Technical Data

Typical Factory Test Procedures for Medium Voltage Products

Bulletins 1500, 6000, 7000, 7700

Topic Page
Summary of Changes 2
Scope 2
Physical Inspection 2
Electrical 3
Witness Test 4
Additional Resources 5
Typical Factory Test Procedures for Medium Voltage Products

Summary of Changes
This publication contains new and updated information as indicated in the following table.

Topic Page
Added Physical Inspection section 2
Added Witness Test 4

Scope
This document provides a general description of the tests performed on medium voltage products manufactured by
Rockwell Automation. All testing procedures are developed and controlled under the guidelines of the Rockwell
Automation quality system. This system is registered to ISO 9001, and is regularly reviewed and audited by a third-party
registrar.
The tests are performed in accordance with applicable requirements and/or specifications of Canadian Standards
Association (CSA), Underwriters Laboratories (UL), National Electrical Manufacturers Association (NEMA),
European Standard (EN) and International Electrotechnical Commission (IEC), and to the capability of the Rockwell
Automation test facility.

Physical Inspection
1. Verify that the drawings and other project-specific documentation are correct, and make sure that the order
number, customer name, and project name are consistent on all documents.
2. Verify component certifications, as required.
3. Verify that the product meets all applicable engineering and workmanship standards and specifications.
• Verify paint quality.
• Verify that all components are present, not damaged, and are correctly installed.
• Verify structural integrity.
4. Verify that warning nameplates and isolation barriers are present to protect personnel and equipment.
• Check for appropriate warning labels and nameplates to advise personnel of possible hazards.
• Check that appropriate barriers are in place to isolate all medium voltage compartments. Barriers are to ensure
that personnel cannot touch live medium voltage in a cell that is otherwise de-energized.
5. Verify that bus and bus connections have proper clearance, creepage, phasing, and torque.
• Visually check to verify electrical clearances, creepage allowances, and bend radii.
6. Check the tightness of all control and power wires.
• All hardware connections are torqued to standards and all crimps are proper.
• Check for cross-threaded hardware.
7. Verify the mechanical interlocks.
• Verify the operation of any isolation switches, mechanical interlocks, and door interlocks.

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 Typical Factory Test Procedures for Medium Voltage Products

Electrical
1. Functional checks are performed wherever possible; otherwise, inspection and continuity checks are made.
• Continuity checks are performed on all parts of the control circuit that cannot be verified by cycling the
equipment.
• Trace or continuity checks are performed on all power wiring.
• Verify the control wiring is identical to the electrical schematics.
2. A “HI-POT” dielectric withstand test is performed on all buswork and power cables from phase-to-phase and
phase-to-ground (except solid-state components, low voltage controls, and instrument transformers). The voltage
level that is used for this test depends on the nominal AC voltage of the product (Table 1).
Table 1 - Hi-POT Tests on Medium Voltage Components
Medium Voltage Product Nominal AC Voltage Hi-POT AC Voltage Duration
Starters 2300…5000 16,000 1s
5000…7200 22,000 1s
Drives/SMCs 2400 8000 1 min
3300…5000 13,500 1 min
5000…7200 18,500 1 min
10,000…12,000 28,000 1 min
12,000…15,000 36,000 1 min

3. Component devices are functionally operated in circuits as shown on electrical diagrams or as called for by specific
test instructions.
• Calibration of printed circuit boards according to specifications.
• I/O checks
• Programmable devices
4. Instruments, meters, protective devices, and associated controls are functionally tested by applying the specified
control signals, current and/or voltages. Multi-function protective relays and like devices are not programmed –
these types of devices are only functionally tested.
5. The product must function in accordance with the electrical diagram.
a. Medium voltage starters are inspected for the following:
— Electrical interlocking
— Overload protection and ground fault, if applicable
b. Medium voltage Smart Motor Controllers (SMCs) are inspected for the following:
— Electrical interlocking
— Motor protection and ground fault
— Motor start tests at rated voltage
— Motor stop tests (if applicable) at rated voltage

Rockwell Automation Publication 1500-TD220F-EN-E - June 2016 3

Typical Factory Test Procedures for Medium Voltage Products

c. The following tests are performed on MV drives, as applicable:

— Control power failure test
— Rectifier gating checks
— Inverter gating checks
— Line converter tests
— Machine converter tests
— Load tests
— Power module failure tests
— Transformer over-temperature tests
— Cooling fan failure tests
— Remote control tests
Drives are accelerated to the test facility’s nominal frequency of the motor, under load, and then decelerated to
10 Hz. This cycle may be repeated continuously for up to 0.5 hour.
Drives are tested under constant load at the nominal frequency of the test motor.

Witness Test
An optional witness test is available. This test is conducted at the Rockwell Automation manufacturing facility. The
witness test is hosted by a Rockwell Automation Application Engineer and/or Project Manager and Quality Control
Inspector.
A review of the electrical and mechanical drawings for the purchased equipment is done with the Application Engineer
and/or the Project Manager before starting the witness test. The witness test is separated into two individual elements:
equipment physical inspection and electrical inspections.

1. Physical inspection
• All power and ground bus hardware is present and labeled.
• Engraving of unit and master nameplates are correct.
• Physical layout and dimensions of the equipment are verified against engineering documentation.
• All components are verified against engineering documentation to be present and correctly installed.
• Warning nameplates, isolation barriers, and mechanical interlocks must provide sufficient safety/isolation for
personal and equipment.
• Verify operation of isolation switch handle and door interlocks.
2. Electrical inspection
• Control power at the rated voltage is applied to the equipment and a functional demonstration of customer
purchased options and control devices is completed.
• Instruments, meters, protective devices, and associated controls are functionally tested by applying the specified
control signals, current and/or voltages.
• The operation of the vacuum contactor is demonstrated, where applicable.
• IntelliCENTER® system operation is demonstrated, where applicable.

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 Typical Factory Test Procedures for Medium Voltage Products

3. Medium voltage operation - MV drives and soft starters are temporarily installed in the MV test bay and operated
on an MV dynamometer.
• Applying voltage to the equipment and connecting to a test motor in the MV test facility.
• Medium voltage soft starters will have their starting and stopping functionality demonstrated by starting and
stopping the test motor.
• Medium voltage drives are operated over a range of operating speeds and loads on a dynamometer, up to the
maximum capability of the designated test facility.

Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.
Resource Description
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, http://www.rockwellautomation.com/global/
Provides declarations of conformity, certificates, and other certification details.
certification/overview.page

You can view or download publications at http://www.rockwellautomation.com/global/literature-library/

overview.page. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.

Rockwell Automation Publication 1500-TD220F-EN-E - June 2016 5

Rockwell Automation Support
Use the following resources to access support information.

Knowledgebase Articles, How-to Videos, FAQs, Chat,

Technical Support Center www.rockwellautomation.com/knowledgebase
User Forums, and Product Notification Updates.
www.rockwellautomation.com/global/support/get-support-
Local Technical Support Phone Numbers Locate the phone number for your country. now.page
Find the Direct Dial Code for your product. Use the www.rockwellautomation.com/global/support/direct-
Direct Dial Codes code to route your call directly to a technical support
engineer. dial.page

Installation Instructions, Manuals, Brochures, and

Literature Library www.rockwellautomation.com/literature
Technical Data.

Product Compatibility and Download Center Get help determining how products interact, check
features and capabilities, and find associated www.rockwellautomation.com/global/support/pcdc.page
(PCDC) firmware.

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Publication 1500-TD220F-EN-E - June 2016

Supersedes Publication 1500-TD220E-EN-E - August 2014 Copyright © 2016 Rockwell Automation, Inc. All rights reserved. Printed in Canada.