Rockwell Automation Allen-Bradley 7703E User manual

Medium Voltage SMC OEM Components, 10…15 kV
Bulletin Number 7703E
Installation Instructions
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 aboutpractices 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 successfulapplication 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.
BURNHAZARD:Labels may be onor inside theequipment, for example, adriveormotor,toalert peoplethatsurfacesmay
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potentialArcFlash.ArcFlashwillcausesevereinjuryor death.WearproperPersonalProtectiveEquipment(PPE).FollowALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 3
TableofContents
Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1
Receiving and General
Information Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Handling Procedures for Electrostatic Sensitive Devices . . . . . . . . . . . 7
Standards and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 2
PowerBrick Installation Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sizing the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PowerBrick Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Typical Mounting, 10…12 kV PowerBrick System . . . . . . . . . . . . . . . 13
Typical Mounting, 12.1…14.4 kV PowerBrick System. . . . . . . . . . . . 14
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PowerBrick Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Voltage Sensing Board Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mounting and Connecting the Voltage Sensing Board. . . . . . . . . . . . 17
Current Loop Gate Drive Power Assembly (CLGD) . . . . . . . . . . . . . 19
Chapter 3
ControlComponentInstallation Interface Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Interface Board Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SMC-50 Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
EMC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting Interface Board to Voltage Sensing Board. . . . . . . . . . . . 28
Connecting Fiber Optic Multiplexer Board to Gate Driver Board . 29
Additional Control Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Chapter 4
Main and Bypass Switching
Device Installation Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Main Contactor or Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bypass Contactor or Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Table of Contents
Chapter 5
Typical Wiring Diagrams Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 6
Final Test Procedures Final Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dielectric Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Additional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Medium Voltage SMC-50 Module. . . . . . . . . . . . . . . . . . . . . . . . . . 37
Voltage Sensing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Appendix A
Component Deratings Deratings Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Appendix B
Typical Schematic Diagrams Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix C
Spare Parts PowerBricks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 5
Preface
Summary of Changes
Scope 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;
however, some of the devices 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 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 9). Each form of PowerBrick assembly is
applied with other Bulletin 7703E control components and power devices, in
forming a complete solution.
Topic Page
Replaced all references from SMC Flex to SMC-50 Throughout
Changed MV Ratio parameter number to 169 18, 37
Replaced dimensions graphic to show updated SMC-50 board 23
Replaced SMC Flex interface board graphic with SMC-50 24
Updated control terminal designations and descriptions 27
Replaced multiplexer board graphic 29
Replaced typical power circuit wiring diagram to reflect SMC-50 interface board 34
Replaced typical power system diagram to reflect SMC-50 interface board 46
replaced typical control circuit graphic to reflect SMC-50 interface board 47

6Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
Resource Description
CENTERLINE MediumVoltage SMC-50 Motor Controller
user manual, publication 1560F-UM001 Provides information on installing, commissioning, operation, programming, troubleshooting, and
parameter information for MV SMC-50 controllers
Industrial AutomationWiring and Grounding Guidelines,
publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website: rok.auto/certifications Provides declarations of conformity, certificates, and
other certification details.

Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019 7
Chapter 1
Receiving and General Information
Receiving See Getting Started, General Handling Procedures for Medium Voltage
Controllers, publication MV-QS050. This document is included with your
shipment and contains information regarding receiving, unpacking, initial
inspection, handling, storage, and site preparation.
Handling Procedures for
Electrostatic Sensitive
Devices
To guard against electrostatic damage (ESD) to equipment, the following
precautions should be observed when handling electrostatic sensitive devices.
1. Use a 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, see Guarding Against Electrostatic Damage, publication
8000-4.5.2.
Standards and Codes
•CEC(CanadianElectricalCode)
• CSA 22.2 No. 253 (Canadian Standards Association) – Medium Voltage
AC Contactors, Controllers and Control Centers
• NEC (National Electrical Code)
• NEMA ICS Standards (National Electrical Manufacturers’ Association)
ATTENTION: Printed circuitboards contain components that can be damaged
by electrostatic charges that build upon personnel during normal activities.
Exercise the following precautions when handling electrostaticsensitive
devices.Failure to do so may damage the device andrender it inoperable.
IMPORTANT It is recommended that the user be familiar with the following safety and
design standards and codes, and any additional local codesthat a medium
voltage controller must comply with:

8Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Chapter 1 Receiving and General Information
• 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 IEC 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-IN001F-EN-P - July 2019 9
Chapter 2
PowerBrick Installation
Identification A PowerBrick™ is shown in Figure 1.
Figure 1 - Single-phase PowerBrick
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(1)
(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-IN008 for additional details.)
Voltage(2)
(2) Voltage ranges: 12000 = 10000…12000V (5 PowerBricks in series per phase)
13800 = 12001…14400V (6 PowerBricks in series per phase)
Current (A)
7703E-PPMT 12,000V 3 PH, 50/60 Hz 160
7703E-PPMA 340
7703E-PPMC 580
7703E-PPNT 13,800V 160
7703E-PPNA 340
7703E-PPNC 580

10 Rockwell Automation Publication 7703E-IN001F-EN-P - July 2019
Chapter 2 PowerBrick Installation
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
Sizing the Enclosure
Use the data in Table 3 to assist in calculating the enclosure size.
Table 3 - PowerBrick Specifications
Dimensions See Figure 2, Figure 3, and Figure 4 for PowerBrick dimensions and mounting.
Catalog Number Voltage Sensing Board Input (3 PH, 50/60 Hz)
7703E-VSM 10,000…12,000V
7703E-VSN 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.
Description 160 A, 340 A
InputVoltages
(50/60 Hz)
10,000…12,000V
12,001…14,400V
3 phase, +10%, -15%
AmbientTemperature 0 °C…40 °C (32 °F…104 °F)
Power Section
(for 3 phases)
30 SCR at 10…12 kV
36 SCR at 12.1…14.4 kV
Repetitive Peak Inverse
Voltage Rating 10 to12 kV…32,500 PIV
12.1…14.4 kV…39,000 PIV
Thermal Capacity(1) 600% of FLA, 10 s
450% of FLA, 30 s
dv/dt Protection R.C. Snubber Network
Maximum Heat
Dissipation (kW) Start or Stop Cycle (at 450% FLA)
160 A 340 A 580 A Continuous(2)
10,000…12,000V 27 57 98 0.5
12,001…14,400V 32 69 117 0.5
Altitude 0…1000 m (0…3,300 ft)
(See Controller DeratingsTable on page 6, publication 1503-BR010F)
Net ShippingWeight
(3 PH)
Rating (kV) 10…12 12.1…14.4
Weight kg (lb) 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.