onegear smc 15kv soft starter

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Insert Photo Here

1

OneGear™Medium Voltage Arc Resistant Soft Starter

10-15kV up to 11MW

Paul PlavicheanuGlobal Product Manager IEC MV MCC

Medium Voltage Business

OneGear 10-15kV SMC Soft Starter• Arc Resistant MV soft starter up to 11MW.

– Allows for controlled Acceleration/Deceleration of MV motors on pre-defined patterns

– Minimize mechanical wear resulting from full-voltage motor starting

– Reduce energy consumption, down time and enable longer system life by helping limit line disturbances from inrush currents

– Improve motor protection and system performance with data-driven information from networked motor control

– Help protect personnel and assets with industry leading arc flash-resistant design– ArcShield™

– Lowest MTTR with easy replacement of components

OneGear 10-15kV SMC Soft Starter

• SMC Flex control provides intelligence, performance, flexibility, diagnostics and communications:

Connect to multiple network types including EtherNet DeviceNet and ControlNet.

I/O Electronic overload

Integral bypass

OneGear 10-15kV SMC Applications• The OneGear 10-15kV SMC Soft Starter is ideal for heavy industries and

key applications Water/Wastewater: pumps HVAC: chiller/compressors Oil &Gas: pipeline compressors, process terminals, refineries Pulp and paper Pumping stations

• Minimize mechanical wear with innovative starting and stopping control modules for ample design flexibility



6


• Control modes to reduce water hammer with optional pump control

– To reduce fluid surges in centrifugal pumping systems

(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

OneGear 10-15kV SMC Flex Family 7761

8

Certification IEC 62947-1

IEC 622271-1 IEC 622271-200 Annex A

Ratings Current

160, 340, 580 Amps

Short Circuit and Bus Bracing 31.5 kA

Arc Resistant Protection 31.5 kA, 0.5 sec.

OEM Controller 7761Complete Controller 7762/63 Retrofit Controller 7760

OneGear 15kV SMC Overview - Ratings

Voltage(50/60 Hz)

Maximum Output Ratings

160 Amp Unit

340 Amp Unit

580 Amp Unit

10,000 2,200 3,000

4,750 6,500

8,00011,000

11,000 2,5003,250

5,300 7,000

9,000 12,000

13,800 3,150 4,000

6,700 9,000

11,000 15,000

kW

HP

kW

kW

HP

HP

OneGear 13.8 kV SMCFlex

10

Line Cable Section

Start Controller

BypassController

Power Converter

Incoming Cables Motor Cables

Additional MCCs / SMCs

Power Bus Located in Upper Rear Section

Additional MCCs / SMCs

(Confidential – For Internal Use Only) Copyright © 2010 Rockwell Automation, Inc. All rights reserved. 11

OneGear 15 kV SMC Overview – Cubicle

Approximate Bulletin 7762 dimensions (smaller than most competitors)

Front Side

• Designed for new applications• Factory wired and tested• Includes:

– Input controller– Power electronics– Control circuitry– Bypass controller

OneGear 10-15kV SMC Complete Controller

7763 (7762 vacuum contactor up to 12kV)

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 12

Bypass Controller

Power ConverterStart Controller

• Retrofit existing fixed speed controllers• New installations where the SMC is fed

from a Main Feeder Breaker• Includes:

– Integral bypass controller– Power electronics– Control circuitry

OneGear 10-15 kV SMC Flex Retrofit Controller

7760

13

Bypass Controller

Power ConverterCABLE CONNECTION

UNIT

OneGear 10-15 kV SMC Flex OEM Controller 7761

• Ability to design and build customized SMC Flex controllers

• Partnering solution for – Power Integrators– Switchgear OEMs

POWER CONVERTER

Overall Safety Interlocking

• No doors can be opened until power is isolated from the compartments• To Open Doors:

– Rack out start breaker, isolating the start breaker compartment and cable compartment• Start breaker door can now be opened

– Rack out bypass breaker and close earthing switch(optional) in bypass unit, isolating the bypass breaker compartment and cable compartment

• Bypass breaker door can now be opened– Power converter doors can be opened with both breakers racked out and the earthing switch set


Power Coverter – Door Interlocking


• There are 3 medium voltage doors in the power converter compartment• The doors are interlocked to the start and bypass breakers and the earthing switch

through a Guardmaster™ electromechanical safety relay

Guardmaster™ Safety Relay

Lock-out Provisions

• Lock-out provisions via integrated key locks or provision for padlocks are available as both standard and optional equipment to lock the following components in the de-energized, disconnected or grounded position

• Standard– Pad Lock Provision on Earthing Switch.– Pad Lock Provision on Apparatus Racking– Pad Lock Provision on Apparatus/Feeder

(Cable) compartment door. • Optional

– Key Lock on Earthing Switch– Key Lock on Apparatus Racking– Pad Lock Provision on Shutters


Power Converter Cubicle: Common Bus design


Horizontal Power Bus:

Allows for multiple units to be connected side to side on Common Bus

Power Converter Cubicle


A - PowerBrick™ removable cart

B - Low voltage compartment

B - Voltage feedback

OneGear 10-15kV SMC – PowerBrick technology

• The workhorse of the OneGear 10-15kV SMC; the PowerBrick™ houses the power in a compact design helps reduce component count for increased reliability and efficiency.

• Power electronics arranged in removable “stacks” which helps reduce maintenance time and spare parts inventory.

• Reduced footprint• PowerBricks can be removed

independently for inspection or repair. • Precision torquing of the power

semiconductor clamp not required.

Power Converter Lower Bus


• With doors open and carts removed, the lower bus is exposed. • This bus is de-energized and isolated by the main and bypass breakers being

racked out and by the optional earthing switch being engaged before the doors can be opened


15 kV SMC OEM Components

Product Selection Guide, 10-15 kV, 160 / 340/ 580 AmpDescription Component Selection

PowerBrick Assembly (7703E-PP__-x) One RequiredControl Module (7703E-_1FX) One RequiredInterface Board (7703E-INTB) One RequiredFiber Optic Cables (7703E-__FO__) One RequiredVoltage Sensing Board (7703E-VS_) One RequiredFiber Optic Multiplexer Board (7703E-MUXB) One Required

Main Line Switching Device andShort Circuit Protection One Required

Bypass Switching Device One Required Gate Drive Test Power Supply (7703E-PS_) Optional Required for testing, commissioning, and troubleshooting gate-firing circuits. Can be either a circuit breaker or a contactor with main switch and fuses. Can be either a circuit breaker or contactor. Provided by others.


OneGear 15 kV Components

• New higher voltage sensing system– Monitors line and load voltages– Higher voltage resistors– Features to hold high voltage

wires at required spacing


OneGear 15 kV Components

• 7703E-MUXB• New fiber optic multiplexer

board to accommodate additional gate drive signals for higher voltages– Controls up to 36 SCRs– Fed from existing SMC Flex

interface board– Connects directly to gate

drive boards on PowerBricks– 110 to 240 VAC, 50/60 Hz

power supply

(Confidential – For Internal Use Only) Copyright © 2007 Rockwell Automation, Inc. All rights reserved.25

15 kV SMC OEM Component Mounting

• Typical vertical mounting arrangement for 10-12 kV– Five (5) PowerBricks per

phase, connected together, mounted independently (i.e. on enclosure backplate)

– Overall PowerBrick assembly dimensions (incl. clearances):1326 mm (52.2 in.) Wide1654 mm (65.1 in.) High627 mm (24.7 in.) Deep

• At 12.1-14.4 kV, there are six (6) PowerBricks per phase 12.1-14.4 kV PowerBrick Assembly

(Confidential – For Internal Use Only) Copyright © 2007 Rockwell Automation, Inc. All rights reserved.26

15 kV SMC OEM Component Mounting

10- 12 kV Mounting with Typical Clearances

132652.2[ ]

165465.1[ ]

62724.7[ ]

160,06.30[ ]

25,00.98[ ]

80,03.15[ ]

90,03.54[ ]

160,06.30[ ]

160,06.30[ ]

Circuit Breaker Cubicle

A - Apparatus Compartment

(Confidential – For Internal Use Only) Copyright © 2010 Rockwell Automation, Inc. All rights reserved.

Circuit breaker cubicles are used for the start and bypass units on the soft starter and are also used for mains, feeders and bus ties

B - Horizontal Bus Bar

C - Load Termination Compartment

D - Low Voltage Compartment

E - Arc Exhaust Plenum

Apparatus Compartment

• The apparatus compartment contains either a vacuum breaker or a vacuum contactor

• The apparatus compartment has metal shutters at the rear that close when the apparatus is racked out into the test or withdrawn position


Overall Features

• Main bus is located on the top rear of the units. Bus bushings are located between sections to isolate the bus compartments from each unit


Load Termination Compartment

• Motor cables are terminated in the load termination compartment of the bypass unit

• There is an optional earthing switch located in the load termination compartment that earths the motor cables.

• If the earthing switch is present, it must be closed in order to open any MV door in the soft starter


ArcShield arc-resistant design as a standard

– The ArcShield arc flash-resistant cabinet redirects arc flash energy away from personnel

– Pressure relief vents in the top of the unit via an overhead plenum. – The cabinet provides IEC 62271-200 Annex A, IAC AFLR, 31.5 kA, 0.5 sec– Product tested with low voltage open– The ArcShield design helps protect personnel and equipment

OneGear 10-15kV SMC

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

31

Actual photographs of successful ArcShield testing.

OneGear SMC and MCC, up to 15kV

Safe, reliable and flexible motor control

Real-time monitoring, control and system-wide communications

Superior safety, performance and reliability

FOR INDUSTRIAL APPLICATIONS WORLDWIDE


Choose Allen-Bradley OneGear™ Motor Controllers

onegear smc 15kv soft starter

Documents