Rockwell Automation Allen-Bradley OneGear Bedienungsanleitung

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

4Rockwell Automation Publication 7712-UM001D-EN-P - October 2017

Table of Contents

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

6Rockwell Automation Publication 7712-UM001D-EN-P - October 2017

Table of Contents

Notes:

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:

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