OneGear 7.2 kV Motor Controller—Full-voltage, Non
Contents
1. omnes 69 IO Key cape eda cst acne saan E 69 4 648 425 69 KC Key 69 KD and KE Key for Output Cables Cabinet Door 69 DOCK Essais inire Dub 70 Rockwell Automation Publication 7712 UM001C EN P June 2013 Table of Contents CONNECHONS 2 Fade 70 Motor Connection from 7719 70 Motor Connection from7712 70 Interlock Operation Sequence One Motor 70 Initial COTON itr tod bee ec R 70 70 70 Drive for pean 71 Output Cabinet nn iii 71 Interlock Operation Sequence Two 71 Rockwell Automation Publication 7712 UM001C EN P June 2013 5 Table of Contents Notes 6 Rockwell Automation Publication 7712 UM001C EN P June 2013 Introduction Who Should Use this Manual Service and Maintenance ArcShield Arc Flash Resistant Enclosure Features Preface 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 controller2. 70005 2B ke 70005 2B 0005 2B Rockwell Automation Publication 7712 UM001C EN P June 2013 25 Chapter 3 26 XC XC XC_XC BT_MV 0006 2BC 1 0006 29BC 2 0004 4CC 3 0009 4BC 4 0009 4BC 5 0008 2CC 6 0008 3CC 7 0013 29BC 8 0013 3BC 9 0008 2BC 10 0008 3BC 11 0013 2AC 12 Start up Procedure TRUCK POSITION ES O lt 20 xz ay 1 0012 1D QS_TK 12 ra rm H 13 33 0012 1D 05 0009 7B QC M 0009 7B QC NOD 0006 4D NC 0006 2B 1 0004 7 13 2 0013 3 22 gt 0009 6B 23 gt 0009 6B 24 gt 0009 7 0012 3D 05 0012 1D 05 1 0007 7B L2 N 1 0009 4C No 7o007 70 etos an 1 XC XC 0016 3B 1 PRG INTELLIVAC 36 O 8 Ll K L 9 37 Rockwell Automation Publication 7712 UM001C EN P June 2013 840 85 XC 0005 5C QE ES 0005 5C QE ES 0005 5 ES 0005 5 QE ES 0005 5C 0005 5C QE ES 0005 5C QE ES 86 lt 87 lt 0008 7B M PS SSDUL FO_SSOL PWR_IN TEU a 0011 4C cco 7 2 MID STAT CNT STAT 0008 7B XC XC M XC XC 80 81 0008 7B XC XC M XC XC 82 83 e 0 0008 7B XC XC M XC XC XC XC 0002 1 o10
3. Short circuit making and breaking tests Starter Make Break 1CO at 6 1 kA Earthing Switch Making 5x CQ 31 5 kA Peak SCPD Coordination Type 40kArms 10 fused Type B 40kArms 1CO fused Type C 5 1kArms 3 0 unfused Degree of Protection External surface 4 Internal barriers IP2X Arc Tests 7712 Starter 31 5 kA 0 5 s line side 62 IEC60470 6 104 20969 E 26 Powertech 07 08 2011 IEC 60265 6 107 1 EP 2485R Rockwell Automation HCL 1EC60470 6 106 3 1 20969 C 26 Powertech IEC60470 6 106 3 2 07 07 2011 60470 6 106 3 3 60470 5 13 ER 070 2012 Rockwell Automation ED DUE ER 070 2012 Rockwell Automation IEC 62271 200 Annex A AFLR 20158 2 08 16 18 2010 Powertech Rockwell Automation Publication 7712 UM001C EN P June 2013 Appendix C Troubleshooting Door Interlock Circumvention Door interlocks ensure user safety and should only be defeated in the event of mechanical failure Earthing Switch to Door components To avoid shock hazards complete the Power Lockout procedure on page 27 before servicing the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION This procedure requires contact with medium voltage WARNING Use suitable personal protective equipment PPE per local codes or regulations Failure to do so my result in severe burns injury or death
4. IMPORTANT Before circumventing earthing switch to door interlock e contactor cart must be in the test withdrawn position This procedure should only be used if the earthing switch cannot be closed causing the door not to open 1 Open the LV door 2 In order to circumvent the earthing switch to door interlock remove three M6 flat head screws located on the door Figure 44 Rockwell Automation Publication 7712 UM001C EN P June 2013 63 AppendixC Troubleshooting Figure 44 Circumvent Earthing Switch to Door Interlock REMOVE THESE M6 FLAT HEAD SCREW DETAIL SCALE 0500 USH THIS END WITH A SCREW DRIVER FROM OUTSIDE NTERLOCK MOUNTING fe fe BRACKET DETAIL B SCALE 0 500 3 Push the top edge of the interlock mounting bracket downward using a flathead screwdriver Open the door Reverse steps 1 through 2 to reassemble the mounting bracket to the door 64 Rockwell Automation Publication 7712 UM001C EN P June 2013 Troubleshooting Appendix Door to Isolation Shutter components To avoid shock hazards complete the Power Lockout procedure on page 27 before servicing the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION This procedure requires contact with medium voltage WARNING Use suitable personal protective eq
5. 1100 504 kg FVNR Controller 13 78 86 71in 4331in 11081 1 The height dimension does not include the plenum 574 mm 22 60 in which is removed for shipping and installed by the customer The total height of the unit including an installed plenum is 2674 mm 105 27 in 12 Rockwell Automation Publication 7712 UM001C EN P June 2013 General Information Chapter 1 ArcShield Com ponents The Bulletin 7712 ArcShield enclosure typically includes a pressure relief vent Installation Requirements The pressure relief vent opens under arc flash conditions allowing hazardous flames and gases to exit the enclosure via plenum ATTENTION The low voltage panel area is sealed to prevent flames and gases from entering however suitable personal protective equipment PPE must be ATTENTION To ensure arc flash resistant integrity A used whenever working on live circuits The pressure relief vent must not be tampered with and must not be used as a step No alterations can be made to the ArcShield structure All covers plates and hardware removed for installation or maintenance purposes must be re installed and properly secured Failure to do so voids the arc flash resistant integrity Power cable entry points are to be treated as the boundary between a hazardous location and sealed accordingly Failure to do so voids the arc flash resistant integrity A plenum must be used to direct the arc flash energ
6. cart and the load terminals To avoid shock hazards the MV and LV doors must be closed Failure to do so may result in severe burns injury or death Rockwell Automation assumes no responsibility for injuries to personnel who do not follow the safety procedures prior to servicing or operating the equipment 1 ATTENTION The following procedure applies medium voltage to the contactor Operating position is designed only for performing normal functions of this equipment operation on the contactor will affect the MV status on the load side When the contactor cart is racked to operating position the MV parts on the line side including CPT is default has been chosen would be connected to the line side buses of this equipment so that they would be energized by MV As a result of energizing CPT control power would be applied to the LV circuit connected to it Rockwell Automation Publication 7712 UM001C EN P June 2013 21 Chapter 3 22 Start up Procedure The cart must be in the operating position and the earthing switch must be open It is not possible to operate the contactor by the test power supply while the contactor cart is in operating position To perform any operation with the contactor engaged either MV should be applied on the line side bus of this equipment so that the MV energized on cart CPT would power up the control circuits or a customer supplied power supply should have been wired to the LV panel as desig
7. the shutter door position Green The shutter door is closed Figure 17 the cart is completely redrawn in the test position Red The shutter door is open Figure 18 the indicator will change immediately after moving the cart from test withdrawn position to the service position The color of the indicator will change to red even if the shutter door is partially open Figure 15 Shutter position Indicator Indicator Close position Green Open position Red Viewing Window Rockwell Automation Publication 7712 UM001C EN P June 2013 33 Chapter4 Equipment Operation TIP If the shutter door is partially or fully open an interlock prevents the MV door from opening viewing window Figure 16 shows the position of the contactor cart Figure 16 Viewing Window Viewing Window Indicator Figure 17 Shutter closed 34 Rockwell Automation Publication 7712 UM001C EN P June 2013 Equipment Operation Chapter 4 Figure 18 Shutter open Rockwell Automation Publication 7712 UM001C EN P June 2013 35 Chapter4 Equipment Operation Notes 36 Rockwell Automation Publication 7712 UM001C EN P June 2013 Required Tools Maintenance of Industrial Control Equipment Chapter 5 Maintenance Torque wrench 0 48 Ibeft 0 65 Nem e Sockets 3 8 in 7 16 in 9 16 in e Ratchet handle and extension e Wrenches 7 16 in 1 2 in 9 16 in Feeler gauges 0 050 in 1 3 mm 0 080 in
8. 104 F with a relative humidity of up to 95 non condensing Higher ambient temperature conditions are supported with factory assistance The controller must be derated for ambient temperatures above 40 C 104 F The equipment operates at altitudes from 0 1000 m 3300 ft above sea level without de rating For applications above 1000 m 3300 ft the maximum current and Basic Impulse Levels B LL of the controllers and incoming line unit shall be de rated and vacuum contactors breakers will be compensated for operation at the specified altitude Rockwell Automation products use materials that comply with Class 1 Industrial Clean Air sulphur environments as defined in IEC Standard 60654 4 Operating Conditions for Industrial Process Measurement and Control Equipment and G1 as defined in ISA S71 04 1985 Environmental Conditions for Process Measurement and Control Systems Airborne Contaminants Rockwell Automation Publication 7712 UM001C EN P June 2013 11 Chapter1 General Information Product Dimensions and Figure 3 Controller Dimension Diagram Weights 43 47 350 13 78 2674 105 27 2200 86 6 9 i l 16 m 3 K 22 270000099 Table 1 Approximate Dimensions and Weights 7712 250 A single fuse 350 mm 2200 mm 1100 mm 489 kg FVNR Controller 13 78 86 71in 43 31in 10751b 7712 330 A double fuse 350 mm 2200
9. 2 mm 0 020 in 0 5 mm Flat blade screwdriver Nyogel 759G Lubricant Allen Bradley part no 80158 357 51 e MV Door Key e Allen Key e Speed Wrench Cart latch key Earthing Switch operating tool hazardous Severe injury or death can result from electrical shock bump or unintended actuation of controlled equipment Recommended practice is to disconnect and lockout control equipment from power sources and release stored energy if present Refer to National Fire Protection Association Standard No NFPA7OE Part II and as applicable OSHA rules for Control of Hazardous Energy Sources Lockout Tagout and OSHA Electrical Safety Related Work Practices for safety related work practices including procedural requirements for lockout tagout and appropriate work practices personnel qualifications and training requirements where it is not feasible to de energize and lockout or tagout electric circuits and equipment before working on or near exposed circuit parts 1 ATTENTION Servicing energized Industrial Control Equipment be Periodic Inspection Industrial control equipment should be inspected periodically Inspection intervals should be based on environmental and operating conditions and adjusted as indicated by experience An initial inspection within 3 4 months after installation is suggested See National Electrical Manufacturers Association Standard No ICS 1 3 Preventive Maintenance of Industrial Con
10. Lubricate if specified in individual product instructions Note Allen Bradley magnetic starters contactors and relays are designed to operate without lubrication do not lubricate these devices because oil or grease on the pole faces mating surfaces of the operating magnet may cause the device to stick in the ON mode Some parts of other devices are factory lubricated if lubrication during use or maintenance of these devices is needed it will be specified in their individual instructions if in doubt consult your nearest Allen Bradley Sales Office for information Terminals Loose connections in power circuits can cause overheating that can lead to equipment malfunction or failure Loose connections in control circuits can cause control malfunctions Loose bonding or grounding connections can Increase hazards of electrical shock and contribute to electromagnetic interference EMI Check the tightness of all terminals and bus bar connections and tighten securely any loose connections Replace any parts or wiring damaged by overheating and any broken wires or bonding straps Coils If a coil exhibits evidence of overheating cracked melted or burned insulation it must be replaced In that event check for and correct overvoltage or undervoltage conditions which can cause coil failure Be sure to dean any residues of melted coil insulation from other parts of the device or replace such parts Rockwell Automation Publication 7712 UM00
11. 0016 5B 1 PN_RSTR E1 PLUS CT INPUT 9 0007 3B 9 0008 20 Chapter 4 Equipment Operation Power Lockout Procedure The power lockout procedure removes all power from user accessible areas ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death ATTENTION Always perform the power lockout procedure before servicing equipment Failure to do so may result in severe burns injury or death Open Contactor The contactor can operate open or closed only when the contactor cart is in the operating or test position 1 Remove the close command applied on IntelliVAC Ifthe system is running at Local mode push the Open button on the low voltage control panel e Ifthe system is running at System mode apply the Open command from a higher level controller 2 Openlow voltage door to check the contactor status LED of IntelliVAC it must be off Power Down Low Voltage Section Besides either customer supplied LV power or defaulted CPT mounted on the contactor cart the Low Voltage Section can also be powered by a temporary LV test power supply 1 Turn the selection switch to Off 2 Unplug the temporary test power supply 3 Disconnect any customer supplied power supply using standard lockout tagout procedures Rockwell Automation Publication 7712 UM001C EN P June 2013 27 Chapter4 Equipment Operation
12. KC Keys for doors e 1 Key in the Drive door Prevent the door to open when key is removed e 1 Key in the Drive Input door Prevent the door to open when key is removed e 1 Key in the Drive Output door Prevent the door to open when key is removed e 1 Key in Output Cables Cabinet door Prevent the door to open when key is removed KD KE KD and KE Key for Output Cables Cabinet Door Keys in the Output Cables Cabinet door e Prevent the door to open when key is removed Rockwell Automation Publication 7712 UM001C EN P June 2013 69 Appendix D Mechanical Interlock for 7712 and PowerFlex 7000 Drive Connections Interlock Operation Sequence One Motor 70 Transfer Block e Standard Transfer Block located inside drive cabinet e All 5 KC Keys need to be placed in the transfer block to release KA and Motor Connection from 7719 Limited to one cable per phase Motor Connection from 7712 Limited to one cable per phase Initial Condition doors closed Bypass Drive Input Drive Output contactors in open and the cart withdrawn Bypass earth switch closed KC and KD keys in earth switch KA key in the Drive Input cabinet in transfer block KB key in Drive Output cabinet in transfer block KC keys 4 in transfer block one in earth switch in Bypass cabinet To Run Drive Open earth switch lock open with KC Place all KC keys in transfer block Jake KA and KB keys and place in Drive Inp
13. rotate the insulators as required The overtravel must remain at least 0 065 in 1 65 mm on each bottle 5 Tighten the load terminal nut on each bottle assembly Apply wrenches to the load terminal nut and to the flattened section of the movable bottle shaft to prevent damage to the bellows 6 Tighten the load terminal nut while holding the bottle shaft steady Do not turn the insulator as this changes the gap 7 The final contact gap for all three bottles must be between 0 180 0 200 in 4 57 5 08 mm If this is the case the replacement procedure is complete If further adjustment is required all three gaps can be adjusted simultaneously by loosening the stop bracket bolts and adjusting the height of the gap adjustment screw at the rear of the contactor Figure 33 To adjust the height of the screw first loosen the locking nut 8 When the gap is correct tighten the gap adjustment screw locking nut 9 Position the stop bracket lightly against the armature plate and tighten the bolts securing the stop in position Ensure that the actuator plate contacts the gap adjustment screw and the armature plate contacts the stop bracket Figure 33 Rockwell Automation Publication 7712 UM001C EN P June 2013 49 Chapter5 Maintenance Figure 33 Contact Gap Adjustment Gap Adjustment Screw Gap Adjustment Screw Locking Nut sa jj LXS Stop Bracket Bolts Stop Bracket 10 Reconnect the lower termin
14. KB 67 Appendix D Mechanical Interlock for 7712 and PowerFlex 7000 Drive Figure 49 PowerFlex Drive with Two Motor Synchronous Transfer Bypass using OneGear 7712 Controllers Incomer Bypass M1 Bypass M2 Drive Input VFD Drive Output Output Cables Output Cables 7791 7712 MB 72D 7712 7712 DO 7712 7712 r 1 68 i i L Figure 50 Transfer Block Rockwell Automation Publication 7712 UM001C EN P June 2013 Keys Mechanical Interlock for 7712 and PowerFlex 7000 Drive Appendix D KD and KE Keys Keytolock the earthing switch close in the Bypass Cabinet e Prevent rotation access to the earthing switch shaft after key is removed and the earthing switch is in close position KC KC Key Keytolock the earthing switch open in the Bypass Cabinet e Prevent rotation access to the earthing switch shaft after key is removed and the earthing switch is in open position KA and KB Keys Key to lock the contactor cart Drive Input and Drive Output in the redrawn position e Need to operate based on the contactor cart position Key is captive in the lock until the contactor is fully racked out and the key is turned e When the key is removed the lock must prevent racking the cart in It must be possible to open the door and remove the cart The existing door to cart interlock prevents racking the cart in when the door is open
15. Replace the existing auxiliary Rewire the terminals with correct wire and secure the auxiliary with the mounting hardware Figure 42 Auxiliary Contacts Replacement AUXILIARY MOUNTING 27 HARDWARE M35 HEX NUT WASHER SCREW DETAIL D SEE DETAIL D Auxiliary Contacts Adjustment The auxiliary is mounted to a slotted L bracket using a M3 5 cheese head screw washer and nut The L bracket with the auxiliary is mounted to the base of the earthing switch using two M6 taptie The switch must be positioned so the roller of the auxiliary sits on top of the actuator hump Horizontal Adjustment 1 Loosen the auxiliary mounting hardware two M3 5 hex nuts 2 Adjust the auxiliary as required 3 Secure the adjusted position of auxiliary by tightening the nut 56 Rockwell Automation Publication 7712 UM001C EN P June 2013 Maintenance Chapter 5 Vertical Adjustment 1 Loosen the two tapties that mount the L bracket to the base 2 Move the L bracket up and down as required 3 Secure the adjusted position of auxiliary by tightening the two M6 taptie Figure 43 Auxiliary Contacts Adjustment 7 LOOSEN HARDWARE FOR VERTICAL ADJUSTMENT AUXILIARY OOSEN HARDWARE FOR HORIZONTAL ADJUSTMENT BRACKET DETAIL E Earthing Switch Auxiliary Contacts Inspection Operation of electrical auxiliaries must be validated on a yearly basis IMPORTANT Auxiliaries must be tested electrically with control p
16. Selecting Power Source The selector switch on the Control Switch assembly can either be turned from Normal Off Test Test To test the starter without medium voltage present Normal To operate the starter in normal position Off To prevent the starter from operation Connecting Test Power 1 Disconnect and lock out all feeder power supplies to the starter 2 Rack the contactor cart to the test withdrawn position 3 Iftheunit is equipped with power factor correction capacitors stored energy must be dissipated before entering the power cell or dissipate the power using the following procedure a Verify the contactor cart is in test withdrawn position b Open the LV door c Plug the appropriate power supply 120 or 230V into the auxiliary power receptacle on the control panel d Move the control switch to the Test position p e Electrically operate the contactor by pushing the Start button on the unit or at a remote location f Disengage the contactor and turn the control switch to the Normal position Disconnect the external power supply g Complete the Power Lockout procedure 4 Usea 120V power cord and plug into the 120V plug on the Control Switch Assembly see Figure 6 on page 20 to test the starter without Medium Voltage being present in the starter Racking Contactor Cart change the condition of the contactor cart e the main cabinet door must be closed e earthing switch must be open e thecontactor status m
17. front of the cart will slide forward and lock the end of the racking screw locking in the same time the cart position The tool access flap must cover the opening after the speed wrench is redrawn Earthing Switch Operation IMPORTANT Before opening the earthing switch ensure e contactor cart is in the withdrawn test position and the door is closed and latched Open Earthing Switch 1 Insert the earthing switch tool at the end of the earthing switch shaft Figure 10 Figure 10 Open Earthing Switch Earthing Switch Shaft f Earthing Switch Tool 2 Rotate the earthing switch tool approximately 65 clockwise until the switch is completely open Close Earthing Switch IMPORTANT Before closing the earthing switch ensure e contactor cart is in test withdrawn position if the cart is in the operating position the earthing switch will not close and door is closed and latched Rockwell Automation Publication 7712 UM001C EN P June 2013 Equipment Operation Chapter 4 1 Insert the earthing switch tool at the end of the earthing switch shaft Figure 11 Figure 11 Close Earthing Switch Earthing Switch Shaft Earthing Switch Tool 2 Rotate the earthing switch tool approximately 60 counterclockwise until the switch is completely closed Earthing Switch Positioning Indicators arrow at the end of the earthing switch shaft indicates the state of the s
18. qe 19 Preliminary Checks uoo ad sce ela NE EDD es 19 Testing Contactar 20 Mest Power Suppi 21 ODeratilig o tete Sob Sio dois 21 Chapter 4 Power Lockout Procedure 27 OBEN 27 Power Down Low Voltage Section 27 BEGINS POWT OMIS RENE 28 Connecting Test Se AES Se tae oss nn 28 Racking Contactor Cart nee 28 Operation of Motor Controller 30 Farthing seit douce 30 Farthing Switch Positioning Indicators 31 ARR E pM tud Ms Pt a aes 32 Connect EN PUBS ed oies 32 Shutter Position Indicator 33 Rockwell Automation Publication 7712 UM001C EN P June 2013 3 Table of Contents Maintenance Spare Parts Certification Data Troubleshooting Mechanical Interlock for 7712 and PowerFlex 7000 Drive Chapter 5 Required nd 7 37 Maintenance of Industrial Control Equipment 37 Periodic TNS PECON enr 37 PP Ei dies 38 Operating ERR ERU t Ease Suis 38 PELLIT 38 en Oe 38 Piot Lights 2 wena n
19. shutter is not completely shut off or the earthing switch is not completely closed 20 Rockwell Automation Publication 7712 UM001C EN P June 2013 Start up Procedure Chapter 3 When performing any actions during testing the plug connected to the contactor cart must be firmly connected If the plug is not correctly connected the contactor cart will not operate reliably Test Power Supply ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death Verify that the contactor cart has been racked to its test withdrawn position 1 Open thelow voltage door 2 Plug the appropriate power supply into the test power receptacle 3 Move the control switch to test position so that the control circuit is powered by the test power supply After the tests disengage the contactor and move the control switch to the normal position Disconnect the external power supply 5 Complete the Power Lockout procedure IMPORTANT 115 not possible to use any test power supply after the contactor cart has been racked out of the test position set of auxiliary switches on the contactor cart prevent the MV parts from being back fed by any low voltage power supply through the CPT Operating Position ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death
20. 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 EC 60470 High voltage Alternating Current Contactors and Contactor Based Motor Starters e EC 62271 100 High voltage Switchgear and Control Gear Circuit Breakers EC 62271 1 High voltage Switchgear and Control Gear Common Specifications e EC 62271 200 High voltage Switchgear and Control Gear EC 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 Rockwell Automation Publication 7712 UM001C EN P June 2013 7 Preface Co ntroller Unit A nameplate is attached to the front door of the structure see Figure 1 Refer to Identific ation the nameplate for information such as series number section number enclosure type unit ratings and bus ratings Figure 1 Typical Structure Nameplate HIGH VOLTAGE INDUSTRIAL CONTROL EQUIPMENT INSULATING LEVEL LIGHTNING IMPULSE VOLTAGE FREQUENCY BUSBAR CURRENT SHORT TIME WITHSTAND CURRENT DURATION OF SHORT CIRCUIT ALTITUDE CLASS M MADE IN CANADA ENCLOSURE 25 08 nameplate is also found in the low voltage compartment see Figure 2 w
21. 01C EN P June 2013 Safety Interlock and Accessibility Requirements Chapter 2 Opening the Medium Voltage Door components To avoid shock hazards complete the Power Lockout procedure on page 27 before servicing the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION This procedure requires contact with medium voltage IMPORTANT Failure to open the medium voltage door in the proper manner could damage or jam the mechanical door interlocks This may result in the mechanical interlocks not operating as intended and may result in the door becoming jammed in the closed position TIP This procedure is contained on a label on the door of the controller for your reference 1 Electrically open the contactor by pressing the STOP button on the controller or at the remote control location 2 Move the contactor cart to the isolated position 3 Ensure the earthing switch is closed page 30 4 Liftthe release handle and swing the door to the left Close and secure the medium voltage door in the reverse order of opening Rockwell Automation Publication 7712 UM001C EN P June 2013 17 Chapter 2 18 Safety Interlock and Accessibility Requirements Figure 5 Enclosure Compartments ArecShield Plenum Low Voltage Door Controller STOP Button 110 Medium Voltage Door Release Handle Ea
22. 10 QS TK XN 7 has oO T a 1 12 Start up Procedure 0012 1D 08 XN 6 0016 18 PN AXVI 10012 32 0012 3 0012 3D REM XC XN QS TK BT MV QS TK XC_XN XC XC 1 8 18 NU 19 8 10 00x 7 220 VAC L GND eee QB CTRLA BONE 89 XC XN 81 XC XC 81 e c 8 S o No Es S S V 0012 4 KI IVM DR 1 1 2 _ XC XC 1 QB CTRLB 1 0018 7A FO_SSOL 9 the 3 4 0007 5 HAND T 0012 4B DR 1 1 REM OFF gt SG STP m XC_XC KG_REM STOP XC XC AUTO KI IVM 0007 6C gt EE E A 1 9 HAND OFF AUTO 0009 14 lt 0009 84 lt Rockwell Automation Publication 7712 UM001C EN P June 2013 Start up Procedure Chapter 3 1 00071 12 4 0007 8E 0012 1D 0009 7B 0012 1D NEC XC XC 05 QC M QS TK XC XC Lo z H Lo 0013 6A 0013 6B 0013 6B 0013 6C R3 Le R4 T2 0010 6E RS L3 6 0010 3E 0012 1D 0009 7B 0012 1D XC XC XC XC 05 TK QC QS TK XC XC PL FF 1 JM_19 Ho Fe 7 So B 0012 7B XC_XC FO_SSOL FRIP XC_XC PL_TRP 14 97 Ed 98 50 1 e 0009 7B 0012 1D 0012
23. 1C EN P June 2013 Maintenance Chapter 5 Pilot Lights Replace any burned out lamps or damaged lenses Photoelectric Switches T he lenses of photoelectric switches require periodic cleaning with a soft dry cloth Reflective devices used in conjunction with photoelectric switches also require periodic cleaning Do not use solvents or cleaning agents on the lenses or reflectors Replace any damaged lenses and reflectors Annual Maintenance Task Page Requirements Remove Contactor Cart 39 Remove and Replace Fuses 42 Contactor Cart Maintenance 44 Replace the Vacuum Bottles 44 Calibrate the Overtravel and Contact Gap 47 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 Remove Contactor Cart To replace the fuses the contactor cart must be removed from the cabinet Below the contactor cart door are two pin holes that receive the pins on the service cart 1 Align the service cart with the enclosure ensuring the contactor cart platform is the same elevation as the service cart rails 2 Move the service cart to the cabinet and insert the cart pins into the enclosure Figure 19 ATTENTION A locking key on the front of the cart must be engaged to ensure the s
24. 4B 0012 3D XP M 15 QC M 05 TK KI IVM 0012 5 5 AG in as 0009 3B 0008 3B 0013 3 1 0008 3C 1 0013 3B 11 0004 6A Le 0004 6B L3 0004 6B 0012 4B PS _CC_IV_M_LOC CC IV M KI_IVM 4 1 2 EC ac 0016 1B j 4REM PN AXVI PIENE T x I E TT CREER c Mr cix c E m aC MN CR CAE 1 240VAC 50 60Hz 11 12 e xc B gt _ QB CSH XC XC EH Xt xc CSH_L1 1 CSH_L1A 1 CSH_L1B 1 CSH_L2A 4 d 00161 IREM AXVI 4 eee d em tees TT TT TT 7840 S0 60Hz di N 74 E dnx C C MC 71 240 50 60Hz 1 19 XC JM 18 0008 7 0008 7C REM xc xc QB MSH QC MSH XC XC EH XC XC QC MSH xc xc SH L1d 1 2 L1A R5 L3 R6 T3 MSH_L1B 07 _MSH_C2B R3 L8 _ R4 T2 MSH_L2A 4 MSH_L2 0016 1B 1 PN AXVI 0002 1 LDC XM V MAD FF VREF Xc XC pg EE EE Le SEHE poe ge XC XC XC XC VBO VE PI_LVREF p A B JM 7 1 LOC XC XC XC XC pc E CO Co PN TSBI 0012 6B FO_SSOL 42 L1 XM TSB I CT INPUT 6 47A 0005 2B
25. Bulletin 771 Allen Bradley OneGear 7 2 kV Motor Controller Full voltage Non reversing Publication Number 7712 UM001C EN P i RA baa eye YE m d bi i 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
26. IET 39 Annual Maintenance Requirements EA Rd 39 Remove Contactor Catt ws heh hee da Gees 39 Remove and Replace Fuses 42 Contactor Cart Maintenances PERI AREE CEPI REA 44 Replace the SA a 44 Calibrate the Overtravel and Contact 47 Lubricate the Contactor Cart 50 Farthing Switch Maintenances inn ed etx eo b mea Sani 53 Inspect and Lubricate Earthing Switch Mechanism 53 Ground Connection 55 Toggle Assembly Inspection ude Rire ie 55 Farthing Switch Auxiliary Maintenance 56 Auxiliary Contacts 56 Auxiliary Contacts Adjustment 56 Farthing Switch Auxiliary Contacts 27 Appendix Typical Bulletin 7712 Parts 59 Appendix B Test Sumindty 61 High Voltage Controlgear sn ace 61 Appendix C Door Interlock Circumvention 63 Farthing Switch Door Loeb em b anos 63 Door to Isolation 5 65 Appendix D Cee a eee eer E 69 KD RARE
27. LV control Short time and peak withstand tests Main bus 50 kA 3 s Ground bus 60 kA 3 s Vertical bus 50 kA 0 3 s Earthing switch 31 5 kA Mechanical Operation Tests Earthswitch and starter 5000 Interlock 25C0 Earthswitch Class M1 2000 Overload Current Tests 6 15 2 4 kA 30 Table 3 Test reports verifying ratings assigned by the manufacturer Test According to Standard Clause Test Reports Issued By 20969 B 26 Powertech 07 06 2011 ER 059 2012 Rockwell Automation IEC 82271 1 6 2 10 ER 004 2012 Rockwell Automation IEC 60470 6 4 IEC 62271 1 6 4 20969 B 26 07 06 2011 Powertech 60470 6 5 1 62271 1 6 5 Table 3 11071 C 03 29 31 2011 KEMA IEC 6470 6 101 1 20969 A 26 Powertech 07 06 2011 11069 B 03 28 2011 KEMA 20158 1 08 16 18 2010 Powertech 20969 D 26 07 08 2011 Powertech IEC 62271 102 6 101 EP 2485R Rockwell Automation HCL IEC 62271 200 6 6b IEC 6470 6 101 2 ER 069 2012 Rockwell Automation IEC 6470 6 101 3 ER 069 2012 Rockwell Automation IEC 62271 102 4 106 6 102 ER 110 2011 Rockwell Automation IEC 6470 6 102 7 20969 B 26 Powertech 07 06 2011 20969 B 26 07 06 2011 IEC 60470 6 6 IEC 6227101 6 6 2 IEC 562271 200 Rated making and breaking capacity tests AC4 Fused starter making 4 kA 100C Table 10 12 kV TRV Fused starter breaking 3 2k250 80 A 250 Table 10 12kV TRV IEC 62271 1 6 102 4 20969 A 26 Powertech 07 06 2011 IEC 62271 1 6 102 5 20969 A 26 07 06 2011
28. 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 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 wi
29. Product Satisfaction Return Rockwell Automation tests all of its products to help 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 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 Solutions 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 Die
30. TCH POSITION OF TRUCK MV TRANSFORMER VOLTAGE CONTROL POWER INTELLIVAC MAIN CONTACTER MV MTR MOTOR AC INDUCTION PI LVCSH PRESENTING INFORMATION CUSTOMER LOW VOLTAGE SUPPLY FOR CABINET SPACE HEATER CIRCUIT PI LVMSH PRESENTING INFORMATION CUSTOMER LOW VOLTAGE SUPPLY FOR MOTOR SPACE HEATER CIRCUIT 1 LVT PRESENTING INFORMATION CUSTOMER LOW VOLTAGE SUPPLY FOR TEST CIRCUIT PI VREF PRESENTING INFORMATION CUSTOMER VOLTAGE REFERENCE SUPPLY PL_OFF PILOT LIGHT OFF PL_RUN PILOT LIGHT RUN PL_TRP PILOT LIGHT TRIP AXVI WARNING LABEL MORE THAT ONE LIVE CIRCUIT L1 Le L3 GND 00121C WB MP 0009 7B 0012 3 05 TK QC M 05 TK Li L1 Ti Ti n SEU 1 1 gt 0005 1 _ 1 BV_CPTI 0012 1D 0006 2 t 2 Lem 0004 8 gt BC_CT en Te 2 0004 8 gt i 0004 8B E gt 1 42 1 44 lt 46 47 lt j lt j 0012 1D 0012 1D 0012 1D 0012 1D T3 T3 0005 1 T3 GND GND GND PE 0014 3 0014 3B 40014 3 0014 3 0014 3D 0014 3D 0014 3E 0014 3E T QE ES L1 1 GND PE Rockwell Automation Publication 7712 UM001C EN P June 2013 23 Chapter 3 0012 3B 24 4 2 700124
31. al connections at the rear of the contactor and replace eleven M8 bolts to install the fuse mounting mold Lubricate the Contactor Cart 1 Grease the contactor interlock rod using Aeroshell No 7 Figure 34 Figure 34 Lubricate interlock rod APPLY GREASE INTERLOCK ROD DETAIL A SCALE 1000 50 Rockwell Automation Publication 7712 UM001C EN P June 2013 Maintenance Chapter 5 2 Grease the front assembly guide rod on both side of the cart using Aeroshell No 7 Figure 35 Figure 35 Lubricate guide rod APPLY GREASE TO THE GUIDE ROD DETAIL SCALE 1000 3 Grease door to cart interlock sliding bracket Using Aeroshell No 7 Figure 36 Figure 36 Lubricate the sliding bracket APPLY GREASE TO THE SLIDING BRACKET DETAIL SCALE 2 000 Rockwell Automation Publication 7712 UM001C EN P June 2013 51 Chapter5 Maintenance Grease the tulip fingers Using Nye lubricant Nyogel 759G Figure 37 Figure 37 Lubricate the Tulip Fingers APPLY NYOGEL TO ALL TULIP FINGER APPLY NYOGEL TO ALL TULIP FINGER 52 Rockwell Automation Publication 7712 UM001C EN P June 2013 Maintenance Chapter 5 Earthing Switch Inspect and Lubricate Earthing Switch Mechanism Maintenance 1 Inspect the lubrication between the ground stab and the earthing switch blades 2 Apply Nye lubricant Nyogel 759G to the ground stab Figure 38 as needed Figure 38 Lubricate Earthing Switch Mec
32. and PowerFlex 7000 Drive Notes 72 Rockwell Automation Publication 7712 UM001C EN P June 2013 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 or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New
33. er frequency withstand voltage Rated frequency Rated normal current busbar Rated normal current Rated short time withstand current Rated peak withstand current Rated duration of short circuit bus bar Rated duration of short circuit vertical bus bar Arc Hash classification Appendix B 7 2kV 60 kV 20 kV 50 60 Hz 2000 A 330A 50 kA rms 125 kA 3s 0 35100 31 5 15 AFLR The Controlgear starter unit provided with vacuum contactor model 7712 and components have been tested per following applicable standards See Table 3 for test parameters and test reports IEC 60470 High voltage alternating current contactors and contactor based motor starters IEC 62271 1 High voltage switchgear control gear Part 1 Common specifications e IEC 62271 102 High voltage switchgear and control gear Part 102 Alternating current disconnectors and earthing switches e IEC 62271 200 High voltage switchgear and control gear Part 200 AC metal enclosed switchgear and control gear for rated voltages above 1 kV and up to and including 52 kV Rockwell Automation Publication 7712 UM001C EN P June 2013 61 AppendixB Certification Data Performances Dielectric Tests Power frequency withstand 20 kV 1 min Impulse 15 60 kV 1 2 50 us LV control 2 kV 1 min Measurement of Circuit Resistance Temperature Rise Test 7712 Starter 250 Verification of operating limits 10 1596
34. ervice cart does not roll when removing the contactor cart Rockwell Automation Publication 7712 UM001C EN P June 2013 39 Chapter 5 40 Maintenance Figure 19 Securing Service Cart to the front of the Cabinet Aligning Holes for Tapered Pin Latching Bracket Lever Handle 3 Insert cart latch key into the cart latch disengagement and turn the key approximately a quarter turn clockwise Figure 20 Ensure latch is disengaged from the rail Figure 20 Contactor Cart Latch Disengage cart latch Rockwell Automation Publication 7712 UM001C EN P June 2013 Maintenance Chapter 5 4 Keeping the key engaged grasp the handle Figure 21 and remove the contactor cart from the enclosure onto the service cart Figure 21 Contactor Cart Removal Handle 5 Once the contactor cart is extracted from the cabinet secure the cart using the latch and the service cart wheels to prevent movement Figure 22 Contactor Cart removed from enclosure SECURED WITH LATCH DETAIL A Rockwell Automation Publication 7712 UM001C EN P June 2013 41 Chapter5 Maintenance Remove and Replace Fuses 1 Unscrew eight M8 bolts to remove the red Glastic cover Figure 23 Figure 23 Remove Glastic cover M8 BOLT GLASTIC COVER M8 BOLT r j 42 Rockwell Automation Pub
35. gem 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 7712 UM001C EN P June 2013 Supersedes Publication 7712 UM001B EN P September 2012 Copyright O 2013 Rockwell Automation Inc All rights reserved Printed in Canada
36. hanism GROUND STAB ARTHING SWITCF BLADES DETAIL A SEE DETAIL A Rockwell Automation Publication 7712 UM001C EN P June 2013 53 Chapter5 Maintenance 3 Grease Aeroshell No 7 the main shaft mating surface of cam and gear mating surface of shaft and gear housing Figure 39 Figure 39 Lubricate Earthing Switch Mechanism REASE THE MAIN SHAFT SEE DETAIL DETAIL SCALE 1000 lt DETAIL SCALE 1000 REASE ALL THE MOVING PARTS 54 Rockwell Automation Publication 7712 UM001C EN P June 2013 Maintenance Chapter 5 Ground Connection Inspection 1 Inspect the torque seal for the ground connection 2 Ifseal is broken apply 11 14 5 Nem to secure and apply torque seal Figure 40 Ground Connection Inspection CONNECTION DETAIL B ROUND CONNECTION Toggle Assembly Inspection 1 Inspect the torque seal of the shoulder bolt for the toggle assembly 2 Ifseal is broken apply 4 4 Ibeft 6 0 Nem to secure the shoulder bolt and apply torque seal Figure 41 Toggle Assembly Inspection TOGGLE ASSEMBLY DETAIL C Rockwell Automation Publication 7712 UM001C EN P June 2013 55 Chapter5 Maintenance Earthing Switch Auxiliary Auxiliary Contacts Replacement Maintenance 1 Remove all the wire connected to the auxiliary and mark each wire for rewiring 2 Remove the auxiliary mounting hardware M3 5 hex nut washer and cheese head screw 3
37. initial startup and after any maintenance is performed This test power supply should be within the IntelliVAC Vacuum Contactor Controller specifications 1503 UM053_ EN P CPT on the cart is not energized when the contactor is in the test withdrawn position ATTENTION Always perform the power lockout procedure before servicing equipment Failure to do so may result in severe burns injury or death test position To avoid potential of shock hazards disconnect and lockout incoming power before proceeding Failure to lockout incoming power will result in a live bus cell Once the shutter between power cell and bus cell is open it may cause severe burns injury or death Rockwell Automation does not assume any responsibility for injuries to personnel who have not completed the following safety procedure prior to servicing the equipment ATTENTION The following procedure requires racking the contactor cart to its Connect an appropriate power cord to the power receptacle in the low voltage compartment Figure Figure 6 Location of Control Switch and Auxiliary Power Receptacle Control Switch Auxiliary Power Receptacle It is possible to open the MV door while the cart is in the test withdrawn position and the earthing switch is closed The shutter behind the cart in the MV compartment should be closed under this situation This should be confirmed after opening the MV door If the MV door cannot be opened smoothly the
38. ith specific unit and motor application information Figure 2 Typical Unit Motor Nameplate HIGH VOLTAGE INDUSTRIAL N CONTROL EQUIPMENT C S uum CATALOG UNIT SERIES 3PH Hz kv BIL 5 7 EE INTERRUPTING CAPACITY CLASS EZ FUSED i VOLTS Pouvoir DE COUPURE CLASSE EZ AVEC FUSIBLES MVA COW TROL MOTOR MOTEUR EXCITATION VOLTS SYNCHRONOUS STARTER ONLY i DEMARREUR SYNCHRONE SEULEMENT SERVICE FACTOR FACTEUR DE MADE CANADA FABRIQUE AU CANADA a 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 8 Rockwell Automation Publication 7712 UM001C EN P June 2013 Preface Additional Resources The following table lists publications that provide related information Resource Description OneGear 7 2 kV Motor Controller Full voltage Provides technical specifications and Non reversing and Incoming Line Unit Technical overview of the features and functions provided Data 7712 10001 by the controller and in coming line unit OneGear SMC Flex Solid State Motor Controller Provides a outline for the overall fabrication 10 15 kV Specification Guide 7760 SR001 performance and functional requirements for a medium voltage
39. lication 7712 UM001C EN P June 2013 Maintenance Chapter 5 2 Replace each fuse by removing four M10 nuts Figure 24 Figure 24 Fuse Removal USE MIO NUT MONA T 3 Replace the M10 nuts and reattach the Glastic cover using the 8 bolts Rockwell Automation Publication 7712 UM001C EN P June 2013 43 Chapter5 Maintenance Contactor Cart Maintenance Replace the Vacuum Bottles Under normal conditions vacuum bottles will last at least 1 000 000 operations however all three bottles must be replaced if any wear indicator line Figure 25 reaches the bearing regardless of the number of operations Figure 25 Vacuum bottle wear indicator Vacuum Bottle Wear indicator line on operating shaft access the vacuum bottles the glastic cover must be removed See page 42 1 Unscrew eleven 8 bolts to remove the fuse mounting mold Figure 26 Figure 26 Remove Fuse Mounting Mold FUSE MOUNTING MOLD 44 Rockwell Automation Publication 7712 UM001C EN P June 2013 Maintenance Chapter 5 TIP Before removing the vacuum bottles mark the installed bottles clearly to avoid confusing them with the replacement vacuum bottles 2 Remove the lower terminal connections at the rear of the contactor Figure 27 Figure 27 Remove lower terminal connections TERMINAL CONNEC TION 3 Remove the load terminal retaining bolt at the rear of the contactor and the vacuum bottle mounting bolt at the t
40. ll 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 gt gt gt Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Preface General Information Safety Interlock and Accessibility Requirements Start up Procedure Equipment Operation Table of Contents Introductio s ns sn be Red ida bie dust fud 7 Who Should Use this Manual eere y Service and Maintenance 7 ArcShield Arc Flash Resistant Enclosure Features 7 Controller Unit Identification 8 Additional Resources sd RI DLE Cb e Rd 9 Chapter 1 Environmental Conditions 11 Product Dimensions and Weights 12 ArcShield Components Installation Requirements 13 Chapter 2 Recommended Torque Values 15 Open the Enclosure cocer e tte PERPE A VITRE EE eS 16 Opening the Low Voltage 16 Opening the Medium Voltage Door 17 Chapter 3 COntactOr INS DeCtO lis EU ded
41. ned Test the Contactor Contactor must be in the withdrawn test position 1 Connect the appropriate external power supply 120V or 230V AC to the test receptacle in the control panel Turn the selector switch to the TEST position let the contactor close during the test procedure Do not jumper any contactor cart position auxiliary contacts Using jumpers for these contacts can result in equipment damage or injury to personnel ATTENTION Some control circuit configurations may require control jumpers to 2 Electrically operate the contactor several times Inspect the armature plate to verify that it fully contacts the magnetic cores Contactor should close when close command is given IntelliVAC module will detect and display fault if a problem exists 3 Turn the selector switch to the OFF position and disconnect the external power supply Inspect the area around the magnetic cores of the vacuum contactor and remove any metal filings if present This type of debris is attracted to the coil once it is energized and could prevent the contactor from closing properly Rockwell Automation Publication 7712 UM001C EN P June 2013 Start up Procedure Chapter 3 Figure 7 Typical Wiring Diagram Electrically Held Vacuum Contactor with IntelliVAC Control DEVICE DESIGNATIONS I BC CT BH BV_CPT1 DEVICE DESCRIPTION TRANSFORMER CURRENT TEMPERATURE ACTUATED SWITCH CABINET SPACE HEATER SWI
42. op of the contactor Figure 28 Figure 28 Mounting and Retaining bolt removal VACUME BOTTLE MOUNTING LOAD TERMINAL RETAINING BOLT DETAIL A AND HARDWARE SCALE 0 500 Rockwell Automation Publication 7712 UM001C EN P June 2013 45 Chapter5 Maintenance 46 4 Loosen the load terminal nut on one bottle assembly tilt the bottle forward out of the contactor and unscrew it from the insulator stud Figure 29 Remove bottle braces and repeat for the two remaining bottles The load terminals insulators and overtravel spring assemblies remain in the Contactor Figure 29 Remove Vacuum Bottles NSULATOR STUD OAD TERMINAL NUT 5 Install a new bottle by tilting an insulator forward and threading the bottle onto the stud The threads must align to prevent cross threading Thread the bottle down leaving a gap of approximately 4 82 mm 0 25 mm 0 190 in 0 01 in between the top of the bottle and the bottom surface of the line terminal Figure 30 Use an appropriate measuring tool to set the gap This gap is precisely calibrated later in this section The wear indicator line on the bottom of the bottle s movable shaft must be visible from the front of the contactor Repeat this step for the remaining two bottles Rockwell Automation Publication 7712 UM001C EN P June 2013 Maintenance Chapter 5 Figure 30 Establishing Contact Gap 0 190 in 4 82 mm Vacuum Bottles Insulator 6 Install
43. ower off Refer to the unit electrical drawing to determine the test locations on the terminals located in the low voltage compartment Rockwell Automation Publication 7712 UM001C EN P June 2013 57 Chapter5 Maintenance Notes 58 Rockwell Automation Publication 7712 UM001C EN P June 2013 Typical Bulletin 7712 Parts Spare Parts numbers are available Part Number 1503VC BMCS 80174 902 14 R Power Fuses Primary fuses CPT Contactor cart 80158 357 51 80026 795 01 PN 125239 Contactor Parts 81057 496 52 80026 230 01 28325 042 01 80153 567 01 80153 552 02 80158 743 52 Description Intellivac Intellivac internal fuse ENG Data ENG Data ENG Data Nyogel 7596 lubricant Contactor cart auxiliary contact Earthing switch auxiliary contact Vacuum bottles set of 3 Main contactor coils 2 required Coil retaining ring Return spring Armature plate Auxiliary assembly Rockwell Automation Publication 7712 UM001C EN P June 2013 Appendix Recommended Stocking Quantity w N N NYO Contact your local Rockwell Automation office to ensure that the following part 59 AppendixA Parts Notes 60 Rockwell Automation Publication 7712 UM001C EN P June 2013 Test Summary Certification Data High Voltage Controlgear Starter Model 7712 Rating Rated Voltage Rated lightning impulse withstand voltage Rated pow
44. reduced voltage solid state motor controller RVSS for use with induction and brush type synchronous motors How to Successfully Apply Medium Voltage Soft Provides guidelines for selecting and applying otarters 1560E WP023 medium voltage starters SMC Flex Controller with Pump Control Provides guidelines for applying the SMC Flex 150 WP003 controller with pump control General Handling Procedures for Medium Provides basic information on installation site Voltage Controllers Quick Start 05050 preparation Medium Voltage Contactor 400A User Manual Provides general guidelines for the application 1502 0 052 EN P installation and maintenance of 400A medium voltage vacuum contactors 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 Rockwell Automation Publication 7712 UM001C EN P June 2013 9 Preface Notes 10 Rockwell Automation Publication 7712 UM001C EN P June 2013 Environmental Conditions Chapter General Information The chapter contains information essential for proper installation of the OneGear 7 2 kV Bulletin 7712 medium voltage controller Read all information in this chapter before beginning the controller installation in Chapter 2 The standard controller is rated to operate in an ambient temperature range of 0 40 32
45. rthing Switch Rockwell Automation Publication 7712 UM001C EN P June 2013 Contactor Inspection Preliminary Checks Chapter 3 Start up Procedure See Chapter 2 in Medium Voltage Contactor 400A Publication 1502 UM050 EN P or 1502 UM052_ EN P for information on pre energization inspection vacuum bottle integrity test and insulation resistance test 1 Contactor current and voltage ratings are correct for the attached load Control voltage is correct 1 Protective relay settings are correct Heater elements if provided in the overload relay are secure and undamaged J All equipment is correctly grounded External power and control connections match the electrical diagrams J All hardware is correctly reinstalled and torqued to the correct specification see Recommended Torque Values on page 15 L1 All barriers are replaced and in the correct position All fuses are the correct class type and rating L1 Mechanical interlocks function properly 4 Contactor cart functions properly Earthing switch functions properly 4 Microprocessor based protection relay is correctly programmed J Enclosure interior is free from dirt metal chips loose hardware and or tools Rockwell Automation Publication 7712 UM001C EN P June 2013 19 Chapter3 Start up Procedure Testing Contactor Operation The contactor must be tested without any applied medium voltage This should be done for
46. talling line and load cables or enclosure access panels use the following Values torque specifications Table 2 Hardware Torque Specifications Hardware Size Tightening Torque Required 1 4 in M6 6 ft lb 8 Nem 5 16 in M8 12 ft lb 16 Nem 3 8 in M10 20 ftelb 22 Nem 1 2 in M14 48 ft lb 65 Nem Rockwell Automation recommends the use of the appropriate tools to successfully complete the maintenance procedures on these components If you cannot obtain such tools contact your area Rockwell Automation sales office for assistance ATTENTION Some components of this product incorporate Imperial hardware Rockwell Automation Publication 7712 UM001C EN P June 2013 15 Chapter2 Safety Interlock and Accessibility Requirements Open the Enclosure Doors The controller contains separate low voltage and medium voltage compartments IMPORTANT Themedium voltage door is interlocked to the isolation shutter and or the earthing switch The low voltage panel compartment and power cell are separated by an isolation barrier Opening the Low Voltage Door Using an Allen key turn the two 1 4 turn fasteners 90 clockwise and swing the door to the left Close and secure the low voltage door in the reverse order of opening Figure 4 Enclosure Compartments ArecShield Plenum 1 4 turn Fasteners Low Voltage Door Medium Voltage Door E 16 Rockwell Automation Publication 7712 UM0
47. the load terminal retaining bolts at the rear of the contactor Leave the load terminal nuts loose for fine adjustment of the overtravel and contact gap 7 Install the vacuum bottle mounting bolts at the top of the contactor reverse of step 3 Ensure the threads align to prevent cross threading Hold the bottle to prevent it from turning while torquing the vacuum bottle mounting bolts Calibrate the Overtravel and Contact Gap 1 Close the contactor by using the TEST control circuit in the starter Insert a feeler gauge of 0 065 in 1 65 mm into the overtravel gap of a bottle assembly Figure 31 2 Rotate the insulator until the gap is correct Repeat for the two remaining bottles IMPORTANT This establishes synchronization between the three vacuum bottles Rockwell Automation Publication 7712 UM001C EN P June 2013 47 Chapter5 Maintenance Figure 31 Establishing Overtravel Overtravel Gap 0 065 in 1 65 mm 3 Measure dimension 1 for all three bottles with the contactor still energized Figure 32 4 De energize drop out the contactor and measure dimension A2 for all three bottles The contact gap is the difference of A2 minus A1 Record the gap for all three bottles 48 Rockwell Automation Publication 7712 UM001C EN P June 2013 Maintenance Chapter 5 Figure 32 Measuring Contact Gap IMPORTANT The contact gaps must be synchronized within 0 02 in 0 5 mm If the gaps are not synchronized
48. trol and Systems Equipment for general guidelines for setting up a periodic maintenance program Some specific guidelines for Rockwell Automation products are listed below Rockwell Automation Publication 7712 UM001C EN P June 2013 37 Chapter 5 38 Maintenance Contamination If inspection reveals that dust dirt moisture or other contamination has reached the control equipment the cause must be eliminated This could indicate an incorrectly selected or ineffective enclosure unsealed enclosure openings conduit or other or incorrect operating procedures Replace any improperly selected enclosure with one that is suitable for the environmental conditions refer to NEMA Standard No 250 Enclosures for Electrical Equipment for enclosure type descriptions and test criteria Replace any damaged or cracked elastomer seals and repair or replace any other damaged or malfunctioning parts e g hinges fasteners etc Dirty wet or contaminated control devices must be replaced unless they can be cleaned effectively by vacuuming or wiping Compressed air is not recommended for cleaning because it may displace dirt dust or debris into other parts or equipment or damage delicate parts Operating Mechanisms Check for proper functioning and freedom from sticking or binding Replace any broken deformed or badly wont parts or assemblies according to individual product renewal parts lists Check for and retighten securely any loose fasteners
49. uipment PPE per local codes or regulations Failure to do so my result in severe burns injury or death IMPORTANT Before circumventing door to isolation shutter interlock The contactor cart must be fully withdrawn Earthing switch must be closed 1 Open the LV door 2 Remove the four M6 bolts located on the compartment floor Figure 45 Figure 45 Circumvent Door to Isolation Shutter Removing the bolts REMOVE THESE M6 BOLTS DETAIL SCALE 0 500 Rockwell Automation Publication 7712 UM001C EN P June 2013 65 AppendixC Troubleshooting 66 3 Insert a flat head screw driver through the hole on the LV compartment floor and push the lever mounting plate left to release the interlock hook located at the door Figure 46 Figure 46 Circumvent Door to Isolation Shutter SE A SCREW DRIVER TO PUSH LEVER MOUNTING TO LEFT DETAIL SCALE 0500 4 Reverse steps 1 through 2 to reassemble the lever arm to roof of the MV compartment Rockwell Automation Publication 7712 UM001C EN P June 2013 Incomer 7791 Appendix D Mechanical Interlock for 7712 and PowerFlex 7000 Drive Figure 47 PowerFlex drive with bypass using OneGear 7712 controllers Bypass 7712 MB Drive Input 7712 D VFD Figure 48 Transfer Block Rockwell Automation Publication 7712 UM001C EN P June 2013 Drive Output 7712 DO Output Cables 7791 F
50. unit 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 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 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
51. ust read OPEN Rockwell Automation only Failure to do so can cause damage to equipment ATTENTION The contactor cart must be racked out using tools supplied by personal injury or death 28 Rockwell Automation Publication 7712 UM001C EN P June 2013 Equipment Operation Chapter 4 1 Open the tool access flap on the door using a flat screw driver Figure 8 Figure 8 Open Tool Access Flap SE FLAT SCREW DRIVER TO OPEN FLAP ARTHING SWITCH IN OPEN POSITION 2 Rotate the cover counterclockwise exposing the square end of the cart screw 3 Insert the speed wrench and push toward rear of cabinet The wrench must be pushed toward rear of cabinet to unlock the cart raking screw The pressure must be maintained for the entire cart insertion withdraw operation Ifcart is in test withdrawn position rotate the speed wrench clockwise to insert the cart Figure 9 From test to service position requires 11 complete rotations a mechanism stops the screw rotation after 11 turns The last turns require more torque to overcome the cart engagement resistance Figure 9 Position Speed Wrench REQUIRES 11 COMPLETE ROTATIONS TO INSERT CART Rockwell Automation Publication 7712 UM001C EN P June 2013 29 Chapter4 Equipment Operation Operation of Motor Controller 30 5 Withdraw speed wrench tool IMPORTANT The tool must be withdrawn from the mechanism without any rotation This ensures the locking plate in the
52. ut and Drive Output doors Turn keys to unlock carts Rack in Drive Input and Drive Output carts Run drive To Run Bypass e Open Drive Input contactor and Drive Output contactor Note Use electrical interlock to prevent Bypass and Drive Output contactors being closed at the same time for manual bypass not synchronous Optional withdraw Drive Output cart with electrical interlock to Bypass Rack in Bypass cart Rockwell Automation Publication 7712 UM001C EN P June 2013 Mechanical Interlock for 7712 and PowerFlex 7000 Drive Appendix D e Start motor in Bypass The Drive can now be tested in DC mode with Drive Input contactor closed and Drive Output contactor open To open Drive for Service Open Drive Input contactor withdraw cart e Lock open remove KA and KB keys and place them in transfer block Remove KC keys use to open doors To open Output Cabinet Open Bypass contactor and withdraw cart e Close earth switch Lock closed remove KD key e Put KD and KC keys in door to open Interlock Operation Sequence Two Motors In order to operate M1 and M2 motors we use the interlock sequence described for one motor configuration The only difference is that the Output Cables Cabinets do not require a KC Key o open the Output Cables Cabinet the appropriate earthing switch interlock key is required Rockwell Automation Publication 7712 UM001C EN P June 2013 71 Appendix D Mechanical Interlock for 7712
53. witch Depending on the position of the earthing switch the arrow points to the corresponding decal located on the door Earthing switch OPEN Unearthed Earthing switch CLOSED Earthed Open Closed Position Indicator Decal In the closed position Figure 12 the arrow points toward I red background Figure 12 Switch indicator Off Closed position Rockwell Automation Publication 7712 UM001C EN P June 2013 31 Chapter4 Equipment Operation Contactor Cart 32 In the open position Figure 13 the arrow points toward green background Figure 13 Switch indicator On Open position IMPORTANT LV must be connected for unit functionality The LV plug should only be disconnected when the contactor cart is removed from the unit for service Connect LV Plug connect or disconnect the LV Plug the contactor cart must be in the test withdrawn position The LV Plug and cable is attached on the cabinet door and is connected to the equipment in the LV cabinet on the top 1 Orient the LV plug aligning the guide pins on the cart with the openings in the plug 2 Push down the plug and secure the connection with the locking arm mounted on the cart Figure 14 Rockwell Automation Publication 7712 UM001C EN P June 2013 Equipment Operation Chapter 4 Figure 14 Connect LV Plug Shutter Position Indicator An indicator in the door Figure 15 changes color red or green depending on
54. y to a suitable location Failure to do so voids the arc flash resistant integrity See Publication 7712 IN001_ EN P for plenum installation instructions All wiring between the low voltage panel and the power cell must be routed through a suitable gland to ensure flames and gases are not transmitted into this area as fitted from factory The medium voltage power cell doors must be properly secured using the handle mechanism refer to instruction label on the power cell door and page 16 Failure to do so voids the arc flash resistance integrity Rockwell Automation Publication 7712 UM001C EN P June 2013 13 Chapter1 General Information Notes 14 Rockwell Automation Publication 7712 UM001C EN P June 2013 Chapter 2 Safety Interlock and Accessibility Requirements components To avoid shock hazards complete the Power Lockout procedure on page 27 before servicing the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION This procedure requires contact with medium voltage IMPORTANT Forgeneral information on handling medium voltage controllers and preparing the installation site see publication MV QS050 EN P ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death Recommended Torque When ins
Download Pdf Manuals
Related Search