OneGear SMC 15kV Soft Starter

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
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OneGear™
Medium Voltage Arc Resistant Soft Starter
10-15kV up to 11MW
Paul Plavicheanu
Global 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

• 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
8,000
11,000
11,000
2,500
3,250
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
Bypass
Controller
Power Converter
Incoming Cables Motor Cables
Additional
MCCs / SMCs
Power Bus Located in Upper Rear Section
Additional
MCCs / SMCs

(Confidential – For Internal Use Only)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 Converter
Start 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 Converter
CABLE 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

(Confidential – For Internal Use Only) Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 22
15 kV SMC OEM Components
Product Selection Guide, 10-15 kV, 160 / 340/ 580 Amp
Description Component Selection
PowerBrick Assembly (7703E-PP__-x) One Required
Control Module (7703E-_1FX) One Required
Interface Board (7703E-INTB) One Required
Fiber Optic Cables (7703E-__FO__) One Required
Voltage Sensing Board (7703E-VS_) One Required
Fiber Optic Multiplexer Board (7703E-MUXB) One Required
Main Line Switching Device and
Short 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

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.) Wide
1654 mm (65.1 in.) High
627 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

15 kV SMC OEM Component Mounting
10- 12 kV Mounting with Typical Clearances
1326
52.2[ ]
1654
65.1[ ]
627
24.7[ ]
160,0
6.30[ ]
25,0
0.98[ ]
80,0
3.15[ ]
90,0
3.54[ ]
160,0
6.30[ ]
160,0
6.30[ ]

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 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

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