, unit ratings, and bus ratings.
Figure 1 - Typical Structure Nameplate
A nameplate is also found in the low voltage compartment (see Figure 2) with
specific unit and motor application information.

Rockwell Automation Publication 7712-UM001D-EN-P - October 2017 9
Preface
Figure 2 - Typical Unit/Motor Nameplate
Refer to these nameplates whenever you contact Rockwell Automation for
assistance. Be prepared to provide information such as series number, structure
series, unit series, diagram schematic, and catalog number.
Additional Resources The following table lists publications that provide related information.
You can view or download publications at http://
www.rockwellautomation.com/literature/. To order paper copies of technical
documentation, contact your local Rockwell Automation distributor or sales
representative.
Resource Description
OneGear 7.2 kV Motor Controller - Full-voltage, Non-
reversing and Incoming Line Unit - Technical Data, 7712-
TD001
Provides technical specifications and an overview of the
features and functions provided by the controller and in-
coming line unit.
OneGear SMC Flex Solid-State Motor Controller (10…15
kV) Specification Guide, 7760-SR001
Provides a outline for the overall fabrication,
performance and functional requirements for a medium
voltage, reduced-voltage solid state motor controller
(RVSS) for use with induction and brush type
synchronous motors.
How to Successfully Apply Medium Voltage Soft
Starters, 1560E-WP023
Provides guidelines for selecting and applying medium
voltage starters.
SMC-Flex Controller with Pump Control,
150-WP003
Provides guidelines for applying the SMC-Flex controller
with pump control.
General Handling Procedures for Medium Voltage
Controllers Quick Start, MV-QS050
Provides basic information on installation site
preparation.
Medium Voltage Contactor 400A User Manual, 1502-
UM052
Provides general guidelines for the application,
installation, and maintenance of 400A medium voltage
vacuum contactors.

10 Rockwell Automation Publication 7712-UM001D-EN-P - October 2017
Preface
Notes: