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Chapter 1

1. M IV i gc reo 2 3 N 6 AUX 12 5 L G N B IV 1 o EC 8 B B N ENS 6 AUX 12 5 o G FILTER FEMC N N M IV 1 START 13H 13H 9 o UR MODULE MODULE M IV STATUS STATUS BH Hie CONTACTOR STATUS B IV MC CLOSE 9 55 3c 1 15H Hie BC CONTACTOR STATUS P FEM FILTER P 11 le 12 14 15 16 17 18 19 20 21 SMC FLEX CONTROL TERMINALS AUXI uP TO SPEED SCANpor t AUX 2 AUX 3 AUX 4 FAULT ALARM NORMAL PTC TACH GROUND INPUT INPUT FAULT H H r1 H 23 25 26 27 28 29 30 31 33 34 CLOSE UR SMCFLEXIB INPUT POWER ul Le N Product Overview 1 31 MAIN CONTACTOR BYPASS CONTACTOR MASTER C
2. AN3IAdICX23 SLOWS A 3 a910 ALVO _ SLD SHLHONOWHL 557 SHOLONGNOD 19 T alele _ n 5 5 4I ANO OLIOSNNOO gt 5 5 5 an gt V 3SVHd SNOLIDSNNOD 3HM a 15 2 SALNNIN JO WOWININ 52 V HLM YNOH SPHVIS OWLIACIADSAIN Tv sa 22 es sao gt gt 86 Za be 2 be EN won 128 gt 5 Zano 9xL L i XL eeveosvt d be cL 8 T m 2 5 SS gt z gt TL
3. Ka CLT SV xi xe 06V 28 INTERFACE _ BOARD zi 11 ES 22 4 m BYPASS CONTACTOR BC BE C D IL Jee RECTIFIER SE MM NN BLK Y gt gt N 3 Y BC MASTER START STOP SIGNAL CR FROM EXISTING STARTER 55 CR H BC 4 BYPASS CONTROL P EMC FILTER te 14 15 16 7 19 20 et SMC FLEX CONTROL TERMINALS AUX 1 UP TO SPEED SCANport Q AUX 2 AUX 3 AUX 4 FAULT ALARM NORMAL GRDUND J INPUT INPUT FAULT 1H 24 25 27 29 32 33 34 SMCFLEXIB INPUT 17 Figure 4 Bulletin 1560E Relay Control Circuit Without Stop Control 1560E UM051A EN P September 2005 C 8 1560E and 1560E Relay Control BYPASS CONTACTOR MASTER CONTROL BYPASS CONTROL
4. Ceo Common 20V test point Overvoltage test point sense terminal Figure 3 4 Test Power Application on Gate Driver Board 7 yellow LED on the upper right hand side of the energized gate driver circuit should be lit it may appear dim depending on ambient light conditions This is normally sufficient to verify that the gate drive system is functioning however a more detailed check can be made utilizing steps 8 and 9 1560E UM051A EN P September 2005 Commissioning P rocedures 3 9 8 The gate driver board voltage may be checked by connecting a DC voltmeter to TP4 and see Figure 3 4 With the specified portable test power supply connected the voltage should be 9 to 12 VDC If the current loop is energized and the gate test pulses are not activated the voltage should be 18 to 22 VDC 9 actual gate pulse may be checked by connecting an oscilloscope between TP1 and TP3 see Figure 3 4 The pulse should appear as shown in Figures 3 5 and 3 6 microsecon Figure 3 5 Gate Pulse Detail Typical SCR ABB 20 15 1 0 05 00 05 10 15 20 25 3 0 Milliseconds Figure 3 6 Gate Pulse Test Waveform 10 If no pulse is observed and the yellow LED 1 lit check for a shorte
5. Gate Driver Boards Gate Driver Snubber Circuit and Sharing Resistor Frame Assembly Figure 9 18 Power Module Assembly one phase 3300 4160 V 600 A 1560E UM051A EN P September 2005 Gate Driver Boards EAS 2 2 x e Troubleshootin 9 25 Heatsink Assembly Line connection Load connection Gate Driver Snubber Circuit and Sharing Resistor Frame Assembly Figure 9 19 Power Module Assembly one phase 5500 6900 V 600 A 1560E UM051A EN P September 2005 9 26 Troubleshootin Snubber and Resistor Circuit If the resistance checks from the Thyristor testing section were abnormal Testing and the thyristors checked out OK there may be a problem in the snubber or resistor circuits 1 Remove all power from the equipment 549 To avoid shock hazard ensure main power has been disconnected before working on the controller motor or control devices Verify that all circuits are voltage free usin
6. 5 j 8 VA Y gt s 8 10 i0 8 10 5805 14 14 14 8 c 3 Bo Sao Bu 8 8 3 8 900 20 3 8 1560E UM051A EN P September 2005 Figure 9 23 3300 4160 V Module Wiring 180 360 600 A Troubleshooting 9 33 58 gf 33 H 11534 y gkg 8 8 2 5 1 8 g gt gt d gt 8 8 4 0 80 86 9 80 88 88 88 8 8 p VAY AA NYY Mc 8 20 gs gi p 3 B E eg 8 8 T H 8 0 8 8 5 aoa 8 8 8 8 8 8o Bo 8 5 5 5 8 9 9 9 19 19 19 88 200 8 8 8 0 j 9 wwr Fe 9 Fo 8 Figure 9 24 6900 V Module Wiring 180 360 600 1560E UM051A EN P September 2005 9 34 Troubleshooting 1560E UM051A EN P September 2005 Safety and Preventative Periodic Inspection Caper 10 Maintenance The Maintenance Technician should become familiar with the layout and be aware of the basic system parameters Only qualified technicians should be allowed to work with this equipment under competent supervision General housekeeping is the key to maintaining power electr
7. 12 5 L G N FILTER FEMC N N 4 B 1V 1 CR 4 MASTER CONTROL START STOP SIGNAL MODULE CR FROM EXISTING STATUS STARTER 1 CLOSE 9 4 BYPASS CONTACTOR CLOSE CONTROL COAST STOP 11 B IV 253 t 15H Hie 4 BYPASS CONTROL AUX CONTACTOR STATUS P e e E 1 12 13 14 15 16 17 18 19 20 21 SMC FLEX CONTROL TERMINALS Aux UP TO SPEED SCANport AUX2 AUX 3 AUX 4 FAULT ALARM NORMAL PTC TACH GROUND INPUT INPUT FAULT 1 H r1 H 23 24 25 ee 27 29 32 33 SMCFLEXIB INPUT Le N Figure 1 24 Bulletin 1560E IntelliVAC Control Circuit WithStop Control 1560E UM051A EN P September 2005 1 36 Product Overview 06v XX 4 BOARD zm om d mU 41 3 1 M 5 4 Tel pi 2 3 Mov N Na GH BYP
8. M M o MoV gt MC ME ME D 11 41 RECTIPIER X 1 OH H H HHI BK 1 gt REC MOV 1 MoV N T Y 4 A M B lt M o MoV 2 BC BE BE BE D i HH PH HHI RECTIFIER BLK Y REC MOV 2 MoV N SERVA B CN 5 STOP o CR MC CR OFF LOCAL REMOTE 55 BC CR 1 t 11 4 FEM FILTER EMG e e iv 13 14 15 te 17 18 19 R SMC FLEX 24v CONTROL TERMINALS AUX L v CAN UP TO SPEED N SCANpor t NETWDRK AUX2 AUX 3 AUX 4 B FAULT ALARM NorMAL EK PTC TACH GROUND 4 INPUT INPUT FAULT 1H 24y 23 24 25 26 27 28 29 30 31 32 33 34 SMCFLEXIB INPUT POWER B L2 N MAIN CONTACTOR BYPASS CONTACTOR MASTER CONTROL BYPASS CONTROL MAIN CONTROL AUX Figure Bulletin 1562 Relay Control Circuit With DeviceNet or DPI Communication and Optional Local Off Remote 1560E UM051A EN P September 2005 1560 1560 Relay Control C 7
9. Quantity Description Part Number 1 per pair Sharing resistor 32 5 k 225W two 2 5 taps 80025 753 01 R lperSCR Current loop gate driver board CLGD 80190 519 01 R 1 per controller Voltage Sensing Board VSB 81000 199 55 R 1 per controller Interface Board 80190 440 01 R 1perSCR 3 Fiber Optic Cable 25m 80025 549 03 R 1 per controller Test Power Supply 120 VAC for North America 80187 051 51 R Universal 80187 245 51 R 1 per controller Current loop transformer 50VA 115 230 0 6V 80022 133 01 5ft 80018 246 55 6ft 80018 246 51 per controller Current loop cable assembly 1 80018 246 52 8 ft 80018 246 53 9 ft 80018 246 54 1 per controller Current loop sense CT 80022 163 01 Referto Table D 1 for an explanation of the number of SCRs per controller which is voltage dependant Different lengths are used for the various configurations The current loop total length must equal 21 ft for proper operation Table D 5 Accessories Qty per controller Description Part Number 1 Control Module Standard 41391 454 01 S1FX Control Module Pump Control 41391 454 01 B1FX Fan 120 V 80025 248 01 R 1 Fan 240 V 80025 248 02 Fuse Extractor 80144 491 02 Optional equipment Notes 1 Reference only 2 1503 For OEM products refer to OEM supplied documentation for specific spare parts list 15
10. 4 INTERFACE BOARD B IV gt 1 o TC 8 3 A BB N c 5 G gt gt BYPASS CONTACTOR G N FILTER DEVID N N B IV BC 13H CR MASTER CONTROL START STOP SIGNAL MODULE CR FROM EXISTING STATUS STARTER B IV CLOSE 518 BYPASS CONTACTOR CLOSE CONTROL B IV 8 0225 15H 3c BYPASS CONTROL AUX CONTACTOR STATUS FEM EMC FILTER IN P E le 13 14 15 16 17 18 19 20 21 SMC FLEX CONTROL TERMINALS AUXA UP TO SPEED SCANport AUX3 AUX 4 FAULT ALARM NORMAL PTC TACH GROUND INPUT INPUT FAULT 1 H H 1 H 23 24 25 26 27 28 2 30 31 32 33 34 SMCFLEXIB INPUT POWER L2 N Figure 1 23 Bulletin 1560E IntelliVAC Control Circuit WithoutStop Control 1560E UM051A EN P September 2005 Product Overview 1 35 INTERFACE BOARD 22 23 eC 4 EC TCD 3 2 A BB N t B cl NET ak aes MM BYPASS CONTACTOR
11. B CN 7 5 fuh gt BC BC BE BE BE BE D 1H HH H H H s k gt BYPASS CONTACTOR REC MOV 2 N 4 Y A B BE OPTION START STOP 97 MASTER CONTROL MC CR STOP Lo MC 1 SS BYPASS CONTROL FEM EMC FILTER EME IN e E Pals te 5 16 17 SMC FLEX CONTROL TERMINALS AUX L UP TO SPEED SCANpor t AUX 2 AUX AUX 4 FAULT ALARM NORMAL GROUND INPUT INPUT FAULT 1 H 1 H 23 25 26 27 30 31 33 34 55 MAIN CONTROL AUX SMCFLEXIB INPUT POWER ul L2 N Figure 2 Bulletin 1562E Relay Control Circuit WithStop Control 1560E UM051A EN P September 2005 C 6 1560E and 1560E Relay Control INTERFACE BDARD
12. TT VOLTAGE FEEDBACK REV 24 2 23 1 MADE p SERIAL DA MMNUMBER 0 o QUE ia T SEE SE Figure 9 20 Voltage Sensing Board 1560E UM051A EN P September 2005 9 28 Troubles hooting 1560E
13. Installation 2 9 Phase 1 Line Connections Voltage Sensing Module Phase 2 Line Connections Load Connections top exit shown Phase 1 front through 3 back Current Transformers Phase 3 Line Connection Bypass Vacuum Contactor Figure 2 5 Power Connections 1560 180 3604 5500 to 6900 V 1560E UM051A EN P September 2005 2 10 Installation Power Connections cont Phase 1 Power Stack Assembly Phase 2 a 7 Power Stack Assembly E X JO Q 8 3 2 Power Stack Assembly 5 lo Figure 2 6 Power Connections 1560E 600A 2400 to 6900 V 1560E UM051A EN P September 2005 Phase 1 Line Connections Voltage Sensing Module Phase 2 Line Connections Load Connections top exit shown Phase 1 front through 3 back Current Transformers Phase 3 Line Connection Bypass Vacuum Contactor Installation 2 11 Impor
14. Note For ease of programming values after using the Enter key to edit use the Sel key to jump to the digit that needs to be modified then use the arrow keys to scroll through the digits The Bulletin 20 HIM LCD interface modules may be used to program and control the SMC Flex controller The human interface modules have two sections a display panel and a control panel The display panel duplicates the 3 line 16 character backlit LCD display and programming keypad found on front of the SMC Flex controller Refer to Chapter 4 for a description of the programming keys refer to Appendix E for a listing of human interface module catalog numbers that are compatible with the controller Note Bulletin 20 HIM Rev3 002 or later must be utilized with the SMC Flex Note Extension cables are available up to a maximum of 10 m in total length Note A maximum of two HIM modules can be installed Communications 8 3 The control panel provides the operator inteface to the controller Jog Start The green start button when pressed will begin motor operation Proper setup of the HIM port is required Stop The red stop button when pressed will halt motor operation and or reset a fault Jog The jog button is active only when a control option is present Pressing the jog button will initiate the option maneuver for example Pump Stop The Bulletin 20 HIM interface module s stop push button is not intended to b
15. aeo asa 5 gt 5 po gt 5 gt 5 4 4 vo 2 TX la b bu ow 250 o zo on Ro 1 did 4 4 4 4 TT 4 gt 4 NIS 4 v pt NIV Figure 1 19 Typical SMC Flex Power System Bulletin 1560E 3300 4160V shown 1560E UM051A EN P September 2005 Product Overview 1 27 Functional Desc ription The following functional descriptions and associated control circuits are for units using IntelliV AC contactor control modules For units with electromechanical relay control refer to Appendix C The control circuit schematics shown below assume that control power is fed from the same source as the primary circuit If external control power is used additional control interlocking may be required to avoid unexpected motor start up The control interlock should ensure that a motor start request is not inadvertently applied when the primary circuit is disconnected Bulletin 1562E Basic Control Controlled Start only When wired as shown in Figure 1 20 the controller operates as follows Pressing the Start button initiates the start sequence Relay CR closes and applies control power to terminal 17 of the SMC Flex module The Aux 4 Normal closes en
16. Description Action Display Amps vo 1 Press the ESC key to go from the status display to the Main menu c3 2 Scroll with the Up Down keys until Wain M the P references option is 52 highlighted Memory Storage 3 Press the Enter key to access the Filo Parameter menu cD SetUp 4 Scroll with the Up Down keys until the option you want use GP File Monitoring Motor P rotection Vu 1 etc is highlighted For this Motor Protection example Set Up will be used 5 Press Enter to select the Set Up m group eu i FEP Group 6 Set Up and press Vu ER TTE 7 Scrollto the Starting Mode Paramei parameter by using the Up Down Vu Starting Mode keys and press Enter Ramp Time 8 Press Enter to select the option Scroll to the option of your choice PR by using the Up Down keys For Vu 53773 Starting Mode this example we will choose Current Limit 9 Press the Enter key to accept the new setting eu 10 Scrollto the next parameter by using the Down key Continue 52 pa Time did the process until all desired Sece settings are entered TheSMC Option advises the user if any control option i e Pump Control is resident This parameter is factory set and cannot be modified by the user The display will indicate that the second line is now active by highlighting the first character If the LCD 156
17. 51 SSvd SuOLOCCONOO CIXON OW9 SIWALSAS dl AINO ANNOYS OL LO3NNOO D NWOHS 3SvHd SNOLLOJNNOO V 5 SNOLLO3NNOO JAM SALANIN YNOH Yad S HV ELS OML er 4 9m gt stn lt stn be 9v o 5 4 w 2 o v X Sar 2 sao 51 gt gt 96 zu gt E 5 be 2 Lj gt E 5 a zano 9xL L 29 Bv be zL a m aa a gt v 5 Tea fe n 5 SDGIHOWS ONISNAS CVO XE OWS v z boe 1 gt 5 1 5 babe 1 2 papa 55 mt ml
18. Tea be SNISN3S VLOA 3OV H3LINI 5 a LINDYID TOHINOO OL v 1 4 4 A 2 gt ve E s 1 gt papa 1 5 9 Qa 5 e _ Te ex E E E E aso aso aeo aso asal asal 142 XSTSOWS OL 5 5 5 fro 5 5 et 1 1 AOV gt gt vs 24 zs tes lea 53514 uv SNLLIATT Ww bna 7 1 n SNLLIATT 4 e 5 1 gt i o N X as OvNOLLdO D THD 1 21 TI 2 9 GE O9TV Figure 1 18 Typical MV SMC Flex Power System Bulletin 1562E 3300 4160V shown 1560E UM051A EN P September 2005 Product Overview 1 26 NOA ONAY avo
19. Allen Bradley Medium Voltage SMC Flex Motor Controller Bulletins 1503E 1560E and 1562E User Manual for Series K Peur avi Sit Automation Important User Information Solid state equipment has operational characteristics differing from those of electro mechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www ab com manuals g1 describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable 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 describ
20. aem Parameter 3 Default User Group Parameter Description Number Units Min Max Settings Settings Fault 1 124 0 255 Fault 2 125 0 255 Linear List Fault 3 126 0 255 Fault 4 127 0 255 Fault 5 128 0 255 Disable Coast Option 1 Input 132 ae 21 Basic SetUp T Fault NC Network Coast Stop Input 133 Stop Option Coast 1560E UM051A EN P September 2005 6 Parameter Information 1560E UM051A EN P September 2005 Functional Description Appendix 1560E and 1562 Relay Control The following functional descriptions and associated control circuits are for units using electromechanical relay control Bulletin 1562E Basic Control Controlled Start only When wired as shown in Figure C 1 the controller operates as follows Pressing the Start button initiates the start sequence Relay CR closes and applies control power to terminal 17 of the SMC Flex module The auxiliary contact 2 set for normal closes picking up MC which completes the hold in circuit on the start button and closes the main contactor The SMC Flex module examines the line voltage looks for fault conditions checks phase rotation calculates zero crossing information and begins gating the SCRs to start the motor When the motor approaches rated speed the SMC Flex module closes the up to speed auxiliary contacts closing relay BC which closes the bypass contactor The motor then
21. seen 2 17 EMC Compliance 2 18 ronde 2 19 Control Terminal Designations esee 2 20 Commissioning Procedure Chapter 3 Preliminary re ei terere riae teta to ect inan 3 1 System Characterisll68 eder dest iar e Pi T les ERR 3 2 Preliminary 3 3 3 3 Hi Pot and Megger Test eere 3 4 Typical MV SMC Flex Power System Diagram 3 5 Connection and Test Information for Interface Board 3 6 Power Supply TESIS erae teer Leste rio renes eee e ue good eo 3 7 Control Function retener terret ins 3 10 Resistance Checks 3 11 Verify System Grounding 3 11 Voltage Sensing Module 3 12 M 3 12 Programming Chapter 4 E 4 1 Keypad Description ir 4 1 Programming MOV ori eei 4 1 Menu Structure Hierarchy 4 2 Parameter Linear irt eme et 4 4 PASS WOIG M 4 5 Parameter Management 4 6 Parameter 4 8 OM SALE MT EET 4 9 Current Limit Start 4 9 Dual Ramp
22. Amps ERE MTU Press any key to access the Main menu Main Menu Parameter Memory Storage Scroll with the Up Down keys until the Parameter option is shown Main Menu Parameter Memory Storage Press the Enter key to access the Parameter option Scroll with the Up Down keys until the Monitoring option is MINES displayed Set U Press the Enter key to access the Monitoring group Press the Enter key to access the Ia cL 1177 Metering Metering group Refer to Metering on page 1 16 or Figure 4 2 on page 4 3 for details on the metering functions 1560E UM051A EN P September 2005 52 Metering cont i 7 Scroll through the Metering FG 1 parameters with the Up Down c Vot keys to access the desired Vu information Press the Enter key Volts Phase to view that parameter Volt FG Volts Phase HH Volt Pit 4 Current Phase A Amps F GI Current Phase B Amps Gig 6 Current Phase C Amps 7 Watt Meter 2 Kilowatt Hours KWH 0 Elapsed Time Hour Gig 10 Meter Heset No F Gig Pit 11 Power Factor F 12 Mtr Therm Usage 99MTU The metering values tha
23. BLK Y Mov N Y B B N BE START STDP SIGNAL EXISTING STARTER BC 11 CR MASTER CONTROL OFF LOCAL REMOTE JE CR GER 3C BYPASS CONTROL Firer gt P E u 15 16 17 19 20 22 SMC FLEX CONTROL TERMINALS AUX CAN UP TD SPEED DEVICENET SCANport NETWDRK AUX 3 AUXA FAULT ALARM NORMAL EU PTC TACH GROUND 24V NPUT INPUT FAULT 1 H 1 H 23 24 25 26 27 28 29 0 31 33 WIRE SMCFLEXIB MAIN CONTACTOR INPUT POWER L2 N Figure C 6 Bulletin 1560E Relay Control Circuit With DeviceNet or DPI Communication and Optional Local Off Remote 1560E UM051A EN P September 2005 C 9 C 10 1560E and 1560E Relay Control 1560E UM051A EN P September 2005 Power Stacks Spare Parts Table 0 1 Replacement SCRs SMC pud Description Part Number 180 Amp 360 Amp 1500 Individual no matching required 6 per controller 80156 815 61 R 80156 894 71 R 2500 Individual no matching required 6 per controller 80156 893 71 R 80156 894 71 R 4800 Matched set of two 6 sets per controller 80156 893 72 R 80156 894 72 R 7200 Matched set of three 6 sets per controller 80156 893 73 R 80156 894 73 R 9 Due to stringent torqu Itis mandatory thatthe ent
24. Control Function Tests Servicing energized industrial control equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Recommended practice is to disconnect and lock out control equipment from power sources and allow any stored energy in capacitors to dissipate The safety related work practices of NFPA 7OE Electrical Safety Requirements for Employee Workplaces must be followed if it is necessary to work in the vicinity of energized equipment 1 Apply rated control voltage to the control circuit 2 Using the control schematic apply control signals to cause relays and contactors to energize to verify operation 3 Remove any jumpers used in the test and restore all circuits to normal when finished 1560E UM051A EN P September 2005 Commissioning P rocedures 3 11 Resistance Checks To ensure that resistors and connections have not been damaged during shipment and installation the following resistance tests should be performed before energizing the starter 1 Remove all power from the equipment Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment 2 Measure DC resistance per the following chart Table 3 A Power Circuit Resistance Measurements Location of Prob
25. Ensure that the SCRs are properly seated on the locating pins in the heatsinks and rotate each SCR so that the leads are oriented toward the front right side of the assembly Advance the centre nut until the spring assembly engages the top heatsink Make sure the clamp is properly seated on the locating pins in the top and bottom heatsinks before beginning to tighten Tighten the centre nut until the indicator washer becomes loose with some friction The clamp is now at the proper force and must not be clamped any tighter If the indicator washer becomes too loose no friction back the centre nut off slowly until the washer is loose with some friction Replace the shorting bar Torque hardware to 30 N m 20 ft Ib For 3 8 in hardware in the T slots of aluminum heatsinks the recommended torque is 22 N m 16 ft Ib Do not overtorque these connnections as the slots will be damaged and the connection will be compromised Troubleshooting 9 15 Power Circuit SCR Replacement Procedure cont Troubleshooting cont C Install Refurbished Stack 1 Inspect all connections on the module Inspect wire insulation and components for damage 2 Install the module in the cabinet Watch for power cables and fibre optic cables as module is slid into place Tighten locking nuts at the bottom of the module 3 Connect power cables and tighten hardware to 30 20 ft lb 4 Install gate driver board ensuring that the locking tabs on the
26. Initial torque Increase initial torque setting Current limit setting Increase current limit setting Kickstart Increase kickstart time or turn off Fan does not operate Wiring Check wiring and correct if necessary Failed fans s Replace fan s Motor stops too quickly Time setting Verify the programmed stopping time and correct if with Soft Stop option necessary Motor stops too slowly Stopping time setting Verify the programmed stopping time and correct if With Soft Stop option necessary Misapplication The Soft Stop option is intended to extend the stopping time for loads that stop suddenly when power is removed from the motor Fluid surges with pumps still occur with the Soft Stop option Misapplication Soft Stop ramps voltage down over a set period of time In the case of pumps the voltage may drop too rapidly to prevent surges A closed loop system such as Pump Control would be more appropriately suited Refer to Publication 150 911 Motor overheats Overload Blocked ventilation Duty cycle Allow motor to cool and reduce load Remove blockage and ensure motor is being adequately cooled Preset Slow Speed and Accu Stop options Extended operation at slow speeds reduces motor cooling efficiency Consult motor manufacturer for motor limitations Smart Motor Braking option Check duty cycle Consult motor manufacturer for motor limitations Motor short circuit Winding fault Iden
27. 10 H3S 0 CLT SOO gt T 06 INTERFACE BOARD d 23 3 Mov C D REETIFIER 11 gt REC Mov gt N Y B B 3E BC START STOP SIGNAL CR FRDM EXISTING STARTER COAST STOP 11 BC Fitter P 11 12 13 14 15 16 17 18 19 20 21 SMC FLEX CONTROL TERMINALS UP TO SPEED SCANpor t AUX 2 AUXA FAULT ALARM NORMAL GRDUND INPUT INPUT FAULT 25 27 29 31 32 SMCFLEXIB INPUT POWER LL L2 N 1560E UM051A EN P September 2005 Figure C 5 Bulletin 1560E Relay Control Circuit WithStop Control 1560E and 1560E Relay Control 110v Hi H3 H4 xi xe INTERFACE 4 BOARD N ot MEM M 4 BYPASS BC BC D H hH H H H RECTIFIER
28. For switching sufficient impedance should be connected in series with the capacitor bank to limit the inrush current A method of limiting the surge current is to add inductance in the capacitor conductors This can be accom plished by putting turns or coils of wire in the power connections to the capacitors 6 inch diameter coil six loops For more information refer to NEMA standard ICS 2 Part 2 Capacitor Applications Care should be used in mounting the coils so that they are not stacked directly on top of each other or they will have a cancelling effect Also the coils should be mounted on insulated supports away from metal parts so they will not act like induction heaters Any covers or barriers removed during installation must be replaced and securely fastened before energizing equipment Failure to do so may result in severe burns injury or death Installation 2 15 Power Bus Isolation S witch Isolation Switch Fuse Fuse Contactor E Isolation Contactor di dt Inductor di dt Inductor Capacitor PFCC Contactor Power Factor X Correction Capacitor Bypass Contactor i Motor Figure 2 7 Typical One Line Diagram Showing 2 Different Styles of Power Factor Capacitor Connections 1560E UM051A EN P September 2005 2 16 Installation Surge Arrestor Protection Devices 1560E UM051A EN P September 2005 Rockwell Automation hig
29. Red ON when test pulses on SMC Flex control module Ribbon connectors to connect to SMC Flex control module j Current normal operation underneath control module feedback test points ROCKWELL RU AUTOMATIO 1821 VCOM M LED Yellow ON h when Phase LC ibbon connector breit L gate signal active LT to Voltage 1 ibre Er GATE LINE A Sensing Board ransmitters oltage LOAD A send gate PULSE TP4 Phase feedback test lines signalsto lt ICOM gate signal points LOAD B driver boards 3 Module common E unec TP8 Common for connectto earth PYP C Current loop 5 Gate Pulse TPs ground if the power 0 power supply system is grounded
30. Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter This is notto indicate how the motor windings are configured Do not select Delta for MV applications 1560E UM051A EN P September 2005 Programming 4 13 Parameter Option Kickstart Time A boost current is provided to the motor for the programmed time period 0 0 to 2 05 Kickstart Level Adjusts the amount of current applied to the motor during kickstart 0 to 90 of locked rotor torque Stop Input Coast Stop Option Allows the user to selectthe operation of terminal 18 Stop Input Option 1 Input Disable Coast Stop Option Fault Fault NC Allows the user to select the operation of terminal 16 Option Input 1 Network Option 2 Input Disable Slow Speed Dual Ramp Fault Allows the user to select the operation of terminal 15 Option Input 2 Fault NC Network Clear Fault Emergency Run Stop Mode Allows the user to program the 5 controller for the type of stopping that best fits the application Disable Soft Stop Linear Speed Stop Time 0 0 to 120 5 This sets the time period which the controller will ramp the voltage during a stopping maneuver CT Ratio 1 to 1500 Scales the CT input to actual motor current 5 amp secondary assumed 1 Config Normal Up to speed Fault Alarm Network Contact is provided as standard with the SMC Flex controller
31. The CT assembly can be oriented to allow either top or bottom load cable exit Phase 2 Power Stack Assembly Phase 1 Power Stack Assembly H N Phase 3 Power Stack Assembly 12 e Voltage Sensing Module Load Connections s top exit shown Phase 1 front Through 3 back 5 Line Connections Phase 1 top Through 3 bottom Current Transformers Bypass Vacuum Contactor Figure 2 4 Power Connections 1560 180 360A 2400 to 4160 V 1560E UM051A EN P September 2005 Phase 1 Power Stack Assembly Phase 2 Power Stack Assembly Phase 3 Power Stack Assembly T 9
32. several modular components including Frame mounted or loose power stacks including gate driver boards Loose interface and voltage feedback boards Fiber optic cables for SCR firing Microprocessor based control module Bypass vacuum contactor 1560E UM051A EN P September 2005 1 2 Product Overview Description cont 1560E UM051A EN P September 2005 1560E Retrofit Controller A medium voltage solid state controller designed to work in conjunction with an existing customer supplied starter It includes Tin plated copper horizontal power bus optional continuous bare copper ground bus Power electronics bypass vacuum contactor Three 3 current transformers A low voltage control panel complete with microprocessor based control module Top and bottom plates to accommodate power cables Note See Interlocking page 2 12 1562E Combination Controller A medium voltage solid state controller that provides isolation and protection for new installations It includes Tin plated copper horizontal power bus optional A continuous bare copper ground bus Power electronics A main non load break isolating switch and operating handle An isolation vacuum contactor A bypass vacuum contactor Three 3 current limiting power fuses for NEMA Class E2 operation Three 3 current transformers A control power transformer optional A low voltage control panel complete with microproc
33. which provides circuit isolation motor switching and overload and overcurrent protection When wired as shown in Figure 1 23 the controller operates as follows When a start is initiated in the existing motor controller and the contactor or breaker closes a contact must be supplied to tell the 1560E to start also A CR contact will apply control voltage to terminal 17 of the SMC Flex module When stopping the motor the contactor in the existing controller will open removing power from the motor and then the CR relay The bypass hold in rung will keep the bypass contactor closed for a short time The Fault contact on the SMC Flex module should be wired into the existing controller to trip the main contactor or breaker in the event of a fault condition sensed by the SMC Flex module If possible it is better to have the SMC Flex module control the main contactor directly In this case the control circuit would look like and function like the descriptions above for the Bulletin 1562E Bulletin 1560E Basic control With Controlled Stop When wired as shown in Figure 1 24 the controller operates much the same as described above for the Standard module The control signal uses terminal 16 instead of 17 and a coast stop can be achieved by opening the connection to terminal 17 Itis more important in this configuration to integrate the control circuit of the 1560E with the existing controller for better control
34. 2 1562 Combination Controller esses 1 2 SMC Flex Control 1 2 Starting Modes cnr eerte eee tote tete e 1 3 1 3 Selectable Kickstart 1 4 Current Limit Start cce t tt HERR 1 4 Dual Ramp Statt auctis een 1 5 Pull Voltage Start uci eoe re te rrt pete 1 5 Preset Slow Speeds om een prie tiere nea 1 6 Linear Speed Acceleration and Deceleration 1 7 Soft 1 8 Protection and 1 9 Overlodd ett eniro tene ree A i Free 1 9 Und rload host 1 11 Undervoltag ned eH eere 1 11 ODA NLO Ie Ne 1 11 UnbalanGe e t erede 1 12 Stall Protection and Jam Detection sese 1 12 Ground 1 13 Thermistor PTC Protection 1 14 MS M 1 16 Line 1 16 Excessive Starts Hout 1 17 Overtemperaltute oec ice ri ER 1 17 1 17 COMMUNICATION 5 x xy IO EE dos RENT 1 18 Programming hee ee 1 19 Status NGIC AU OM uie eae etd te 1 19 Control Optom assess 1
35. 20 Pump Control Option ecien iann DP dates 1 20 Pump Application Considerations esses 1 21 Braking Control Option tre eter tete 1 22 Hardware Description nnde 1 23 PowetModul 5 c tae 1 23 Current Loop Gate Driver 1 23 Intertace ete et ror eei ie 1 24 1560E UM051A EN P September 2005 ii Table of Contents MV Dialog Plus Medium Voltage Controller User Manual Product Overview cont Chapter 1 Page Typical MV SMC Flex Power System Diagrams Bulletin 1562E 3300 4160 1 25 Bulletin 1560E 3300 4160 1 26 Functional Descriptions a re reus 1 27 Bulletin 1562E e Basic Control Controlled Start Only 1 27 Bulletin 1562E Basic Control With Controlled Stop 1 28 Bulletin 1562E DPI Control Controlled Start Only 1 28 Bulletin 1560E Basic Control Controlled Start Only 1 29 Bulletin 1560E Basic Control With Controlled Stop 1 29 Bulletin 1560E DPI Control Controlled Start Only 1 30 Schematics Bul 1562E IntelliV AC Control Circuit Without Stop Control 1 31 Bul 1562E IntelliV AC Control Circuit With Stop Control 1 32 Bul 1562E Intel V AC Control Circuit With DeviceNet 1 33 Bul 1560E IntelliV AC Control Circuit Without Stop Control 1 34 Bul 1560E In
36. 8 2 Keypad Description kite knees 8 2 Connecting the Human Interface Module to the Controller 8 4 HIM Control 8 4 Control iod cisci ir UE E SR 8 6 Loss of Communication and Network 8 6 SMC Flex Specific Information 8 6 Default Input Output Configuration eee 8 7 Variable Input Output Configuration eee 8 7 SMC Flex Bit wi 8 8 eu tree tere eee esi deer 8 9 Parameter 8 9 Scale Factors for PLC Communication sese 8 9 Display Text Unit Equivalents 8 10 Configuring Databinks 8 10 Updating Firmware oerte rrt 8 11 1560E UM051A EN P September 2005 Table of Contents MV Dialog Plus Medium Voltage Controller User Manual Troubleshooting Chapter 9 Page General Notes and Warnings eese 9 1 Fault Display Explanation aient tre ttes 9 3 Control Module Removal sees 9 6 Voltage Feedback Circuit 9 7 Voltage Sensing Board Replacement 9 8 Current Loop Power Supply 9 9 Circuit Board Replacement 9 10 Power Circuit Troubleshooting eee 9 11 Thyristor SCR Testing 9 11 SCR Replacement Procedure 9 12 Snubber and Resist
37. Data In C1 3 Volts Phase C A 48 Factory Use 93 Data In C2 4 Current Phase A 49 Factory Use 94 Data In D1 5 Current Phase B 50 Overload A Lvl 95 Data In D2 6 Current Phase C 51 Underload F Lvl 96 Data Out A1 7 Watt Meter 52 Underload 97 Data Out A2 8 Kilowatt Hours 53 Underload A Lvl 98 Data Out B1 9 Elapsed Time 54 Underload A Dly 99 Data Out B2 10 eter Reset 55 Undervolt F Lvl 100 Data Out C1 11 Power Factor 56 Undervolt F Dly 101 Data Out C2 12 tr Therm Usage 57 Undervolt A Lvl 102 Data Out D1 13 otor Speed 58 Undervolt A Dly 103 Data Out D1 14 SMC Option 59 Overvolt F Lvl 104 otor ID 15 otor Connection 60 Overvolt F Dly 105 CT Ratio 16 Line Voltage 61 Overvolt A Lvl 106 V Ratio 17 Starting Mode 62 Overvolt A Dly 107 Auxl Config 18 Ramp Time 63 Unbalance F Lvl 108 Aux3 Config 19 nitial Torque 64 Unbalance F Dly 109 Aux4 Config 20 Cur Limit Level 65 Unbalance A Lvl 110 Aux2 Config 21 Reserved 66 Unbalance A Dly 111 Language 22 Kickstart Time 67 Jam F Lvl 112 Factory Use 23 Kickstart Level 68 JamF Dly 113 Factory Use 24 Option 2 Input 69 jam A Lvl 114 Factory Use 25 Starting Mode 2 70 Jam Dly 115 Parameter Mgmt 26 Ramp Time 2 71 Stall Delay 116 Backspin Timer 27 Initial Torque 2 72 Gnd Fit Enable 117 Factory Use 28 Cur Limit Level 2 13 Gnd Level 118 Factory Use 29 Reserved 74 Gnd Flt Delay 119 Factory Use 30 Kickstart Time 2 75 Gnd Fit Inh Time 120 Factory Use 31 Kickstart Level 2 76 Gnd FItA Enable 121 Factory Use 32 Stop Mode 7
38. Full Load Current S etting Figure 1 10 Restart Trip Curves after Auto Reset 1560E UM051A EN P September 2005 Product Overview 1 11 Underload Utilizing the underload protection of the MV SMC Flex controller motor operation can be halted if a sudden drop in current is sensed MV SMC Flex controller provides an adjustable underload trip setting from 0 to 99 of the programmed motor full load current rating Trip delay time can be adjusted from 0 to 99 seconds e Underload protection is disabled during slow speed and braking operations Undervoltage e Utilizing the undervoltage protection of the MV SMC Flex motor operation can be halted if a sudden drop in voltage is detected The MV SMC Flex controller provides an adjustable undervoltage trip setting from 0 to 99 of the programmed motor voltage Trip delay time can be adjusted from 0 to 99 seconds Note For medium voltage applications undervoltage protection should be set from 80 to 99 An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing Overvoltage e Utilizing the overvoltage protection of the MV SMC Flex motor operation can be halted if a sudden increase in voltage is detected The MV SMC Flex controller provides an adjustable overvoltage trip setting from 0 to 199 of t
39. ME ME D 11 41 L 1 L 1 lt rit lt BLK 1 gt MAIN CONTACTOR REC MOV 1 4 HC 9 B Y A M B Ne ME M nv 4 C BE BE C D 11 11 51 ERE EH 5 m LE BLK 1 BYPASS CONTACTOR REC MOV 2 N Ho B B gt BE AR STOP START alo o CR MASTER CONTROL M R MC 4 BC CR 55 1 BYPASS CONTROL FEM FILTER ERN p gt i 13 14 17 18 t9 at SMC FLEX CONTROL TERMINALS AUX NORMAL UP TO SPEED BYPASS SCANpor AUX2 AUX 3 AUXA FAULT ALARM NORMAL PTC TACH GROUND 1 IE INPUT INPUT FAULT 1 i 23 24 25 26 27 28 31 34 55 Ye SMCFLEXIB INPUT POWER u 1560E UM051A EN P September 2005 MAIN CONTROL AUX Figure C 1 Bulletin 1562E Relay Control Circuit WithoutStop Control 1560E and 1560E Relay Control C 5 lov Se CLT e O CNCNCNONONOTNON INTERFACE XX 3 BDARD 1 ec REC MOV 1 5 OH MC ME ME ME ME 2 HHHHHHI lol MAIN CONTACTOR Mov RECTIFIER
40. Maximum Voltage at PTC Terminals open 30V Maximum Number of Sensors 6 Maximum Cold Resistance of PTC Sensor Chain 15000 Response Time 800 ms The following figure illustrates the required PTC sensor characteristics per IEC 34 11 2 4000 1330 550 250 100 Figure 1 13 PTC Sensor Characteristics per IEC 34 11 2 PTC Trip The MV SMC Flex will trip with a PTC indication if No other fault currently exists PTC protection is enabled The resistance across terminals 23 and 24 is either greater than the relay s response resistance or less than the short circuit trip resistance 1560E UM051A EN P September 2005 1 16 Product Overview Protection and Diagnostics cont 1560E UM051A EN P September 2005 Open Gate An open gate fault indicates that improper SCR firing typically caused by an open SCR gate or driver system has been detected on one of the power poles Before the controller shuts down it will attempt to start the motor a total of three times or as programmed in Parameter 82 An open gate is detected when the module sends a gate signal to the SCRs but does not detect that they turned on SCR turn on is detected when the voltage across the leg L T collapses Line Faults The MV SMC Flex controller continually monitors line conditions for abnormal factors Pre start protection includes e Line Fault with phase indication Line voltage loss
41. Missing load connection Shorted SCR Running protection includes e Line Fault no phase indication Line voltage loss Missing load connection Phase reversal protection can be toggled either ON or OFF Phase reversal protection is functional only at pre start Metering Product Overview 1 17 Excessive Starts Hour The MV SMC Flex module allows the user to program the desired number of starts per hour up to 99 This helps eliminate motor stress caused by repeated starting over a short time period Note The base rating of the MV SMC Flex is two starts thirty seconds each max per hour Applications requiring more frequent starts or longer duration starts should be reviewed with the factory to avoid equipment damage Overtemperature The power module temperature is monitored during starting and stopping maneuvers by thermistors The thermistor is connected to the gate driver board where it is processed and the status is transmitted by fibre optic cable through the interface board to the control module When an overtemperature condition exists 285 C the control module trips and indicates a PTC Power Pole fault An overtemperature condition could indicate high ambient temperature overloading or excessive cycling After the power module temperature is reduced to allowable levels the fault can be cleared see page 9 1 for instructions Power monitoring parameters include e Three phase curr
42. SMC Flex itself The SMC is can be used with all LCD applicable DPI interface Regardless of the type of interface being used the information below can be used to configure the rest of the system Communications 8 7 Default In ut Output The default configuration for 1 4 bytes in and 4 bytes out TX g y y Configuration 4 bytes RX 4 bytes and is arranged according to the following table Table 8 E Produced Data Consumed Data Status Control Word 0 Logic Status Logic Command Word 1 Feedback Reference Thefeedback word is always Current in Phase A The reference word is not used with the SMC Flex however the space must be reserved Variable Input O utput The SMC Flex supports 16 bit DataLinks Therefore the device can be Configuration configured to return additional information The I O message size depends on how many DataLinks are enabled The following table summarizes the I O data sizes Table 8 F Rx Tx Logic Status Reference Data Links Size Size Command Feedback 16 bit 16 bit 4 4 X X 8 8 X X X 12 12 X X X X 16 16 X X 20 20 X X X X X X To configure DataLinks refer to Configuring Data Links on page 8 10 1560E UM051A EN P September 2005 8 8 Communications SMC Flex Bit Identification Table 8 G Logic Status Word Bit 4 Status De
43. This contact is located at terminals 19 and 20 Aux Contacts 1 allows the user to configure the operation of the contacts Control External Bypass N O N C Aux2 Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 29 and 30 Aux Contacts 2 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Aux3 Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 31 and 32 Aux Contacts 3 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Aux4 Config Contact is provided as standard with the S MC Flex controller This contact is located at terminals 33 and 34 Aux Contacts 4 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Parameter Mgmt Recall of factory default parameter values Ready Load Default When programmed for Emergency Run and the Option 2 input is energized a Start command will first close the bypass contactor then the line contactor for an across the line start of the motor A Stop command will open the line contactor first and allow the motor to coast regardless of the programmed Stop Mode For Pump Option mod
44. UM051A EN P September 2005 Measure across R36 R73 2 110 R147 R184 and R221 located at the bottom of each leg of the module The resistance should be 11 3 kohm The two ground connections must be connected to ground or to each other if the module has been removed If the values for each leg vary by more than 1 the voltage sensing module may need to be replaced See Renewal Parts listing in Appendix D and refer to procedure on page 9 8 Grounds must be reconnected on the voltage sensing boards Failure to do so may result in injury death or damage to equipment Note The white high voltage wires must be connected to the correct tap on each leg of the voltage sensing module Failure to do so may result in equipment damage The ribbon cable must be connected to J1 only on the voltage sensing board or the equipment will not function 4 When repairs are complete re assemble all parts check all fasteners and verify all connections are correct and tight Make sure all barriers and mechanical parts are in place and secured Make sure ground wires from the Voltage Sensing Module are securely connected to the ground bar in the low voltage panel Failure to do so may result in severe injury or equipment damage 5 Repeat Thyristor SCR resistance checks page 9 12 and Power Supply Tests page 3 7 Troubleshooting 9 29 Snubber Resistor Replacement When replacing the ceramic wire wound type snubber resistors use caution w
45. Unbalance Alarm Delay Jam Determines the trip level as a percentage of motor full load current and delay period Jam Fault Level Jam Fault Delay Alarm Level Jam Alarm Delay Stall Allows the user to setthe stall delay time Stall Delay Ground Fault Allows the user to enable the ground fault level in amps delay time and inhibittime A separate core balance current transformer is required Ground Fault Enable Ground Fault Level Ground Fault Delay Ground Fault Inhibit Time Ground Fault Alarm Enable Ground Fault Alarm Level Ground Fault Alarm Delay PTC O Allows the user to connect a PTC to the SMC and enable a fault when it becomes active PTC Enable Phase Reversal Determines the proper orientation of line connections to the SMC If Enabled and phases are out of sequence a fault will be indicated Phase Reversal Restarts Allows the userto determine the maximum number of restarts per hour the unit can experience and delay time between consecutive starts Restarts P er Hour Restart Attempts Restart Delay The delay time must be set to a value greater than zero when Undervoltage Overvoltage and Unbalance are enabled Underload detection to function the Motor FLC must be programmed in the Motor Protection group See page 4 16 See details in Ground Fault on page 1 12 See details in Thermistor PTC Protection on page 1 13
46. acceleration ramp time is user adjustable from 0 to 30 seconds Once the MV SMC Flex controller senses that the motor has reached the up to speed condition during the voltage ramp operation the output voltage automatically switches to full voltage and the bypass contactor is closed Percent Voltage 100 Initial Torque Start Run Time seconds Figure 1 1 Soft Start 1560E UM051A EN P September 2005 1 4 Product Overview Starting Modes cont Selectable Kickstart Selectable kickstart provides a power boost at start up that is user adjustable from 0 to 90 of locked rotor torque The additional power helps motors generate higher torque to overcome the resistive mechanical forces of some applications when they are started The selectable kickstart time is user adjustable from 0 0 to 2 0 seconds Kickstart 100 Initial Torque Start gt 6 Run 5 Time seconds Figure 1 2 Selectable Kickstart Current Limit Start e This starting mode provides a true current limit start that is used when limiting the maximum starting current is necessary The Current Limit level is user adjustable from 50 to 600 of the motor s full load ampere rating and the current limit time is user adjustable from 0 to 30 seconds Once the MV SMC Flex controller senses that the motor has reached the up to speed condition during the current limit starting mode the output voltage a
47. codes 1560E UM051A EN P September 2005 Specifications A 5 Table A 5 Shipping Weights and Dimensions Current Horsepower kW Dimensions in inches mm Shipping Weight 400 V V 4200V V V Width Depth Height g Rating 24007 3300 200V 6600V 6900 dth h h Ib k Bulletin 1560E 800 1000 1250 200A 600 746 933 7 i 26 36 1500 2250 2750 660 914 2315 1119 1679 2051 3 7 Bulletin 1560E 2250 2500 200A 1678 1865 36 36 91 1220 554 T 4500 5000 914 914 2315 3357 3730 2750 4000 4500 7500 7500 44 36 91 600A 2051 2984 3357 5595 5595 1117 914 2315 1330 590 Bulletin 1562E 800 1000 1250 ZUR 600 746 932 36 36 91 2 m 1500 2250 2750 914 914 2315 1119 1679 2051 Bulletin 1562E 2250 2500 208 4 1676 1865 62 36 91 2325 1056 n 4500 5000 1575 914 2315 7 3357 3730 Bulletin 1562E 2750 4000 4500 80 36 91 ao 12050 089 8357 7 2032 914 035 2325 1056 7500 7500 80 36 91 5595 5595 2540 914 2315 3000 1364 Weights and dimensions are approximate Certain options such as PFCC will change weight and dimensions Contact factory for certified dimensions and weights 15
48. employ additional mitigation methods The following guidelines are provided for EMC installation compliance Enclosure Install the product in a grounded metal enclosure Wiring Wire in an industrial control application can be divided into three groups power control and signal The following recommendations for physical separation between these groups is provided to reduce the coupling effect Different wire groups should cross at 90 inside an enclosure Minimum spacing between different wire groups in the same tray should be 16 6 in Wire runs outside an enclosure should be run in conduit or have shielding armor with equivalent attenuation Different wire groups should be run in separate conduits Minimum spacing between conduits containing different wire groups should be 8 cm 3 in For additional guidelines please refer to Wiring and Ground guidelines publication DRIVES INO01A EN P Wire earth ground to control terminal 14 Use shielded wire for PTC Input Tach Input Ground Fault Input Terminate shielded wires to terminal 14 Ground fault CT must be inside or within 3 m of metal enclosure Control Power Installation 2 19 To meet produce susceptibility requirements ferrite cores need to be added to the communication lines cores specified below are the split core type so they can be added to existing connections When using an external HIM or DPI interface a core should be a
49. fan if supplied is secured and the rotor is not obstructed H Verify integrity and operation of all interlocks I Inthe case of the 1503E verify wiring and perform all tests in conjunction with OEM documentation MV SMC Flex Module Refer to Chapter 4 for programming procedures The default factory parameter settings are as shown in Appendix B Settings may be different on engineered orders or when option modules or customer requirements dictate different settings Important The module should be programmed with an understanding of how the SMC functions and the characteristics of the motor and driven load Inappropriate settings may elicit unexpected results such as lack of acceleration torque or full voltage starting For Pump Control applications refer to Application Considerations on page 1 20 If the factory settings are not suitable for the application program the module to meet the application requirements Contact your local Rockwell Automation representative or the factory if assistance is required 1560E UM051A EN P September 2005 3 4 Commissioning P rocedures Hi Pot and Megger Test 1560E UM051A EN P September 2005 It is recommended that insulation levels be checked before energizing power equipment This may be done with a High Voltage AC insulation tester HI POT or a Megger See Vacuum Contactor User Manual for suggested HI POT testers and for test procedures for vacuum contactors If using a M
50. from within the controller Operate the contactors and relays manually to ensure that they operate freely Store the equipment in a clean dry place if it will not be installed immediately after unpacking The storage temperature must be between 209 and 75 C 4 F and 167 F with a maximum humidity of 95 non condensing to guard against damage to temperature sensitive components in the controller 1560E UM051A EN P September 2005 2 2 Installation General Precautions In addition to the precautions listed throughout this manual the following statements which are general to the system must be read and understood The controller contains ESD electrostatic discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing the assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures refer to applicable ESD protection handbooks Famuli An incorrectly applied or installed controller can damage components or reduce product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system Only personnel familiar with the controller and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to do this may res
51. full speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button will initiate a brake stop Slow Speed cannot be operated via the HIM Jog Braking Control is not offered for standard use in MV applications Please consult factory for further assistance ATTENTI ON 1560E UM051A EN P TBA 2005 The Bulletin 20 HIM interface module s stop push button is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements Options 6 3 Programming Parameters The following table provides the option specific parameters that are provided with each control option These parameters are in addition to those already discussed in the Basic Set Up and Metering groups Diagrams supporting the options described below are shown later in this chapter Option Parameter Range Pump Control SMC Option Pump Control Pump Control This parameter identifies the type of control present and is not user programmable Pump Stop Time Allows the user to set the time period for the pump stopping function 0101205 Starting Mode Pump Start Soft Start Allows the userto program the Current Limit Start SMC Flex controller for the type of Full Voltage starting that best fits the application Braking Control SMC Option Braking Control SMB Smart Motor Braking This parameter identifies the
52. nylon circuit board supports are all engaged Plug in thermistor and gate connectors and reconnect wires to the left side of the board Plug in the fibre optic cables 5 Replace current loop cable see page 9 9 Tighten the terminals at the current loop power supply to 5 6 N m 50 in Ib 6 Make sure all connections are secure Perform resistance checks according to instructions on Thyristor SCR Testing page 9 12 and test gate drive circuits by performing power supply tests in Chapter 3 page 3 6 1560E UM051A EN P September 2005 9 16 Troubleshootin Figure 9 4 Upper Low Voltage Panel and Power Cell Detail 1562E 2400 to 4160 V 180 360 A 1560 0 051 September 2005 Troubleshootin 9 17 Heatsink 1 1 Heatsink 2 SCR 2 Heatsink 3 Figure 9 5 Power Module Assembly one phase 1000 1300 1500 2400 V 180 360 A Do notloosen Locking Nut Do not adjust Indicating Washer To remove clamp pressure loosen lower center nut so that gap between the clamp surface and the heatsink is approximately 6 mm 0 25 in Figure 9 6 Heatsink Clamp 1560E UM051A EN P September 2005 9 18 Troubleshoo
53. runs at full line voltage When the Stop button is pressed the CR relay opens terminal 17 on the SMC Flex module The AUX4 Normal contact opens dropping out the main contactor allowing the motor to stop The AUX1 contact also opens but is held closed for a short time by the control module This holds the bypass contactor closed for about 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits 1560E UM051A EN P September 2005 C 2 1560E and 1560E Relay Control Functional Description cont 1560E UM051A EN P September 2005 Bulletin 1562E Basic Control With Controlled Stop When wired as shown in Figure C 2 the controller operates in much the same manner as in Figure C 1 Terminal 16 on the SMC Flex module now controls the start and stop maneuvers Terminal 16 must remain energized for the module to run When the Stop button is pressed and CR opens the SMC Flex module will initiate the option stop An uncontrolled or coast stop is achieved by opening the connection to terminal 17 This contact should remain open to ensure all hold in contacts clear to prevent a re start If the motor has started the unit is in the bypass mode and a trip occurs within the SMC Flex module or from an external protection relay AUX4 will open the line contactor immediately AUX1 will remain closed for 10 seconds A trip due to an overload or fault condition
54. sensor input r mi a Sa LED Yellow ON A 5 TERT wen Phase 8 gate signal active power supply is present ue Eee Transmiters 5 gate sig transformer L 3 B connections gt C V LB LED Yellow ON 2 when Phase C im c a signal active gt C TP13 Phase C gate signal PhaseC Fibre Optic4 LED Green Transmitters 34 15 Common for ON when Gate P ulse TPs power is a present EL TP18 19 20 5 4 O Power supply n test points EE SW3 Used to gt TEMP LEDs Green ON when signal defeattemperature DEFEAT present at temperature feedback feedback channels fibre optic receivers Temperature amps oO Feedback Fibre Optic fem c C Receivers BI 4 1 11 LNG Serial Replacement Number P art Number or 110 250 VDC Notes 1 ICOM is the common connection for Gate and Pulse test points 2 VCOM is the common connection for Current and Voltage feedback test points 1560E UM051A EN P September 2005 2 VCOM is not connected to earth ground do not connect and VCOM together either directly or through test probes meter or scope common Figure 3 2 Connection and Test Information for Interface Board Commissioning P rocedures 3 7 Power Supply T
55. supplied documentation and is suitable for commissioning programming calibration metering serial communications diagnostics troubleshooting and maintenance of a standard solid state controller The following flowchart is provided to aid in quick troubleshooting YES Fault Displayed NO Define Nature of Trouble Motor rotates but does not accelerate Motor stops Miscellaneous to full speed while running situations See See See See Table 9 B Table 9 C Table 9 D Table 9 E Figure 9 1 Troubleshooting Flowchart Troubleshooting 9 3 Table 9 A Fault Display Explanation Display Fault Code Possible Causes Possible Solutions Line Loss 1 2 3 Missing supply phase Check for open line e g blown line fuse with phase indication Motor not connected properly Check for open load lead Improper or missing current or Check current transformer connections and module voltage feedback programming Check voltage sensing board connections and module programming Check ribbon cable connections between Interface Board and Control Module Check voltage feedback circuits Consultfactory Shorted SCR 4 5 and 6 Shorted Power Module Check for shorted SCR replace if necessary See Power Circuit Troubleshooting Open Gate 7 8 and 9 Open gate circuitry Perform power supply tests Chapter 3 with phase indication Loose gate lead Check gate lead connections to th
56. text descriptions when viewed from a HIM or through a communication software program such as RSNetworx When receiving or sending information from a PLC each text description has a numerical equivalent Table 8 I has an example of Parameter 44 Overload Class and the appropriate relationship between the text descriptor and the equivalent value This relationship is identical for other similar parameters located in Appendix B Table 8 1 Text Descriptor Numerical Equivalent Disabled 0 Class 10 1 Class 15 2 Class 20 3 Class 30 4 DataLinks are supported in the SMC Flex A DataLink is mechanism used by most drives to transfer data to and from the controller without using an Explicit Message The SMC Flex supports 16 bit DataLinks therefore the device can be configured to return up to four additional pieces of information without the need for an explicit message Rules for Using DataLinks Each set of DataLink parameters in an SMC Flex can be used by only one adapter If more than one adapter is connected multiple adapters must not try to use the same DataLink Parameter settings in the SMC determine the data passed through the DataLink mechanism When you use a DataLink to change a value the value is not written to the Non Volatile Storage NVS The value is stored in volatile memory and lost when the drive loses power Parameters 88 to 103 are used to configure the DataLinks For additional informatio
57. tightness of all terminals and bus bar connections and securely tighten any loose connections Replace any parts or wiring damaged by overheating 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 clean any residues of melted coil insulation from other parts of the device or replace such parts Maintenance 10 3 Solid State Devices Solid state devices require little more than a periodic visual inspection Printed circuit boards should be inspected to determine whether all cables are properly seated in their connectors Board locking tabs should also be in place Necessary replacements should be made only at the PC board or plug in component level Solvents should not be used on printed circuit boards Where blowers are used air filters if supplied should be cleaned or changed periodically depending on the specific environmental conditions encountered For additional information see NEMA Standards Publication No ICS 1 1 1987 entitled Safety Guidelines for the Application Installation and Maintenance of Solid State Control Use of other than factory recommended test equipment for solid state controls may result in damage to the control or test equipment or unintended actuation of the controlled equipment Static Sensitive Items While performing mainten
58. will be cleared and the module will perform the programmed sequence Control Wiring Refer to Chapter 1 Product Overview for typical control wiring examples used with various control schemes 1560E UM051A EN P TBA 2005 6 6 Options 1560E UM051A EN P TBA 2005 Overview Fault Display Diagnostics This chapter describes the fault diagnostics of the MV SMC Flex controller Further this section describes the conditions that cause various faults to occur Protection Programming Many of the protective features available with the SMC Flex controller can be enabled and adjusted through the programming parameters provided For further details on programming refer to the Motor Protection section in Chapter 4 Programming The SMC Flex controller comes equipped with a built in three line 16 character LCD The LCD displays the fault message on the first line the fault code on the second line and the fault description on the third line Faulted Fault 27 COMS LOSS P2 Figure 7 1 Fault Display Note The fault display will remain active as long as control power is applied If control power is cycled the fault will be cleared the controller will re initialize and the display will show a status of Stopped Note You can hit ESC to get to another programming diagnostic list but the SMC Flex will still be in a faulted state Important Resetting a fault will not correct the cause of the fault condition Corre
59. 0 600 5500 to 6900 V To make power connections for a two high cabinet refer to Figures 2 1 to 2 3 and Publication 1500 UMO055B EN P Chapter 2 To make power connections for a one high FVNR cabinet and a 1560E unit proceed as follows Make line connections within the one high cabinet Make load connections at the 1512 CT terminals Bulletin 1560E Refer to Figures 2 4 to 2 6 depending on the rating of the unit Make line connections to the line connection terminals Make load connections to the current transformer terminals 1560E UM051A EN P September 2005 2 6 Installation Power Connections cont Power Stack Assembly Bypass Vacuum Contactor Voltage Sensing Module Non Load Break Isolation S witch Load Cable Connection Point top exit Line Vacuum Contactor Current Transformers Figure 2 1 Cabinet Layout 1562E 180 360 A 2400 V to 4160 V with LV panels not shown 1560E UM051A EN P September 2005 Installation 2 7 Power Cable Lugs Ground Bus Lug Figure 2 2 Incoming Line Cable Connections viewed from the rear with power bus access cover removed Cable Duct Barrier Cable Duct Boot Motor Cable Terminals Figure 2 3 Bottom Cable Exit Configuration with LV panel swung open 1560E UM051A EN P September 2005 2 8 Installation Power Connections cont Bulletin 1560E Refer to Figures 2 4 to 2 6 to make power connections for a 1560E unit Note
60. 00 feet without derating Humidity 5 to 95 non condensing Pollution Degree 2 Seismic UBCRating 1 2 3 4 Some units may require special bracing Contact factory for more information Starter Deratings are in Table A 2 Table A 2 Altitude Derating Power Cell Rating Reduce ud 180A 6 Withstand Rating By 1 000 to 2 000 m Reduce Max Continuous Current R ating b 2122 i n 777 Current deratings shown are the minimum levels Additional derating may be required due to power fuse limitations Please consult factory for additional details Table A 3 Area Available for Cable Entry Exit To Bottom Voltage P Line Load Line Load 5 68 X 9 00 EH 5 68 X 9 00 R 14 60 2300 4160 V 144 X 229 Combined with line 144 X 229 Combined with line 5 68 X 12 55 TT 5 68 X 12 55 1 220 14 62 6900 144 319 Combined with line 144 X 319 Combined with line 5 68 X 12 55 aq 5 68 X 12 55 14 64 144 X 319 Combined with line 144 X 319 Combined with line 5 68 X 5 68 5 68 X 9 00 5 68 X 9 00 5 68 X 9 00 2300 4160 V 144 X 144 144 X 229 144 X 229 144 X 229 5 68 X 9 00 5 68 X 9 00 5 68 X 5 68 5 68 X 9 00 6900 V 144 X 229 144 X 229 144 X 144 144 X 229 5 68 X 9 00 5 68 X 9 00 5 68 X 9 00 5 68 X 9 00 14 14 2300 4160 V 144 X 229 144 X 229 144 X 229 144 X 229 14 16 Al 5 68 X 9 00 7 25 X 15 8
61. 0E UM051A EN P September 2005 display does not provide a highlighted cursor then the controller is in the Display mode Programming 4 9 Soft Start The following parameters are specifically used to adjust the voltage ramp supplied to the motor Parameter Option Starting Mode Soft Start This must be programmed for S oft Start Ramp Time 010 305 This programs the time period that the controller will ramp the output voltage up to full voltage from the initial Torque level programmed Initial Torque 0 to 90 locked rotor torque The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter Kickstart Time 0 0 to 2 05 A boost of current is provided to the motor for the programmed time period Kickstart Level 0 to 90 locked rotor torque Adjusts the amount of current applied to the motor during the kickstart time Ifthe controller senses that the motor has reached full speed before completing the S oft Start it will automatically switch to providing full voltage to the motor Current Limit Start To apply a fixed reduced output voltage to the motor the following parameters are provided for user adjustment Parameter Option Starting Mode Current Limit This must be programmed for Current Limit Ramp Time 0to 305 This programs the time period that the controller will hold the fixed reduced output voltage before switching to full
62. 16 If any voltage is well outside this range there may be problem either with the system voltage or with the voltage sensing board Note that the load side voltages Load A Load B Load C will be very low since the SCRs are not turned on and only a low leakage current flows to the motor If the motor will start and run the line and load voltages should be the same when the bypass contactor is closed 1560E UM051A EN P September 2005 9 8 Troubleshootin Voltage Sensing Board 1 Replacement Ensure there is no power to the equipment aee To prevent electrical shock ensure the main power has 99 Mounting Hardware Mounting Hardware Verify that all circuits are voltage free using a hot stick or appropriate high voltage measuring defice Failure to do so may result in injury or death been disconnected before working on the sensing board Mark the position of the ribbon cable and wires Remove the screws and lift the ring lugs from the terminals to remove the wires Release the locking mechanism located on each side of the ribbon cable connector and pull the ribbon cable straight out to prevent bending the pins Remove the 4 nuts that secure the assembly to the side panel Replace with the new assembly securing with all 4 nuts and washers See diagram below Replace ring lugs on terminals Plug in ribbon cable making sure that it is positioned properly and fitting is secure locking mech
63. 2 09 06 av LSH 92 m 99 E 2 oT 909 ng x at 5 591 avos 9589 652 i m 95 2 9 0 SAO o GSH esa 2 mE cao 140 2 ES 1 5 Tus o ySH o 7 0 5 Jo 59 ra 5 9 89 MDLSIA IHL 15 Ho o SH A0E2 SH 2 i T lt s d D s o 020 o 2SH 252 2 182 I8 3 Blam 2 749 six 3 est ROM ISH T1 270 T am E vy el 25 2s E rn Ar Ta 25 Ta T 2 E Y Gr exc 20ND 5 a worn 2 fase 099 BL 3 5 5 8 1 0 ED 2 29 191 e sofi ext En n 9 160 499 32V3a31NI X314 94S a saavia amp 3 5 3199 X x vis P veo L 1 uoo t 2908 DNISN3S 39 1 710A Figure 3 1 Typical MV SMC Flex Power System Wiring Diagram 5500 6900V shown 1560E UM051A EN P September 2005 3 6 Commissioning P rocedures SW2 When ON up provides test pulses to gate driver circuits NOTE Mustbe OFF down for LED
64. 2E SMC Flex Specifications Page Specifications Table A 1 then 1 Altitude Deratng Table 4 2 ceti ttiv ras A 3 Area Available for Cable Entry Exit Table 3 A 3 Cable Quantity and Size Table A4 4 Shipping Weights and Dimensions Table A 5 A 5 Power Bus and Ground Bus Table A 6 Power Fuses and Losses Table 0 7 Control Wire and Power Wire Table 8 A 8 Parameter Information Parameter 80 M 1 1560 and 1562E Relay Control Functional Description C 1 Bulletin 1562E e Basic Control Controlled Start Only C 1 Bulletin 1562E e Basic Control With Controlled Stop C 2 Bulletin 1562E DPI Control Controlled Start Only C 2 Bulletin 1560E e Basic Control Controlled Start Only C 3 Bulletin 1560E e Basic Control With Controlled Stop C 3 Bulletin 1560E DPI Control Controlled Start Only C 3 Schematics Bul 1562E Relay Control Circuit Without Stop Control 4 Bul 1562E Relay Control Circuit With Stop Control C 5 Bul 1562E Relay Control Circuit With DeviceNet C 6 Bul 1560E Relay Control Circuit Without Stop Control C 7 Bul 1560E Relay Control Ci
65. 5H His BYPASS CONTROL AUX CONTACTOR vert emc riter E N P E 12 13 14 15 16 17 18 19 20 21 ee SMC FLEX CONTROL TERMINALS AUX UP TO SPEED SCANport AUX2 AUX 3 AUX A FAULT ALARM NORMAL INPUT fa 1H 23 24 es e6 27 28 89 30 31 32 33 34 E MAIN CONTACTOR CLOSE CONTROL CONTROL AUX SMCFLEXIB NPUT POWER hr Le N 1560E UM051A EN P September 2005 Figure 1 21 Bulletin 1562E IntelliVAC Control Circuit WithStop Control 10 CLT 9 T xi 06 INTERFACE XX j E BOARD LET RM 21 M IV 1 gc AEM 3 Mov N n 6 AUX HC 12 215 L G N 1 1 gc 2 3 MOV A BB N NOT aux 2 12 5 N o G N pum EMC FILTER FEMC N E N 1 T START egent 13H nH al o o CR MODULE MODULE M IV STATUS STATUS CR is HEH CONTACTOR STATUS B IV LOCAL REMOTE 916 Sh 55 CR 15H BC CONTACTOR STATUS P FEM EMC F
66. 60 1562E are Allen Bradley manufactured starters Refer to Service Manual for specific spare parts list 3 For spare parts for starter and contactor components refer to Documentationon page 1 1 1560E UM051A EN P September 2005 Accessories Table E 1 Accessories Description Description Used With Catalog Number Remote Door Mounted HIM IP66 Type 4 12 P rogrammer Only Spies Remote 1 0 20 COMM R RS 485 DF 1 20 COMM S DeviceNet 20 COMM D ControlNet 20 COMM C E EtherNet IP 20 COMM E Communication Modules Profibus 8 20 COMM P InterBus 20 COMM I LonWorks 20 COMM L ControlNet Fiber 20 COMM Q RS485 HVAC 20 COMM H 1560E UM051A EN P September 2005 2 Accessories 1560E UM051A EN P September 2005 www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen B radley Products Rockwell Software Products and Global Manufacturing Solutions 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 SA NV Vorstlaan Boulevard du S ouverain 36 1170 Brussels 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 T
67. 60E UM051A EN P September 2005 A 6 Specifications Table A 6 Power Bus and Ground Bus Description Specifications Main Horizontal Power Bus Bus Bar Material Tin plated copper Optional Bus Bar Material Silver plated copper Continuous Current Rating at 40 C 10492 1200 2000 and 3000 A Maximum Full Load Temperature Rise 65 C 149 Maximum Full Load Temperature 105 C 221 F Fault Withstand Current Rating 4 5 Cycles 60 RMS SYM 96 ASYM Type of Bus Bracing Molded glass polyester Anti hygroscopic 1200 A Qty 1 6 x 100 mm 1 4 x 4 in Dimensions per Phase 2000 A Qty 2 6 x 100 mm 1 4 x 4 in 3000 A Qty 2 9 5 x 127 mm 3 8 x 5 in 1200 A 65 mm 1 0 in total Cross Sectional Area per Phase 2000 A 129 mm 2 0 in total 3000 A 242 mm 3 75 in total Insulating Material Between Phases and Ground Air Standard Sleeve heat shrink Material Polyolefin Optional Insulation Material for Main Horizontal Bus Thickness 14 mm 0 055 in Anti hygroscopic 0 5 to 1 Electrical Strength 900 V mil Vertical Power Bus Bus Bar Material Tin plated copper Continuous Current Rating at 40 C 10492 400 600 and 800 A Fault Withstand Current Rating cycle n Sleeve heat shrink Material Polyolefin Insulation Material for Vertical Bus Thickness 1 14 m
68. 7 Gnd 122 Factory Use 33 Stop Time 78 Gnd FItA Dly 123 Factory Use 34 Factory Use 79 PTC Enable 124 Fault 1 35 Braking Current 80 Phase Reversal 125 Fault 2 36 Factory Use 81 Starts Per Hour 126 Fault 3 37 Factory Use 82 Restart Attempts 127 Fault 4 38 Factory Use 83 Restart Delay 128 Fault 5 39 Slow Speed Sel 84 Factory Use 129 Factory Use 40 Slow Speed Cur 85 Factory Use 130 Factory Use 41 Slow Accel Cur 86 Factory Use 131 Factory Use 42 Slow Running Cur 87 Logic Mask 132 Option 1 Input 43 Stopping Current 88 Data In Al 133 Stop Input 44 Overload Class 89 Data In A2 134 Factory Use 45 Service Factor 90 Data In B1 1560E UM051A EN P September 2005 Programming 4 5 Password The SMC Flex Controller allows the user to limit access to the programming system through password protection This feature is disabled with a factory set default of 0 To modify the password or login after a password is programmed complete the procedure below Description Action Display ____ vy Press the ESC key to go from the status display to the Main menu Main Menu Diagnostics Scroll with the Up Down keys until Main Menu the P references option is highlighted Preferences Press the Enter key to access the Preferences menu Change Password User Dspy lines Scroll with the Up Down keys until the Change Password option is highlighted Prefer
69. 8 5 68 9 00 7 25 15 88 144 229 184 403 144 229 184 403 Dimensions are in inches mm 1560E UM051A EN P September 2005 4 Specifications Table A 4 Cable Quantity and Size Bulletin Structure Max No amp Size of Max No amp Size of Max No amp Size of Code cables no bus Cables w bus Exiting Load Cables 26W X 91H 1 500 1 500 1 500 660 2311 2 2 250mcm phase 36W X 91H 1 500 1 1 500 914 2311 2 2 250m 2 350mcm phase 91 1 500 1 1 500 8 2 250 2 350mcm phase E 91H 1 500 1 1 500 pee a 914 X 2311 2 eh 2 500m 2 350mcm phase 62 W X 91H 1 500 1 1 500 1302E 1575 2311 m 2 250 2 250mcm phase m phase 80 W X 91H 1 500 1562 2032 2311 1 750mcm phase 2 350mcmiphase 100 W X 91H 1 1000 2 750 id 2540 X 2311 2 4 500mcm phase 1 Restrictions based upon single conductor cable 2 Please contact factory for multiple conductors shielded or other specialized cables 3 Please contact factory if the maximum number size needs to be exceeded We can accommodate special requests by incorporating landing pads if room is available or cable terminating units 4 customer is responsible to size the cables and conduits in accordance with applicable installation
70. ASS CONTACTOR 5 N FILTER P FEMC N START STOP_ SIGNAL FROM EXISTING STARTER gt 13H CR MASTER CONTROL MODULE CR STATUS OFF LOCAL REMOTE CR B IV CLOSE 4 o BYPASS CONTACTOR CLOSE CONTROL B 1V 1 5H BYPASS CONTROL AUX CONTAC TR STATUS FILTER P 14 6 7 19 at 22 SMC FLEX 24 CONTROL TERMINALS AUX UP TDI SPEED CANH TU DEVICENET SCANpor NETWORK AUX2 AUX3 AUX A FAULT ALARM NorMaL CAN L TACH GROUND INPUT FAULT 1 H 1 H EY 23 4 25 26 27 28 29 30 at 32 33 34 WIRE SMCFLEXIB MAIN CONTACTOR INPUT POWER Lt L2 N Figure 1 25 Bulletin 1560E IntelliVAC Control Circuit With DeviceNet or DPI Communication and optional Local Off Remote 1560E UM051A EN P September 2005 Receiving Safety and Codes Unpacking and Inspection Chapter 2 Installation Perform the installation duties correctly Errors may cause commissioning delays equipment damage or personal injury Important For the 1503E refer to applicable documentation from OEM installation grounding interlocking and wiring This manual should be utilized in conjunction with the OEM supplied documen
71. Dly 58 SEC 0 99 0 Overvolt F Lvl 59 V 0 199 0 Overvolt F Dly 60 SEC 0 99 0 Qvervoltage Overvolt A Lvl 61 V 0 199 0 Overvolt A Dly 62 SEC 0 99 0 Unbalance F Lvl 63 0 25 0 TN Unbalance Dly 64 SEC 0 99 0 Unbalance A Lvl 65 96 0 25 0 Unbalance 66 SEC 0 99 0 Jam F Lvl 67 FLC 0 1000 0 Jam F Dly 68 SEC 0 99 0 jam A Lvl 69 FLC 0 1000 0 Jam 70 SEC 0 99 0 Stall Stall Delay 71 SEC 0 0 10 0 0 Pump option modules default to Pump Stop 1560E UM051A EN P September 2005 Table 1 Parameter List cont Parameter Information B 3 Group Parameter Description flee Units Min Max Y 3 Gnd Flt Enable 72 a Disable Gnd Flt Level 73 1 0 5 0 2 5 Gnd Fit Delay 74 SEC 0 1 250 0 0 5 Ground Fault Gnd Flt Inh Time 15 SEC 2 25 10 Gnd Enable 76 Disable Gnd FItA Lvl 71 1 0 5 0 2 0 Gnd FItA Dly 78 SEC 0 250 10 PTC PTC Enable 79 ds Disable Phase Reversal Phase Reversal 80 Disable Starts Per Hour 81 0 99 2 Restart Restart Attempts 82 0 5 2 Restart Delay 83 SEC 0 60 0 Comm Masks Logic Mask 87 8 bit binary Data In Al 88 Data In A2 89 Data In B1 90 Data In B2 91 Data In C1 92 Data In C2 93 Data In 01 94 Data In 02 95 pee Ins Data Out A1 96 Data Out A2 97 Data Out B1 98 Data Out B2 99 Data Out C1 100 Data Out C2 101 Data Out D1 102 Data Out D2 103 Mot
72. ILTER ENC E 14 15 17 1 at SMC FLEX 5 EN CONTROL TERMINALS AUX NORMAL UP T0 SPEED BYPASS SCANport AUX2 AUX3 AUXA FAULT ALARM NORMAL nic PTC TACH GROUND INPUT INPUT FAULT 1 H 1 H 23 25 26 27 ee ee am se 33 CLOSE 9 1 MC SMCFLEXIB INPUT POWER Figure 1 22 Bulletin 1562E IntelliVAC Control Circuit u 72 Product Overview 1 33 MAIN CONTACTOR BYPASS CONTACTOR MASTER CONTROL BYPASS CONTACTOR CLOSE CONTROL BYPASS CONTROL AUX MAIN CONTACTOR CLOSE CONTROL MAIN CONTROL AUX With DeviceNet or DPI Communication and Optional Local Off Remote 1560E UM051A EN P September 2005 1 34 Product Overview
73. MV90 8 0 kV 90 C 194 For72kV rated controllers 8 AWG 8 0 kV EP CSPE 90 non shielded stranded cable is used 72 kV rated controllers 2 AWG 24 0 AWG or 350 kcmil 8 0 kV EP CSPE 90 non shielded stranded cable is used 1560E UM051A EN P September 2005 Appendix Parameter Information Table 1 Parameter List RS Parameter Default User Group Parameter Description Number Units Min Max Settings Settings Volts Phase 1 V Volts Phase B C 2 V Volts Phase C A 3 V Current Phase A 4 A Current Phase B 5 A Current Phase C 6 Watt Meter 1 KW MW Metering Kilowatt Hours 8 KWH MWH Elapsed Time 9 Hours NO Meter Reset 10 ETM Reset NO KWH Reset Power Factor 11 0 00 0 99 Mtr Therm Usage 12 96 0 100 Motor S peed 13 96 0 100 Standard SMC Option 14 Brake Pump Control Motor Connection 15 Line Delta Line e Line Voltage 16 V 0 10000 480 Full Voltage Current Limit Starting Mode 17 S oft Start Soft Start Linear Speed Pump Start Ramp Time 18 SEC 0 30 10 Initial Torque 19 LRT 0 90 70 t Cur Limit Level 20 FLC 50 600 350 Torque Limit 21 LRT 0 100 90 Kickstart Time 22 SEC 0 0 2 0 0 0 Kickstart Level 23 96 LRT 0 90 0 Disable Preset Slow Speed Dual Ramp Fault Option 2 Input 24 FaultNC Disable Network Clear Fault Emergency Run Full Voltage Current L
74. ONTROL BYPASS CONTACTOR CLOSE CONTROL BYPASS CONTROL AUX MAIN CONTACTOR CLOSE CONTROL MAIN CONTROL AUX Figure 1 20 Bulletin 1562E IntelliVAC Control Circuit eWthoutStop Control 1560E UM051A EN P September 2005 1 32 Product Overview 10v 4 H3 He 4 CLT INTERFACE CS BOARD M IV 1 E 2 Mov A BB N z AUX MAIN CONTACTOR L G 1 gc 9 B B N Z aux 5 BYPASS G FILTER FEMC E N 5 STOP sH BH Hia 3 CR MASTER CONTROL MODULE MODULE M IV TATUS STATUS 15H Hte CONTACTOR TATUS STDP o 8 1 i Mime BYPASS CONTACTOR CLOSE CONTROL 9 10 BC CR Iv 55 T 4 1
75. Programming 4 15 Example Settings Undervoltage With Line Voltage programmed for 4160 V and the Undervoltage level programmed for 80 the trip value is 3328 V Overvoltage With Line Voltage programmed for 3300 V and the Overvoltage level programmed for 115 the trip value is 3795 V Jam ee With Motor FLC programmed for 150 Amps and the Jam level programmed for 400 the trip value is 600 Amps Underload e With Motor FLC programmed for 90 Amps and the Underload level programmed for 60 the trip value is 54 Amps average value of the three phase to phase voltages is utilized largest value ofthe three phase currents is utilized The SMC Flex will self protect 1560E UM051A EN P September 2005 4 16 Programmin Motor Information 1560E UM051A EN P September 2005 The Basic Set Up and Overload programming group allows the user to set parameters indicating to the controller which motor is connected It is important to correctly input the data to achieve the best performance from your controller For overload protection it is critical that the data be entered as it appears on the motor nameplate Enter the system voltage in this parameter This must be done to ensure optimum motor performance and correct operation of undervoltage and overvoltage protection Motor Data Entry In the Program mode enter the correct values into the Overload grou
76. Statt certet ertet nie 4 10 Voltage Start 4 11 Speed ciant 4 11 Control 4 11 Preset Slow Speed 4 12 IET 4 12 Motor Protection oe Ere c 4 14 Example E 4 15 Motor Informati ON vi ne rre ere Paro reete 4 16 1560E UM051A EN P September 2005 iv Table of Contents MV Dialog Plus Medium Voltage Controller User Manual Metering Chapter 5 Page cuu E EEE 5 1 Viewing Metering Data eee er rt eee bane 5 1 Options Chapter 6 OVERVIEW axe ena 6 1 Human Interface Module eene 6 1 Programming Parameters terere rei 6 3 Control n 6 5 Diagnostics Chapter 7 OVERVIEW oai 7 1 Fault Display eee ee rre tenet 7 1 Clear aesti UO RARE RERO 7 2 B ffet ee yer eti e e e 7 2 Fault and Alarm Auxiliary Indication 7 3 DefitiOns deec eese reete erronee eade tus 7 4 Communications Chapter 8 8 1 Communication 8 1 Human Interface Moduleres annaran eE
77. age Aux4 Config PTC Enable Backspin Timer Overvolt F Lvl Parameter Mgt O Parameter Mgt Overvolt F Dly Overvokt A Lyi Phase Reversal Dual Ramp Option 2 Overvolt A Dly Input Dual Ramp Parameter Mgt Phase Reversal Starting Mode 2 Parameter Mgt Ramp Time 2 Initial Torque 2 Restart Cur Limit Lvl 2 Unbalance F Lvl d Kickstart Time 2 Unbalance Dly Starts Per Hour Kickstart Lvl 2 Unbalance A Lvl Restart Attempts Parameter Mgt Unbalance A Dly Restart Dly Parameter Mgt Parameter Mgt 3 Slow Running C ur Parameter Mgt 6 Depending upon SMC option selected some parameters may not appear in product display Steps back one level For further information on parameters see Appendix B For further information on parameter management see page 4 7 Option 2 Input Accu Stop Braking Current Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running C ur Stopping Current Parameter Mgt Figure 4 2 Menu Structure Hierarchy 1560E UMOS1A EN P September 2005 4 4 Programming Programming Menu cont Table 4 A Parameter Linear List Parameter No Description Parameter No Description Parameter No Description 1 Volts Phase 46 Motor FLC 91 Data In B2 2 Volts Phase B C 47 Overload Reset 92
78. ains material which will allow the user to operate maintain and troubleshoot the MV SMC Flex family of controllers The family consists of the following Bulletin numbers 1503E 1560E and 1562E Note This user manual pertains to units with Series letter K or later and firmware release 4 or later The following Rockwell Automation publications provide pertinent information for the MV SMC Flex and components MVB 5 0 General Handling Procedures for MV Controllers e 1500 7 055 Medium Voltage Controller Two High Cabinet 200A 400A User Manual e 1502 0 050 400A Vacuum Contactor Series D User Manual e 1502 0 052 400A Vacuum Contactor Series E User Manual 1502 UMOSIC EN P 800A Vacuum Contactor Series D and E User Manual 1560E SRO22B EN P Medium Voltage SMC Flex Controllers General Specifications 1503 UMOS51B EN P Intelli V AC Contactor Control Module The MV SMC Flex is a solid state three phase AC line controller It is designed to provide microprocessor controlled starting and stopping of standard three phase squirrel cage induction motors using the same control module as the Allen Bradley Bulletin 150 SMC Flex 1503E OEM Controller A chassis mount medium voltage solid state controller designed to mount in an OEM or customer supplied structure and designed to work in conjunction with an existing or OEM customer supplied starter It is comprised of
79. ame as described above for the Standard module The control signal uses terminal 16 instead of 17 and a coast stop can be achieved by opening the connection to terminal 17 Itis more important in this configuration to integrate the control circuit of the 1560E with the existing controller for better control of the Stop option The start signal for this scheme cannot be a slave of the main contactor since it must remain closed to accomplish the option stop maneuver The SMC Flex module can be used to control the main contactor such that it will close when a start 15 initiated and remain closed until it has sensed the motor has stopped following an option stop maneuver Bulletin 1560E DPI Control Controlled Start only Refer to Figure C 6 and description on page 1 29 1560E UM051A EN P September 2005 4 1560E and 1560E Relay Control 4 Hl xe 06 i INTERFACE XX B BOARD T d ij D oc M 4 M o ME
80. ance on the MV SMC special precautions must be observed in handling or touching certain static sensitive components in the cabinet Most circuit cards and SCRs can be damaged by Electro Static Discharge ESD If personnel will make contact with an ESD sensitive component during maintenance they must be grounded Grounding should be accomplished with a wrist strap which is connected to an approved ground Overload Maintenance After a Fault Condition See NEMA Standards Publication No ICS 2 Appendix A entitled Maintenance of Motor controllers after a fault condition Final Check Out After maintenance or repair of industrial controls always test the control system for proper functioning under controlled conditions that avoid hazards in the event of a control malfunction 1560E UM051A EN P September 2005 10 4 Maintenance Periodic Inspection cont 1560E UM051A EN P September 2005 Keep Good Maintenance Records This rule will be most helpful in locating possible intermittent problems by pointing to a particular area of recurring trouble within the overall system Furthermore good maintenance records will help reduce major costly shutdowns by demanding the use of proper test equipment and an appropriate inventory of spare parts For additional information see NFPA 70B RECOMMENDED PRACTICE FOR ELECTRICAL EQUIPMENT MAINTENANCE published by the National Fire Protection Association Power Components Power components shou
81. and drives a fibre optic cable if the temperature is below the setpoint 85 C If the temperature rises above the setpoint the driver is turned off and the MV SMC Flex is signalled to stop gating and initiate a temperature fault 1560E UM051A EN P September 2005 1 24 Product Overview Hardware Description cont 1560E UM051A EN P September 2005 Interface Board This circuit board takes current transformer signals plus line side and load side voltage feedback signals from the voltage sensing board and passes them to the SMC Flex for processing The control module produces gating signals for the SCRs which are received on the interface board and used to drive fibre optic transmitters The gating signals are sent to the gate driver circuit board via fibre optic cables The interface board also receives temperature feedback from the gate driver board via fibre optic cable s If the heatsink temperature rises above a set value a signal is sent to the SMC Flex to stop gating the SCRs and initiate a temperature fault For a detailed layout of this circuit board refer to Figure 3 2 on page 3 6 1 25 Product Overview TOXLNOD WOH
82. anism is engaged For personnel and equipment safety ensure both grounding connections are reconnected to the sensing board Mounting Hardware Mounting Hardware Figure 9 2 Sensing Board with mounting hardware placement 1560E UM051A EN P September 2005 Troubleshooting 9 9 Current Loop Power Supply The current loop gate driver CLGD boards receive power from two sources 1 The snubber circuit while the SCR power modules are active 2 The current loop power supply which maintains a pre charge level of power during periods when the SCR power modules are inactive this allows SCR gating while the snubber circuit is being charged KI X2 HI H2 H3 H4 T To Interface Board 1 Div PhaseA amp 2 1 Qj o Phase CLA iQ oO Phase C AT 23 Figure 9 3 Current Loop Power Supply The current loop power supply provides a current of 50 AC to each SCR power module phase assembly If this current is not detected and fed back to the interface boards stop maneuvers will not function and an Alarm will be generated 1560E UM051A EN P September 2005 9 10 T
83. ase be assured that Rockwell Automation is actively seeking alternatives to potentially hazardous materials for which no feasible alternatives exist today in the industry In the interim the following precautionary information is provided for your protection and for the protection of the environment Please contact the factory for any environmental information on any material in the product or with any general questions regarding environmental impact Capacitor Dielectric Fluid The fluids used in the snubber capacitors are generally considered very safe and are fully sealed within the capacitor housings Shipping and handling of this fluid are typically not restricted by environmental regulations In the unlikely event that capacitor fluid leaks out avoid ingestion or contact with skin or eyes as slight irritation could result Rubber gloves are recommended for handling To clean up soak into an absorbent material and discard into an emergency container Do not dispose into any drain or into the environment in general or into general landfill refuse Dispose of according to local regulations If disposing of an entire capacitor the same disposal precautions should be taken Printed Circuit Boards Printed circuit boards may contain lead in components and materials Shipping and handling of these boards are typically not restricted by environmental regulations however lead is considered a hazardous substance Circuit boards must be
84. card on port 5 is enabled 36 One HIM on port 2 and the DPI communication card on port 5 are enabled 44 Two HIMs on ports 2 and 3 and the DPI communication card on port 5 are enabled The Logic Mask parameter Parameter 87 allows the user to configure whether a communication device HIM or network connection can perform control commands such as starting Each communication port can be enabled or disabled as required When a given device is enabled through the logic mask that device is allowed to execute control commands In addition disconnecting any device with the logic mask enabled will result in a communication fault unless the communication fault is disabled When a given device is disabled through the logic mask that device cannot execute control commands but can still be used for monitoring A device that is disabled through the logic mask can be disconnected without causing a fault Stop commands override all start commands and can be initiated from the hardwired inputs or any port regardless of the logic mask The loss of communication fault will follow the functionality as defined in the DPI specification There will be separate faults for each device Since three DPI ports are supported there will be three faults that can be generated DPI provides a separate network fault for each port This fault can be generated directly by the peripheral and is separate from the Communications Loss fault which is actually generated by the
85. cating Washer 1 Do not loosen Gap Figure 9 15 6900V SCR Replacement 180 360 A SCR2 To Remove SCR1 5081 Remove shorting bar hardware Heatsink 2 Pry Heatsinks 1 and 2 apart Extract SCR Heatsink 6 To Insert New SCR Apply thin film of electrical joint compound to surfaces of SCR Install SCR so that itis seated in locating pin of heatsink note orientation of SCR Pry heatsinks to close gap ensuring that SCR is seated properly in both its locating pins Rotate SCR so thatall leads have same direction Locating P in Shorting Bar Proceed to replacement of other SCRs in the matched set SCR2 and SCR5 Heatsink 5 Note You must replace all three SCRs Heatsink 1 of a matched set Shorting Bar Locating Pins Figure 9 16 Removing and Replacing SCR1 SCR2 and SCR5 1560E UM051A EN P September 2005 9 24 Troubleshootin Heatsink Assembly Line connection G oS deoo Load connection Gate Driver Boards Gate Driver Snubber Circuit and Sharing Resistor Frame Assembly Heatsink Assembly Line connection 4 Load connection
86. ctive action must be taken before resetting the fault 1560E UM051A EN P September 2005 7 2 Diagnostics Clear Fault Fault Buffer 1560E UM051A EN P September 2005 You can clear a fault using any of several methods Program the SMC Flex controller for a Clear Fault which can be found in Main Menu Diagnostics Faults If a human interface module is connected to the controller press the Stop button Note stop signal from the HIM will always stop the motor and clear the fault regardless of Logic Mask configuration Logic Mask parameter 87 equals 0 If a RESET push button is present the N O push button auxiliary contact can be connected to Option Input 2 terminal 15 Option Input 2 must be programmed for Clear Fault Cycle control power to the SMC Flex controller Important overload fault cannot be reset until the Motor Thermal Usage parameter 12 value is below 75 See Protection and Diagnostics on page 1 9 for further details The SMC Flex controller stores in memory the five most recent faults Display the fault buffer by selecting the View Faults Queue and scrolling through the fault buffer parameters The information is stored as fault codes and fault descriptions A fault code cross reference is provided in Table 7 A Diagnostics 7 3 Fault Codes Table 7 A provides a complete cross reference of the available fault codes and corresponding fault descriptions Table 7 A Fault Code Cro
87. d gate on the SCR by removing the green plug and connecting an ohmmeter to the gate leads If the LED is not lit and the circuit voltage is as specified in step 8 above pinch the tab on the blue fibre optic connector and carefully pull it straight out of the receiver The end of the connector should glow red to indicate the presence of a gate signal If it does not remove the other end of the cable from the interface board and check that the grey transmitter is emitting red light If it is the fibre optic cable must be replaced If it isn t the interface board should be replaced 1560E UM051A EN P September 2005 3 10 Commissioning P rocedures 11 When each gate driver circuit has been checked disconnect the power supply and remove it from the cabinet The gate drive circuits operate at high voltage when the SMC is energized Failure to remove the portable test power supply will result in equipment damage and may cause severe injury or death 12 Open the switch SW2 on the interface board see Figure 3 3 before returning the unit to service Ensure the red LED is off If the SW2 switch is not in the open position when the SMC is energized the motor will start in an uncontrolled manner and may cause severe damage 13 Check that all plugs and connectors are secure Retrieve all hardware and tools from the equipment Replace and secure any barriers removed during servicing and close all doors before applying power
88. d at both ends Any instruments used for test or troubleshooting should have their case connected to ground for safety Failure to do so may result in damage to equipment or personal injury When reinstalling components or when reassembling the cabinet tighten the following bolt sizes to the specified torque values Hardware Recommended Torque Y4 in 6 6 110 8 5 16 in M8 11 410 15 N m 3 8 in M10 20 ftlb 27 in M12 48 65 Control Wire Terminals 2 0 3 3 2 5 4 0 CLGD Power Assembly Terminals 50 in lb 5 6 SMC Flex Control Module Terminals 5 inlb 0 6 NOTE For 3 8 in hardware in the T slots of aluminum heatsinks the recommended torque is 16 ft Ib 22 N m Do not overtorque these connections as the slots will be damaged and the connection will be compromised Power Connections Installation 2 5 The controller requires a three phase supply and an equipment grounding conductor to earth ground A neutral conductor of the three phase supply is not necessary and is usually not routed to the controller Three phase wiring will connect the controller to the motor Bulletin 1562E The Bulletin 1562E unit is available in two main configurations 1 A modified two high cabinet 180 360A 2400 to 4160 V 2 combination of a one high full voltage non reversing FVNR cabinet and a 1560E unit 600A 2400 to 4160 V and 180 36
89. dded to the HIM cable near the SMC Flex control module The recommended core is Fair Rite no 0431167281 or equivalent When using DeviceNet two cores need to be added to the DeviceNet cable near the SMC Flex control module The recommended cores are TDK ZCAT2033 0930H and TDK ZCAT2035 0930 or equivalent Control Voltage The SMC Flex controller will accept a control power input of 100 to 240V AC 15 10 1 phase 50 60 Hz Refer to the product nameplate to verify the control power input voltage Connect control power to the controller at terminals 11 and 12 The control power requirement for the control module is 75 VA Depending on the specific application additional control circuit transformer VA capacity may be required Control Wiring Table 2 C provides the control terminal wire capacity and the tightening torque requirements Each control terminal will accept a maximum of two wires Table 2 C Control Wiring and Tightening Torque Wire Size Torque 0 75 to 2 5 mm 18 to 14 AWG 0 6 Nm 5 Ib in 1560E UM051A EN P September 2005 2 20 Installation Control Terminal Designations As shown in Figure 2 10 the SMC Flex controller contains 24 control terminals on the front of the controller re Ur OR Figure 2 10 SMC Flex Controller Control Terminals Description Descript
90. disposed of according to local regulations and must not be disposed of with general landfill refuse 1560E UM051A EN P September 2005 10 6 Maintenance Environmental Considerations cont 1560E UM051A EN P September 2005 e Chromate Plating Sheet steel and fasteners may be plated with zinc and sealed with a chromate based dip gold or silver coloured finish Shipping and handling of chromate plated parts are typically not restricted by environmental regulations however chromate is considered a hazardous substance Chromate plated parts must be disposed of according to local regulations and must not be disposed of with general landfill refuse In Case Of Fire This product is highly protected against arcing faults and therefore it is very unlikely it would be the cause of a fire In addition the materials used are self extinguishing i e they will not burn without a sustained external flame If however the product is subjected to a sustained fire from some other source some of the polymer materials will produce toxic gases As with any fire individuals involved in extinguishing the fire or anyone in close proximity should wear a self contained breathing apparatus to protect against any inhalation of toxic gases Disposal When disposing of the product it should be disassembled and separated into groups of recyclable material as much as possible i e steel copper plastic wire etc These materials should th
91. e diagnostic information through the use of communication interfaces The SMC Flex uses the DPI method of communication therefore all standard DPI communication interfaces used by other devices i e PowerFlex Drives can be used in the SMC Flex ScanPort devices are not supported by the SMC Flex Standard DPI communications cards are available for various protocols including DeviceNet ControlNet Remote I O ModBus and Profibus DP Other modules may be available in the future For specific programming examples configuration or programming information refer to the user manual for the communication interface being used A list of available interfaces is located below Table 8 A Communication Interfaces Protocol Type Cat No User Manual DeviceNet 20 COMM D 20COMM UM002 EN P ControlNet 20 20COMM UM003 EN P Remote 1 0 20 COMM R 20COMM UM004 EN P Profibus 20 COMM P 20COMM UM006 EN P RS 485 20 5 20COMM UM005 EN P InterB us 20 20COMM UM007 EN P EtherNet IP 20 COMM E 20COMM UM010 EN P RS485 HVAC 20 COMM H 20COMM UM09 EN P LonWorks 20 COMM L 20COMM UM08 EN P ControlNet Fiber 20 COMM Q 20COMM UM03 EN P Denotes revision level of user manual Example Publication 20COMM UM002C EN P is at revision C The SMC supports three DPI ports for communication Ports 2 and 3 are supported through the serial connection on the sid
92. e with Gate Driver Boards Removed 5500 6900 V 180 360 1560E UM051A EN P September 2005 9 22 Troubleshootin Figure 9 13 Power Module Assembly one phase with Boards and Frame Removed 5500 6900 V 180 360 A SCR4 SCR3 SCR2 cen 1 Heatsink 7 Heatsink 1 Heatsink 6 Heatsink 2 Heatsink 5 Heatsink 3 Heatsink 4 Spacer block must be flat Minimum Height 30 mm 1 25 in Maximum Width 2 200 mm 8 0 in Note SCRI SCR2 and SCR5 a matched set SCR3 SCR4 and SCR6 are a matched set Minimum Length 400 mm 16 0 in Module retaining hardware locations 4 9o g Figure 9 14 6900V Heatsink Assembly 180 360 Positioned on bench for SCR replacement 1560E UM051A EN P September 2005 Troubleshootin 9 23 Do not loosen To remove clamp pressure loosen lower center nut so that the gap between the clamp surface and the heatsink is approximately 6 mm 0 25 inch Locking Nut A 21 mm open end wrench is required Do not adjust 5 Indi
93. e Neutral connection must be connected to the green terminal block in the control panel See Chapter 3 Commissioning 1560E UM051A EN P September 2005 Troubleshooting 9 5 Table 9 D Motor Stops While Running Display Possible Causes Possible Solutions Fault displayed See fault description SeeTable 9 A addressing fault conditions Display is blank Control voltage is absent Failed control module Check control wiring and correct if necessary Replace control module Stopped Pilot devices Check control wiring and correct if necessary 0 0 Amps Failed control module Replace control module Starting Two or three power phases are Check power system missing Failed control module Check voltage sensing module and connections Replace control module Table 9 E Miscellaneous Situations Display Motor current and voltage fluctuates with steady load Possible Causes Motor Erratic Load Possible Solutions Verity type of motor as a standard squirrel cage induction motor Check load conditions Erratic operation Loose connections Shut off all power to controller and check for loose connections Accelerates too fast Starting time Increase starting time Initial torque Lower initial torque setting Current limit setting Decrease current limit setting Kickstart e Lower kickstart time or turn off Accelerates too slow Starting time Decrease starting time
94. e gate driver boards and fiber optics PTC Power Pole 10 Controller ventilation blocked Check for proper ventilation Controller duty cycle exceeded Check application duty cycle Fan failure Replace fan Ambienttemperature limitexceeded Waitfor controller to cool or provide external cooling Failed thermistor Check connection or replace thermistor Failed control module Replace control module Failed gate driver board Testor replace gate driver board Failed fiber optic cable Testor replace cable Failed interface board Testor replace interface board check ribbon cables Motor PTC 12 Motor ventilation blocked Check for proper ventilation Motor duty cycle exceeded Check application duty cycle PTC open Waitfor motor to cool or provide external cooling Check resistance of PTC Open Bypass 13 14 15 Control voltage is low Check control voltage power supply noperable bypass contactor Check control circuit operation Check control plug on contactor ntelliVAC fault Check status of IntelliVAC correct the condition reset the module No load 16 17 18 40 Loss ofload side power wiring Check all load side power connections and motor windings Loss of feedback Check voltage sensing module Line Unbalance 19 Supply unbalance is greater than Check power system and correct if necessary the user programmed value The delay time is too short for the Extend the delay time to match the application ap
95. e of the device and are typically used to interface with a Human Interface Module HIM Port 2 is the default connection with port 3 available by installing a splitter on port 2 Port 5 is supported by connecting one of the modules listed above to the internal DPI comm card connection 1560E UM051A EN P September 2005 8 2 Communications Human Interface Module 1560E UM051A EN P September 2005 The SMC FLEX controller can be programmed with the built in keypad and LCD display or with the optional Bulletin 20 HIM LCD human interface modules Parameters are organized in a three level menu structure and divided into programming groups Note Node addressing of the DPI communication card can be programmed via software or a hand held DPI HIM The onboard HIM cannot be used to address the communication card Keypad Description The functions of each programming key are described below Table 8 B Keypad Descriptions Esc Escape Exit a menu cancel a change to a parameter value or acknowledge a fault alarm Select Select a digit select a bit or enter edit mode in a parameter screen 52 Up Down Scroll through options increase decrease a value Arrows or toggle a bit Enter Enter a menu enter edit mode in a parameter screen or save a change to a parameter value Note Ifahuman interface module is disconnected from the SMC Flex controller while the Logic Mask is set to 1 a Coms Loss will
96. e system The motor current will vary during the acceleration period and may be near the motor rated starting current The pump algorithm does not limit starting current since full voltage is needed to reach full speed with a loaded motor The starting time is programmable from 0 30 seconds and the stopping time is programmable from 0 120 seconds Kickstart is available with this option Product Overview 1 21 Pump Application Considerations 1 Consult factory if start time settings over 30 seconds are required The base rating of the MV SMC Flex is two starts or one start stop combination per hour thirty seconds maximum for each operation A stopping operation counts as a start for purposes of thermal capacity calculations 2 The Pump Control option functions only for centrifugal pumps It is not suited for positive displacement piston or other types of pumps 3 Pump Stop option functions only for a centrifugal pump running at greater than approximately 2 3 of the motor rated horsepower 4 Pump applications with input and or output valves that are closed during starting and or stopping may not benefit from the Pump Control option Consult the factory for applications with valves 5 For starting or stopping times longer than 15 seconds power fuse selection should be reviewed to ensure no element damage occurs The fuse minimum melting time current characteristic curve should be consulted to ensure that at 1 1 tim
97. e used as an emergency stop Refer to the applicable standards for emergency stop requirements The external HIM has a similar programming operation to the built in programmer but note that differences do exist other controls available with the various human interface modules are non functional with the SMC Flex controller 1560E UM051A EN P September 2005 8 4 Communications 1560E UM051A EN P September 2005 Connecting the Human Interface Module to the Controller Figure 8 1 shows the connection of the SMC Flex controller to a human interface module Table 8 C provides a description of each port Note The SMC Flex only supports the use of DPI communication modules and DPI HIM Modules Scanport devices are not supported by the SMC Flex See Figure 1 21 or 1 24 for the control wiring diagram that enables start stop control from a human interface module Port5 DPI Communications Port2 Ports 2 and 3 when two HIMs are connected with a splitter Figure 8 1 SMC Flex Controller with Human Interface Module Table 8 C Description of Ports Port Description 1 Unused Not available for use 2 First 20 HIM connected to SMC Flex 3 Second 20 HIM connected to SMC Flex 5 Communication Board port HIM Control Enable To enable motor control from a connected human interface module follow the procedure below with the connected human interface module s programming keys The Bulleti
98. ease the displayed voltage and visa versa 1 Remove any temporary jumpers or grounding devices used during commissioning 2 Check that all tools are removed from the equipment Any tools or hardware used or dropped during installation and commissioning must be retrieved and accounted for 3 Check that all barriers or covers removed during installation or com missioning have been securely mounted 4 Close and secure all doors and verify function of all interlocks that prevent access to medium voltage compartments when the unit is energized 5 The controller is ready to power the motor Overview Keypad Description Programming Menu Chapter 4 Programming This chapter provides a basic understanding of the programming keypad built into the SMC Flex controller This chapter also describes programming the controller by modifying the parameters Note This User Manual pertains to SMC Flex control modules with version 4 xx firmware or later The keys found on the front of the SMC Flex controller are described below Escape Exita menu cancel a change to a parameter value or acknowledge a fault alarm Select S elect a digit selecta bit or enter edit mode in a parameter screen 52 Up Down Scroll through options increase decrease a value Arrows or toggle a bit Enter Enter a menu enter edit mode in a parameter screen or save a change to a parameter value Note For ease of pro
99. ed 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 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 IMPORTANT Identifies information that is critical for successful application and understanding of the product Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify hazard avoid hazard recognize the consequence Labels may be located on or inside the equipment to alert people that dangerous voltage may be present BURN HAZARD Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures SMC Flex and IntelliVAC are trademarks of Rockwell Automation Inc Preface Service Procedure c c arie ginta Da P 1 Product Overview Chapter 1 Manual ObJecttyes cocer rettet rue 1 1 Documentation eret t re ee e re eere adde 1 1 Ib secs 1 1 15038 OEM Controller 2 rre tenen 1 1 1560E Retrofit Controller ttt aeterne 1
100. eed Sel Slow Speed Dir Slow Speed Acc Metering Basic Overload Comm Masks Language Linear List Volts Phase A B SMC Option Overload Class Jam F Lvl Logic Mask Language All parameters Volts Phase B C Motor Connection Service Factor Parameter Mgt O Parameter Mgt Parameter Mgt Volts Phase C A Line Voltage Motor FLC A Lvl Current Phase A MV Ratio Overload Reset A Dly Current P hase Starting Mode Overload A Lvl Parameter Mgt pata Current Phase Ramp Time Parameter Mgt Data In Al Motor Watt Meter Initial Torque Stall Data In A2 Motor ID Megawatt Hours Cur Limit Lvl niati Data In B1 CT Ratio Elapsed Time Kickstart Time B Stall Dly Data In B2 MV Ratio Meter Reset Kickstart Lvl Underload F Lvl Parameter Mgt Data In C1 Parameter Mgt Power Factor Stop Input Underload F Dly Data In C2 Mtr Therm Usage Option 1 Input Underload A Lvl Ground Fault Data In D1 Motor Speed Option 2 Input Underload A Dly Data In D2 Stop Mode Parameter Mgt Gnd Flt Enable Data Out A1 Stop Time Gnd Data Out A2 Braking Current Gnd Fit DI Data Out B1 Class Hose Gnd Fitinh Time Data Out B2 Service Factor Undervolt F Lvl Gnd FItA Enable Data Out C1 Motor FLC Undervolt F Dly Gnd Lvl Data Out C2 CT Ratio Undervolt A Lvl Gnd FItA Dly Data Out D1 Overload Reset Undervolt A Diy Parameter Mgt Data Out D2 Aux1 Config Parameter Mgt O Parameter Mgt O Aux2 Config PTC Aux3 Config Overvolt
101. egger a 5000 volt type is recommended Solid state devices can be destroyed by high voltage Use jumper wires between heatsinks to short out the SCRs before applying high test voltages to the power circuit Disconnect the white wires L1 T1 L2 T2 L3 T3 from the voltage sensing board and remove the plug connector If voltage transformers are present remove one primary fuse from each device On the 1503E consult OEM documentation for location of voltage sensing board Use caution when performing the HI POT or Megger Test High voltage testing is potentially hazardous and may cause severe burns injury or death Where appro priate the case of the test equipment should be connected to ground Insulation may be tested from phase to phase and phase to ground The recommended level for AC HI POT testing is 2 X Volts where is the rated line to line voltage of the power system The leakage current may be recorded for future comparison testing and must be less than 20 mA If a Megger is used it should indicate 50 k megohms or greater if it is isolated as explained in the next paragraph If the motor is connected the Megger should indicate 5 k megohms or greater If 1560 is being tested it is recommended that the input and output cables be disconnected for each phase 1562E is being tested it is recommended that the main contactor be in the open position and that the output cables be disconnected for each phase See
102. el 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa ockwell Automation Herman Heinrich G ossen Strasse 3 50858 Germany Tel 49 0 2234 379410 Fax 49 0 2234 3794164 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 www ab com mvb Publication 1560E UM051A EN P September 2005 Copyright 6 2005 Rockwell Automation rights reserved Printed in Canada
103. eleration cannot brake the motor load and reduce the stop time Note Consult factory if settings over 30 seconds are required The base rating of the MV SMC Flex is two starts or one start stop combination per hour thirty seconds maximum for each operation stopping operation counts as a start for purposes of thermal capacity calculations Linear Deceleration is not intended to be used as an emergency stop Such usage may result in severe injury or death Refer to the applicable standards for emergency stop requirements 1560E UM051A EN P September 2005 1 8 Product Overview Starting Modes cont 1560E UM051A EN P September 2005 Soft Stop This feature can be used in applications that require an extended coast to rest time The voltage ramp down time is user adjustable from 0 to 120 seconds and is adjusted independently from the starting time The load will stop when the output voltage drops to a point where the load torque is greater than the developed motor torque Percent Voltage Lag Coast to rest Soft Stop Stat amp Run gt lt _ SoftStop gt Time seconds Figure 1 8 Soft Stop Option Note Consult factory if settings over 30 seconds are required The base rating of the MV SMC Flex is two starts or one start stop combination per hour thirty seconds maximum for each operation A stopping operation counts as a start for purposes of the
104. en be sent to local recycling facilities In addition all disposal precautions mentioned above must also be taken for those particular materials 1560 1562 SMC Flex Specifications Table A 1 Specifications Electrical Ratings UL CSA NEMA IEC Power Circuit Method of Connection Motor in delta or star SCRs between windings and supply Number of Poles Equipment designed for three phase loads only 2400 V AC 1596 10 3300 V AC 15 41096 3 6 kV Ratka Vorage Mn 4200 V AC 15 10 12 6900 V AC 15 10 2500 V Rated Insulation Voltage Ui 5000 V y 7200 V 3 6 kV 40 kV Rated Impulse Voltage Uimp 60 kV 7 2 KV 60kV 2500V 7 625 V AC Dielectric Withstand 5000 V 13 250 e M 2 iN 7200 V 18 200 V AC Repetitive Peak Inverse Voltage Rating 2500 V max 6 500 V 2 SCRs per phase 5000 V max 13 000 V 4 SCRs per phase 7200 V max 19 500 V 6 SCRs per phase Output Rating 100 to 7500 hp 75 to 5600 kW Semi Conductor Isolation Fiber optic Operating Frequency 50 60 Hz 50 60 Hz dv dt P rotection RC Snubber Network Transient Protection Integrated overvoltage trigger circuit 180 A Rated Current 360A 600 A 180 A 1000 V us 360 600A 2000 ie di dt 180 360 600 A 200 A us Voltage Drop 2 5 V per SCR without bypass Line to Output Terminals Less than 1 0 V with bypass total Overall Efficiency 99 95
105. ences Change Password User Dspy lines Press the Enter key Press the Up Down keys to enter the desired number If you are Rei modifying the password make a rs 62 Verify 83 note of itas displayed Verification of the new password is required Press the Enter key ea Press the Enter key after you Preferences have completed modifying the password To complete the programming process re enter the Main Menu mode to log out This will eliminate unauthorized process to the programming system Note If you lose or forget the password contact your nearest Rockwell Automation sales office You can also call Rockwell Automation Medium Voltage Product Support at 1 519 740 4790 for assistance 1560E UM051A EN P September 2005 4 6 Programming Parameter Management 1560E UM051A EN P September 2005 Before you begin programming it is important to understand how the controller memory is structured within the SMC Flex controller used on power up and during normal operation Refer to Figure 4 3 and explanations below EEPROM RAM ROM C3 Figure 4 3 Memory Block Diagram Random Access Memory RAM This is the work area of the controller after it is powered up When you modify parameters in the Set Up mode the new values are stored in RAM When power is applied to the con
106. ent e Three phase voltage e Power in MW Power usage in MWh e Power factor e Motor thermal capacity usage e Elapsed time e Motor speed full speed 90 with use of optional tachometer input Notes 1 Voltage measurement is not available during the braking operation of the SMB Smart Motor Braking Accu Stop and Slow Speed with Braking control options 2 The elapsed time and MWh values are automatically saved to memory every 12 hours 3 Motor thermal capacity usage is determined by the built in electronic thermal overload An overload fault occurs when this value reaches 100 1560E UM051A EN P September 2005 1 18 Product Overview 10 Communication 1560E UM051A EN P September 2005 The SMC Flex has the ability to accept up to two 2 inputs and four 4 outputs controlled over a network The two inputs are controlled at terminal 16 Option Input 1 and terminal 15 Option Input 2 For these two inputs see Chapter 4 for the parameter settings and see Chapter 8 for the bit identification By using these two terminals as inputs the Stop Input will need to be programmed to meet the desired stop functionality The four 4 outputs are Aux 1 Aux 2 Aux 3 and Aux 4 auxiliary contacts are programmable to the function found on page 4 13 If programmed to Network or Network NC they can be controlled over a Network Please see Table 8 H which defines the Logic Command Word Control Note For MV a
107. ergizing M IV and which completes the hold in circuit on the start button and closes the main contactor The SMC Flex module examines the line voltage looks for fault conditions checks phase rotation calculates zero crossing information and begins gating the SCRs to start the motor When the motor approaches rated speed the SMC Flex module closes the Aux 1 up to speed auxiliary contacts energizing B IV which closes the bypass contactor The motor then runs at full line voltage When the Stop button is pressed the relay opens terminal 17 on the SMC Flex module The Normal contact opens dropping out the main contactor allowing the motor to stop The Aux 1 contact is held closed for a short time by the control module This holds the bypass contactor closed for about 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits 1560E UM051A EN P September 2005 1 28 Product Overview Functional Description cont 1560E UM051A EN P September 2005 Bulletin 1562 Basic Control With Controlled Stop When wired as shown in Figure 1 21 the controller operates in much the same manner as in Figure 1 20 Terminal 16 on the SMC Flex module now controls the start and stop maneuvers Terminal 16 must remain energized for the module to run When the Stop button is pressed and CR opens the SMC Flex module will initiate the option stop An uncon
108. es 1000V 1300V 1500V 2300V 3300V 4160V 5500V 6900V Cathode to Cathode KOhms 22 30 23 31 21 29 24 32 Cathode to Cathode KOhms 17 23 19 25 20 27 21 29 40 53 43 57 60 806 64 84 Cathode to Gate Ohms 10 40 10 40 10 40 10 40 10 40 10 40 10 40 10 40 Measured between terminals Cathode on CLGD Boards upper two or bottom two within a phase Measured between terminals Cathode on CLGD Boards top to bottom within a phase Measured between line and load terminals within a phase 3 If abnormal readings are obtained refer to Power Circuit Trouble shooting on page 9 12 Verify System Grounding Verify that the Neutral connection on the Interface board matches your power system grounding scheme If the power system is truly ungrounded the VCOM connection on the Interface board must not be connected If the power system is grounded solid resistance zig etc the VCOM connection must be connected to the green terminal block on the control panel Refer to Figure 3 2 for the VCOM connection point on the interface board VCOM VCOM Figure 3 7 System Grounding 1560E UM051A EN P September 2005 3 12 Commissioning P rocedures Voltage Sensing Module Start Up 1560E UM051A EN P September 2005 The voltage sensing module consists of a voltage sensing board and mounting plate refer to Figure 9 2 The voltage sensing board has si
109. es the full voltage locked rotor current of the motor the actual starting or stopping time does not exceed 75 of the fuse melting time 6 Motor overload and or upstream breaker settings may have to be adjusted to allow the starting or stopping current to flow for extended periods 1560E UM051A EN P September 2005 1 22 Product Overview 100 Motor Speed Pump Start amp Run gt lt Stop Time seconds Figure 1 17 Pump Control Option Pump stopping is not intended to be used as an emergency stop Refer to the applicable standard for emergency stop requirements Pump stopping may cause motor heating depending on the mechanical dynamics of the pumping system Therefore select the lowest stopping time setting that will satisfactorily stop the pump Braking Control Option The Braking Control option Smart Motor Braking Accu Stop and Slow Speed with Braking are not offered for standard use in MV applications Please consult factory for further assistance 1560E UM051A EN P September 2005 Hardware Description Product Overview 1 23 The following sections contain descriptions of system components and system operation Each section will be described to give the user an understanding of the MV SMC Flex to facilitate operation and maintenance of the system Refer to Figures 1 18 and 1 19 Typical MV SMC Flex Power System Power Module The controller consists of
110. essor based control module Space for necessary auxiliary control and metering devices Top and bottom plates to accommodate power cables Motor overload protection included in SMC Flex control module SMC Flex Control Module The MV SMC Flex controller offers a full range of starting and stopping modes as standard Soft Start with Selectable Kickstart Soft Stop Current Limit Start with Selectable Kickstart Linear Acceleration with Selectable Kickstart Linear Deceleration Dual Ramp Start Preset Slow Speed Full Voltage Start This option utilizes gating patterns which result in motor and line currents that produce noise and vibration in the motor and or distribution transformer This must be considered before applying this option Starting Modes Product Overview 1 3 SMC Flex Control Module cont Other features that offer further user benefit include Extensive protection features Metering Communication capability e T O Innovative control option provides enhanced performance e Pump Control Start and Stop Control modes These modes features and options are further described in this chapter Soft Start This mode has the most general application The motor is given an initial torque setting which is user adjustable from 0 to 90 of locked rotor torque From the initial torque level the output voltage to the motor is steplessly increased during the acceleration ramp time The
111. ests SW Close slide up to initiate test pulses ATTENTION Servicing energized industrial control equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Before proceeding ensure that all sources of power are isolated and locked out Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Any covers or barriers removed during this procedure must be replaced and securely fastened before energizing equipment Where appropriate the case of test equipment should be connected to ground Isolate incoming power Open the door s providing access to the SCR heatsink assemblies You will be touching components which are connected to the high voltage power circuit so be sure to isolate power as stated above Apply rated control voltage to the control circuits from a separate control source or by plugging into the test source connector and selecting the TEST position of the control switch Current loop Check for 40 5 2 A Locate the SMC Flex Interface board in the control section See Figures 3 2 and 3 3 This circuit board has the control module mounted on it Locate the switch labeled SW2 at the upper left corner of the board Close the switch by sliding the toggle up This starts a pulse generator to supply simulated gate pulse signals via fibre optic cables to the gate driver boards A red LED beside
112. g A Losses 36 Power Bus Losses Watts 1200 150 2000 200 3000 200 Power tosses The losses from a 500 VA control power transformer fully loaded are approximately 50 W per controller Low Votage Panel Losses EET 1560E UM051A EN P September 2005 8 Specifications Table A 8 Control Wire and Power Wire Description Specifications Control Wire All Medium Voltage structures shall be equipped with control w ire which meets the following specifications Type TEW Stranded Copper Wire Tinned AWG Size Control Circuit 14 AWG 1 5 mm AWG Size Current Transformer Circuit 312 2 5 mm Number of Strands 19 Maximum Voltage Rating 600 V Maximum Rated Temperature 105 221 F Terminal Blocks 1492 1 CA3 Power Wire Power wire used to feed the primary of the control power transformer or potential transformers is as follows AWG Size 38 AWG Type Alcatel Excelene XLPE MV90 Insulation Rating 5 0 kV Maximum Temperature R ating 90 C 194 Current Loop Silicone rubber AWM 50 KV DC 150 The controller shall be wired with the following non shielded s tranded wire type based on the current ratings gu wo ee 200 2 EP CSPE MV90 8 0 kV 90 C 194 F 400 4 0 EP CSPE MV90 8 0 kV 90 C 194 F 600 2 x 4 0 EP CSPE
113. g a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Check the snubber components and sharing resistors by isolating them and measuring values as follows See Figures 9 21 to 9 26 RS CS RRx 600 180 and 360A 30Q 600A 0 5 or 0 68 uF 180 and 360A 1 0 uF 600A 32 5 kQ total taps at 2 5 kQ from each end x 1 2 or 3 Replace any out of spec components See Renewal Parts listing in Appendix D 3 If the snubbers and sharing resistors are within tolerances check the resistance of the voltage sensing module refer to Figure 9 20 Remove the ribbon connector from J1 by pressing down on the locking tabs then gently pulling the connector out Take note of which tap the white high voltage wires are connected to then remove them L1 T1 L2 T2 L3 T3 Measure the resistance between each tap and the ground connection and compare to the values in Figure 9 20 1560E UM051A EN P September 2005 Troubleshooting 9 27 Measure 1L3kQ 43M O E 1 E Do D ul a 5 _ E qs LOL ng 9 0 qU fy gt To Interface board Ground Connections 2 1 80190 258
114. ge withstanding ratings or surge arrester rating or cause distorted voltage signals which may be misinterpreted by the MV SMC Flex control system Motor Overload Protection Installation 2 17 Thermal motor overload protection is provided as standard though it must be programmed with the MV SMC Flex controller If the overload trip class is less than the acceleration time of the motor nuisance tripping may occur Overload protection should be properly coordinated with the motor to avoid damage to equipment Two special applications require consideration Two speed Motors and Multi motor Protection Two speed Motors The MV SMC Flex controller has overload protection available for single speed motors When the MV SMC Flex controller is applied to a two speed motor the Overload Class parameter must be programmed to OFF and separate overload relays must be provided for each speed Multi motor Protection The MV SMC Flex controller provides overload protection for only one motor When the MV SMC Flex is controlling more than one motor the Overload Class Parameter must be programmed to OFF and individual overload protection is required for each motor 1560E UM051A EN P September 2005 2 18 Installation EMC Compliance 1560E UM051A EN P September 2005 This product has been designed for Class A equipment Use of the product in domestic environments may cause radio interference in which case the installer may need to
115. gramming values after using the Enter key to edit use the Sel key to jump to the digit that needs to be modified then use the arrow keys to scroll through the digits Parameters are organized in a three level menu structure for straightforward programming Figure 4 1 details the programming menu structure and the three level hierarchy In order to change parameters the controller must be in the STOP mode and the control voltage must be present 1560E UM051A EN P September 2005 4 2 Programmin Programming Menu cont Power up and Status Display d oon Select language being displayed OPERATION LEVEL Choose Mode MAN MENU or Log 5 E SMC Flex Reset to Defaults Change Password Alarms wn i User Dspl Line Faults 1 User Time Device Revision vty User Dspl Video Linear List Reset User Display GROUP MENU Parameter menu continued in Figure 4 2 The SMC Flex controller does not support EEPROM Link Process or Start up modes Steps back one level Shown if password protection is configured Figure 4 1 Menu Structure Hierarchy 1560E UM051A EN P September 2005 Parameter rogrammin PresetSS Option 2 Input PresetSS Slow S p
116. he post 4 Lift out the circuit board and check that the replacement board is the correct part number and revision before installation refer to Appendix D Install the new board by replacing the hardware or pressing down onto nylon stand offs Connect all wires cables and connectors Ensure that all switch and or jumper settings on the new board are identical to those on the old board and correct for the application 1560E UM051A EN P September 2005 Troubleshootin 9 11 Power Circuit Troubleshooting Thyristor SCR Testing If a power semiconductor is suspected of malfunctioning it may be checked as follows 1 Remove all power from the equipment To avoid shock hazard ensure the main power has been disconnected before working on the controller A motor or control devices Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Measure DC resistance per the following chart Table 9 H SCR Resistance Measurements Location of Probes 1000 1300V 1500V 2300V 3300V 4160V 5500V 6900 V Cathode to Cathode KOhms 9 22 30 23 31 21 29 24 32 Cathode to Cathode KOhms 17 23 19 25 20 27 21 29 40 53 43 57 60 80 64 84 Cathode to Gate Ohms 10 40 10 40 10 40 10 40 10 40 10 40 10 40 10 40 Measured between terminals Cathode on SPGD Boards upper tw
117. he programmed motor voltage Trip delay time can be adjusted from 0 to 99 seconds Note For medium voltage applications overvoltage protection should be set from 100 to 115 An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing Undervoltage overvoltage and voltage unbalance protection are disabled during braking operation 1560E UM051A EN P September 2005 1 12 Product Overview Protection and Diagnostics cont 1560E UM051A EN P September 2005 Unbalance e The MV SMC Flex is able to detect an unbalance in line voltages Motor operation can be halted if the unbalance is greater than the desired range The MV SMC Flex controller provides an adjustable unbalance setting from 0 to 25 of the line voltages Trip delay time can be adjusted from 0 to 99 seconds An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing Undervoltage overvoltage and voltage unbalance protection are disabled during braking operation Stall Protection and J am Detection The MV SMC Flex controller provides both stall protection and jam detection for enhanced motor and system protecti
118. he sharing resistors are fragile Troubleshooting 9 13 Power Circuit SCR Replacement Procedure cont Troubleshooting cont 7 Remove two 2 nuts at bottom front of heatsink assembly so the module can be removed using the pull handle Phase C requires angling the module to clear the front cabinet flange Position fibre optic cables and wiring so they will not be damaged as the module is removed from the cabinet 8 Pull module out slowly and slide onto a platform lift or lift the module out of the cabinet The heatsink assembly is heavy approx 25 kg 55 Ib or greater To avoid injury always use two people to remove and handle the assembly Place the heatsink on a cart to aid in its transport 9 Place the module on a flat surface see Fig 9 7 9 10 and 9 14 When tilting the module ensure that wires are not damaged B Replace SCRs Note For 600 A units it is mandatory that the entire stack be replaced The high clamping force requires the factory to tighten the clamp hardware See Appendix D Spare Parts section for part numbers Proceed to step C Note Refer to Figures 9 5 to 9 16 SCR positions are numbered in succession from the top down The SCR cathode is at the end with the wide flange The SCRs must be oriented correctly with the cathode end either up or down depending on the specific assem bly Note the orientation before removing the SCRs and refer to the detail in the appropriate figure i
119. hed to the main structure It will be ram interlocked with the main power cell door which will not allow it to be opened until the main power cell door is opened Installation Installation 2 13 Physical Location The controller is designed for limited front access components may have to be removed and should be installed with adequate and safe clearance to allow for total door opening The back of the unit may be placed against a wall and several units may be set end to end In special cases where floor space is limited and the unit is not against a wall certain cabinet sections may be placed back to back This requirement must be stated in the speci fications in order to mechanically alter the controller Fan The controller may include a cooling fan which is used to cool the component It should be checked for free operation and no obstruction of the airflow Ground Bus Bar Controllers which are delivered in two or more sections or retrofit controllers will require that the ground bus bar 6 mm x 51 mm in x 2 inches which runs the entire length of the equipment in the center back side be reconnected A mechanical lug for 48 410 AWG or 6 250 cable is supplied at the incoming end of the line up When the sections are brought together bus links are used to connect the bus bars Important Refer to 2 high Series B drawings in Publication 1500 UMO055B EN P for power ground bus connection Power and Control Wi
120. hen handling the parts The resistor element is under a thin coating on the ceramic tube and it may be damaged if dropped struck or scraped 1560E UM051A EN P September 2005 Troubleshootin 9 30 383 avari SCOHLWD 2 CIN 3 1 SINIS LVWAH SH HOLIOVdvO 5 so YOLSISSY 5 Su YOLSISSY ONIHVHS gt o CSH o TSH o TO co o 5 cS sc lt lt D TaD To S TS Figure 9 21 1500 2400 V Module Wiring 180 360 A 1560E UM051A EN P September 2005 Troubleshooting 9 31 LINE LOAD SNUBBER CAPACITOR HEATSINKS CATHODE LEAD RED HS1 HS2 Od 2 HS3 LEGEND RR SHARING RESISTOR RS SNUBBER RESISTOR cs HS G GATE LEAD WHITE G1 G2 2 THERMISTOR 0 5 Jy 0 THERMISTOR T GATE DRIVER BOARDS Ov 1 52 Figure 9 22 1500 2400 V Module Wiring 600 A 1560E UM051A EN P September 2005 9 32 Troubleshootin LEGEND SHARING RESISTOR SNUBBER RESISTOR SNUBBER CAPACITOR HS HEATSINKS RR RS cs GATE LEAD WHITE CATHODE LEAD RED G c Y 13 pig Lx 80 80 ls 80 Yo
121. hly recommends that motor surge capacitors and or motor surge arresters not be located on the load side of the SMC The issues that warrant this are Motor and system inductance limits the rate at which the current can change through the SMC If capacitance is added at the motor the inductance is negated The surge capacitors downstream of the SMC represent a near zero impedance when presented with a step voltage from the turn on of the SCRs near the line voltage peak This causes a high level of di dt to occur due to the fact that the motor cables are generally short in length There is very little impedance between the capacitor and SCR to limit the di dt of this capacitor charging current This can result in damage to the power semiconductors SCRs in the SMC It is essential to understand the clamping voltage of the arresters and type of grounding used in the distribution system The switching of the SCRs generates slightly higher than nominal peak line to ground voltages The typical peaks are 1 5 times the nominal line to ground peak voltages These may cause the arresters to conduct which could affect the operation of the SMC and result in faults Depending upon the instance at which the arresters conduct this could also result in SCR damage The capacitance in combination with the line and motor impedance could also be excited by the voltage steps from SCR switching to create resonant voltage swings which could exceed the device volta
122. ified personnel using appropriate local safety work practices and precautionary measures Disconnect the controller from the motor before measuring insulation resistance IR of the motor windings Voltages used for insulation resistance testing can cause SCR failure Do not make any measurements on the controller with an IR tester megger Note The time it takes for the motor to come up to speed may be more or less than the time programmed depending on the frictional load and inertial characteristics of the connected load Note Depending on the application the Braking options SMB Motor Braking Accu Stop and Slow Speed may cause some vibration or noise during the stopping cycle This may be minimized by lowering the braking current adjustment If this is a concern in your application please consult the factory before implementing these options For MV SMC Flex 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 from 9 00 a m to 5 00 p m Eastern time zone 1560E UM051A EN P September 2005 9 2 Troubleshooting See Table 9 A 1560E UM051A EN P September 2005 Motor will not start no output voltage Important In the case of the 1503E refer to applicable documentation from OEM for troubleshooting or repair This manual should be utilized in conjunction with the OEM
123. imit Starting Mode 2 25 Soft Start Soft Start Linear Speed Dual Ramp Ramp Time 2 26 SEC 0 30 10 Initial Torque 2 27 96 LRT 0 90 10 Cur Limit Level 2 28 FLC 50 600 350 Kickstart Time 2 30 SEC 0 0 2 0 0 0 Kickstart Level2 31 96 LRT 0 90 0 Pump modules do notdisplay this parameter Default setting for MV applications is typically Emergency Run Donotsetto Delta 1560E UM051A EN P September 2005 2 Parameter Information Table 1 Parameter List cont Group Parameter Description fied Units Min Max ain Disable Soft Stop Basic Set Up Stop Mode 32 ran Disable Accu Stop Stop Time 33 SEC 0 120 0 Basic Set Up Accu Stop Braking Current 35 FLC 0 400 0 Slow Speed Sel 39 E n 55 High Preset SS Accu Stop Slow Speed Dir 40 7 Pus SS FWD Slow Speed Cur 41 FLC 0 450 0 Slow Running Cur 42 FLC 0 450 0 Accu Stop Stopping Current 43 FLC 0 400 0 Disable Class 10 Overload Class 44 Class 10 1 cs Service Factor 45 0 01 1 99 1 15 Motor FLC 46 1 0 1000 0 1 0 Overload Reset 47 Manual Manual Overload Overload A Lvl 50 MTU 0 100 0 Underload Lvl 51 FLC 0 99 0 Underload F Dly 52 SEC 0 99 0 Underload A Lvl 53 FLC 0 99 0 Underload A Dly 54 SEC 0 99 0 Undervolt F Lvl 55 V 0 99 0 Undervolt F Dly 56 SEC 0 99 0 Undervolt A Lvi 57 V 0 99 0 Undervolt A
124. ination is determined by a hard contact input to terminal 15 When this input signal is low ramp time initial torque 2 are selected Once the Option 2 Input has been setto Dual Ramp you must ESC back to the Parameter File menu Re enter into the Set Up menu to show both Basic Set Up and Dual Ramp Basic Set Up Start Mode This selects the start mode for option 1 Basic Set Up Ramp Time This programs the time period during which the controller will ramp the output voltage up to full voltage for the first Start setup 0to 305 Basic Set Up Initial Torque This parameter establishes and adjusts the initial reduced output voltage level for the first S oft Start Setup 0 to 90 locked rotor torque Dual Ramp Start Mode 2 This selects the start mode for option 2 Dual Ramp Ramp Time 2 This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Start setup 0to 305 Dual Ramp Initial Torque 2 The initial reduced output voltage level for the second Start setup is established and adjusted with this parameter 0 to 90 96 locked rotor torque TheDualRamp feature is available on the standard controller Kickstart can be programmed for both start modes Programming 4 11 Full Vo Itage Start The SMC Flex controller may be programmed to provide a full voltage start output voltage to the motor reaches full voltage within 1 4 seco
125. ion 11 Control Power Input 23 Input 12 Control Power Common 24 Input 13 Control Enable Input 25 Tach Input 14 Control Module G round 26 Tach Input 15 Option Input 27 Ground Fault Transformer Input 16 Option Input 1 28 Ground Fault Transformer Input 17 29 Aux Contact 2 0 18 Stop Input 30 Aux Contact 2 19 Aux Contact 1 Up to Speed 31 Aux Contact 3 20 Aux Contact 1 Up to Speed 32 Aux Contact 3 21 Not Used 33 Aux Contact 4 Normal 22 Not Used 34 Aux Contact 4 Normal Do not connect any additional loads to these terminals These parasitic loads may cause problems with operation which may result in false starting and stopping Aux Contact 1 is always programmed for Up to S peed N O to control the bypass contactor in MV applications Contact 4 is always programmed for Normal N O indication in MV applications RC snubbers are required on inductive loads connected to auxiliary Note The OFF state leakage current a solid state device connected to an SMC Flex input must be less than 6 mA 1560E UM051A EN P September 2005 Preliminary Set Up Commissioning Procedure A Ensure the work area is clean and tidy Pathways to main disconnect and emergency stop push button must be clear and unobstructed B The following test equipment is to be prepared for use Test power supply supp
126. ire power stack be replaced Table D 2 Complete Power Stacks 3 per controller ing specifications for 600A power stacks individual SCRs are not replaceable SMC Rated Voltage max Part Number 180 Amp 360 Amp 600 Amp 1500 80187 513 53 80187 513 52 80187 522 51 2500 80187 513 51 80187 513 52 80187 522 51 4800 80187 514 51 80187 514 52 80187 523 51 7200 80187 521 51 80187 521 52 80187 524 51 9 Due to stringent torquing specifications for 600A power stacks Itis mandatory thatthe entire power stack be replaced Table D 3 Snubber Capacitor Snubber Resistor individual SCRs are not replaceable Snubber Capacitor Part Number 180 360 Amp 600 Amp All voltages 80025 812 02 R 0 68 uF 80025 812 01 R 1 0 uF Part Number Snubber Resistor 180 360 Amp 600 Amp 1500 2500 4800 V 80025 588 02 R 20 Q 100W 80025 642 08 R 15 225W 7200 80025 642 09 R 30 225W 80025 642 08 R 15 O 225W Allparts are ceramic wirewound non inductive winding Resistors are series connected for a total of 60 persnubber for 180 360A assemblies and 30 persnubber for 600A assemblies A controller has one snubber per pair of SCRs i e 3 snubbers for 2500V 6 snubbers for 4800V 9 snubbers for 7200V e 1560E UM051A EN P September 2005 0 2 Spare Parts Table 0 4 Common Parts
127. ld be kept clean and free of dirt and obstructions This will avoid tracking and heat build up thereby increasing the life of the device Control Components Electronic The printed circuit boards are to be kept clean and free of any accumulations of dirt and foreign materials Materials which create static electricity should never be allowed near circuit boards while in the unit or in storage Caution should be used when one is near or handling circuit boards There are no other requirements other than housekeeping standards that the maintenance program requires on the logic control components Fans Physically rotating and observing the fans for noise or binding will indicate if fan failure is evident Interlocks Verify that interlocks function as intended and have not been forced damaged or removed Barriers Verify that all barriers are in place and securely fastened Environmental Considerations Maintenance 10 5 Hazardous materials Environmental protection is a top priority for Rockwell Automation The facility that manufactured this medium voltage product operates an environmental management system that is certified to the requirements of ISO 14001 As part of this system this product was reviewed in detail throughout the development process to ensure that environmentally inert materials were used wherever feasible A final review has found this product to be substantially free of hazardous material Ple
128. led a Comm Fault will occur Network Network faults are faults generated on the network external to the S MC Flex and are annunciated on the LCD display Ground Fault Ground faults are based on feedback from the user supplied 825 CT detecting ground fault currents G round fault parameters of level and time delay must be programmed for proper operation Excess Starts Hour Excess starts hour is displayed when the number of starts in a one hour period exceeds the value programmed Power Loss Power loss indicates that an input power phase is not present The controller s LCD display will identify the missing phase If all three phases are absent when a start command is issued the LCD will display Starting without motor rotation Line Loss F41 F42 F43 During expected SCR gate periods the power pole voltage and currents are monitored If the SCR conduction is discontinued a fault is indicated Phase loss overvoltage and undervoltage protection are disabled during braking operation detection and underload protection are disabled during slow speed and braking operation Additional details regarding fault definitions can be found in Chapter 1 Product Overview 1560E UM051A EN P September 2005 Overview Communication Ports 8 Communications The SMC Flex provides advanced communications capabilities that allow it to be started and stopped from multiple sources as well as provid
129. lied with each controller Multimeters Hi Pot Tester recommended or Megger Oscilloscope with memory optional C Complete drawing package and parts list D Specification of project 1560E UM051A EN P September 2005 3 2 Commissioning P rocedures System Characteristics Job Name Job Number Rated Voltage Rated Current S F Actual Motor Load Load Type Fan Pump Compressor Mixer 7 Other Constant Torque or Variable Torque Actual Motor Data Motor HP Motor Rated Speed Motor F L A Motor S F Motor L R A Frequency Phases 1560E UM051A EN P September 2005 Commissioning P rocedures 3 3 Preliminary Check Programming Ensure that all sources of power are isolated and locked out before working on installed equipment Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in severe burns injury or death A Verify correct power cable phase sequencing and that connections are tight Verify power fuse ratings and condition a Verify control fuse ratings and condition D Check that power cable installation has not damaged components and that electrical spacings have not been reduced Check that fibre optic cables are fully seated in their connectors Check that circuit board plug connectors are installed and fully inserted in their sockets G Check that the cooling
130. lt displayed See fault description SeeTable 9 A addressing fault conditions Display is blank Control voltage is absent Check control wiring and correct if necessary Failed control module Replace control module Stopped Pilot devices Check wiring 0 0 Amps SMC Enable inputis open at Check wiring terminal 13 Terminal 16 is open Check wiring Start Stop control has not been Follow the instructions on page 2 16 to 2 18 enabled forthe human interface to enable control capability module Control voltage Check control voltage Failed control module Replace control module Starting Two or three power phases are Check power system missing Check voltage sensing module and connections Table 9 C Motor Rotates but does not accelerate to full speed Display Fault displayed Possible Causes See fault description Possible Solutions See Table 9 A addressing fault conditions Starting Mechanical problems Check motor nadequate Current Limit setting Failed control module Check for binding or external loading and correct Adjust the Current Limit Level to a higher setting Replace control module Verify that Neutral connection on the Interface board matches your power system grounding scheme If the power system is truly ungrounded the Neutral connection on the Interface board must not be connected If the power system is grounded solid resistance zig zag etc th
131. m 0 045 in Anti hygroscopic 0 5 to 1 Electrical Strength 900 V mil Ground Bus Ground Bus Material Bare copper Optional Ground Bus Material Tin plated copper Continuous Current Rating at 40 C 10492 600 A Dimensions per Phase 600 A 6x51 mm 1 4 x 2 in Cross Sectional Area 600 A 32 mm 0 5 total 1560E UM051A EN P September 2005 Specifications 7 Table A 7 Power Fuses and Losses Description Specifications Power Fuses and Fuse Holders This section details the power fuse and fuse holder technical information that each medium voltage product conforms to Itincludes information on R rated fuses as well as mounting dimensions Fuse Types Rated 2 to 24R A480R 5 0 2 4 kV 2R to 24R A072 7 2 kV 198 388 A051B 5 0 2 4 kV Interrupting Ratings 2 4 kV to 7 2 kV 50 kA RMS SYM 80 RMS ASYM Mounting Center Dimensions Clip On 304 8 mm 12 0 in Bolt On 454 2 mm 17 88 in Maximum Heat Dissipation KW Convection Start or Stop Cycle amp 450 Starting Duty Continuous 180 360 600 Controler Rating 2500V 135 192 453 250 5000V 27 0 38 5 90 5 250 7200 405 57 1 136 0 250 Power Losses Losses kW Current A Fuse Size 10 90 68 125 Power Cell Losses 180 128 350 240 18R 510 360 248 1 000 600 57 1 500 Fully Loaded Bus Bus Ratin
132. n 20 HIM LCD human interface modules with control panels can start and stop the SMC FLEX controller However the factory default settings disable control commands other than Stop through the serial communication port Communications 8 5 To enable motor control from a connected human interface module or communication module you must take the following programming steps 1 Disconnect the HIM and allow to power down 2 Reconnect the HIM On Initializing screen the bottom right corner of LCD shows Port X Note this port number 3 Goto Logic Mask found as follows Main Menu Parameter Communications Comm Mask Logic Mask 4 Set bOX equal to 1 where X is the port number noted in step 2 5 Goto Parameter Management and save as User Store Important Logic Mask must be set to 0 prior to disconnecting a human interface module from the SMC FLEX controller If not the unit will fault on a Coms Loss 1560E UM051A EN P September 2005 8 6 Communications Control Enable Loss of Communication and Network Faults SMC Flex Specific Information 1560E UM051A EN P September 2005 If enabling control from the built in SMC Flex programmer the Logic Mask must be set as follows Table 8 D Logic Mask Requirements Mask Code Description 0 No external DPI devices are enabled 4 Only one HIM on port 2 is enabled 12 Two HIMs are enabled on ports 2 and 3 32 Only the DPI communication
133. n be cleaned effectively by vacuuming or wiping 1560E UM051A EN P September 2005 10 2 Maintenance Periodic Inspection cont 1560E UM051A EN P September 2005 Allen Bradley magnetic starters contactors and relays are designed to operate without lubrication do not lubricate these devices since oil or grease on the pole face mating surfaces of the operating magnet may cause the device to stick in the ON mode Erratic operation can result with injury or death 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 the nearest Rockwell Automation sales office for information Vacuum Bottles The contacts in a vacuum bottle cannot be seen or examined directly They rely on the high vacuum to operate properly and to interrupt current Visually inspect the wear of the main contacts with the contacts closed When any part of the wear indicator located on the front side of the hex shaft moves up into the bearing replace all three vacuum bottles see Vacuum Contactor User Manual The vacuum level should be tested periodically by applying high voltage alternating current across the open bottle using a vacuum tester or Hi Pot equipment see Vacuum Contactor User Manual Terminals Loose connections can cause overheating that can lead to equipment malfunction or failure Check the
134. n regarding DataLinks refer to the user manual for the communication interface being used Communications 8 11 Note Node addressing of the DPI communication card can be programmed via software or a hand held DPI HIM The on board HIM cannot be used to address the communication card Updating Firmware The latest version of firmware and instructions for the SMC Flex can be obtained from www ab com Note MV SMC Flex must use firmware release 3 006 or later This User Manual pertains to units with firmware release 4 xxx or later 1560E UM051A EN P September 2005 8 12 Communications 1560E UM051A EN P September 2005 General Notes and Warnings Troubleshooting For safety of maintenance personnel as well as others who might be exposed to electrical hazards associated with maintenance activities follow the local safety related work practices for example the 70 Part II in the United States Maintenance personnel must be trained in the safety practices procedures and requirements that pertain to their respective job assignments Hazardous voltage is present in the motor circuit even when the SMC Flex controller is off To avoid shock hazard disconnect main power before working on the controller motor or control devices such as Start Stop push buttons Procedures that require parts of the equipment to be energized during troubleshooting testing etc must be performed by properly qual
135. n this chapter 1 Remove the shorting bar Measure the resistance between adjacent heatsinks to determine which 5 5 is are shorted Assemblies with four or six SCRs must use matched sets See Figures 9 8 and 9 14 for the position of the matched sets If an SCR from each set is shorted all of the SCRs in the module must be replaced A properly functionning SCR will measure in excess of 100 kilohms from anode to cathode and 10 40 ohms from gate to cathode 1560E UM051A EN P September 2005 9 14 Troubles hooting 1560E UM051A EN P September 2005 SCR Replacement Procedure cont Important DO NOT loosen any of the nuts on the fiber rods on either side of the clamp bars They must remain as they are to maintain squareness See Figures 9 6 9 9 and 9 15 2 Loosen the clamp by rotating the centre nut below the indicator washer at the top end of the clamp Refer to Figures 9 6 9 9 and 9 15 As the centre nut is rotated the entire spring assembly is retracted from the top heatsink Continue to retract until there is a gap of approximately 6 mm 0 25 in The heatsinks may now be spread apart to allow removal of the SCRs Apply a thin film of Electrical Joint Compound supplied to both faces of the new SCRs Place the new SCRs in position starting from the top and pushing the heat sinks together as you proceed down the stack Make sure the SCRs are positioned and oriented properly Refer to Figures 9 7 9 10 and 9 16
136. nd with the following programming Parameter Option Starting Mode Full Voltage This must be programmed for Full Voltage Linear Speed The SMC Flex provides the user the ability to control the motor speed during starting and stopping maneuvers tach input is required as specified in Linear Speed Acceleration on page 1 7 Parameter Option Starting Mode Linear Speed This must be programmed for Linear S peed Ramp Time 010 305 This programs the time period that controller will ramp from 0 speed to full voltage Kickstart Time 0 0 to 2 2 5 A boost of current is provided to the motor for the programmed time period Kickstart Level 0 to 90 locked rotor torque Adjusts the amount of current applied to the motor during the kickstart time Stop C ontrol The SMC Flex can be programmed to extend the motor stop time beyond the normal coast to rest time There are two standard stop modes Soft Stop and Linear Speed Deceleration Parameter Option This may be set to one of two Soft Stop Stopping Mode standard choices Linear Speed Allows the user to setthe time Stop Time period for the stopping function Referto Chapter 6 for optional stop control modes motor tachometer is required refer to page 1 7 Consult factory if settings over 30 seconds are required The base rating of the MV SMC Flex is two starts or one start stop combination per hour
137. nnection to the the serial port SMC Flex controller Network 30 31 32 DPI network loss Reconnectfor each DPI connected device Ground Fault 33 Ground fault current level has Check power system and motor correct if necessary exceeded programmed values Check programmed ground fault levels to match application requirements Excess Starts Hr 34 Number of starts in a one hour Waitan appropriate amount of time to restart period has exceeded the value Consultfactory if more than 2 starts per hour are programmed required Power Loss 35 36 37 Missing supply phase as indicated Check for open line i e blown line fuse with phase indication Loss offeedback Check CT connections replace Interface board Hall ID 38 Faulty interface Check ribbon cable connections between interface board and control module Replace interface board NVS Error 39 Data entry error Check user data and perform a User Store function Replace control module Line Loss 41 42 43 Line Distortion Check supply voltage for capability to start stop motor High impedance connection Check for loose connections on line side or motor side ower wires System F aults 128 to 209 Control module internal fault Cycle control power to resetthe control module e If fault persists replace control module Prestart fault indication Table 9 B Motor Will Not Start No Output Voltage to the Motor Display Possible Causes Possible Solutions Fau
138. nt Range 1 0 2200 Amps Trip Classes 10 15 20 and 30 Trip Current Rating 120 of Motor FLC Number of Poles 3 Power Requirements Control Module 15 Gate Driver Boards Self powered Contactor See Contactor Specifications Auxiliary Contacts Control Module 20 265 V AC 20 265 V Rated Operation Voltage 5 30 V DC resistive 5 30 V DC resistive Rated Insulation Voltage N A 271V Operating Frequency 50 60 Hz DC 50 60 Hz DC 8300 15 30 VDC 0 88A pilot duty DC 12 Mechanical Ratings Control Module Control Terminals emina M 3 5 x 0 6 Pozidriv screw with self lifting clamp plate SCP D Performance Type 2 SCPD List Class CC 8A 1000 A Available Fault Current DPI Communication Control Module Maximum Output Current 280 mA Metering Functionality Control Module Voltage Current MW MWh Yes Displacement P ower Factor Tachometer Input Control Module Voltage 0 45 VDC Current 1 0mA For stop maneuvers the gate driver boards are pre charged with a current loop power supply 30 VA 1560E UM051A EN P September 2005 Specifications 3 Table A 1 Specifications cont Environmental Ratings UL CSA NEMA IEC Operating Temperature Range 0 C to 40 C 32 F to 10492 Storage and Transportation Temperature Range 20 C to 75 4 F to 149 F Altitude 0 1000 meters 3 3
139. ntrol module screws 5 Carefully rotate the module to the left and unplug the five ribbon cables from the interface board ATTENTION When removing the control module make sure to hold the module in place as the screws are removed to avoid strain on the ribbon cables To install control module follow the reverse order for removal Note The MV SMC Flex must use firmware release 3 006 or later This User Manual pertains to units with firmware released 4 xxx or later 1560E UM051A EN P September 2005 Troubleshooting 9 7 Voltage Feedback Circuit Tests The most straightforward means of checking the feedback circuits is to perform the snubber and resistor testing procedure found on page 9 26 Another possible test involves measuring the feedback voltages at the interface board see Figure 3 2 This can only be done with line voltage applied If the motor does not start it may be necessary to temporarily modify the control circuit to close the line contactor without applying a start signal to the SMC Flex module In this case the three line voltages Line A Line B Line C measured with respect to ground should be as follows check all three phases Table 9 F Voltage Feedback Measurements System Voltage Vit Feedback Voltage 1000 19 21 1300 24 2 6 1500 28 3 0 2400 1 8 2 0 3300 12 14 Feedback Voltage 4160 15 17 4800 10 12 5500 11 13 6600 14 15 6900 15
140. o 40096 of full load current Slow Speed with Braking SMC Option This parameter identifies the type of control present and is not user programmable Braking Control Slow Speed Select Allows the userto program the slow speed that best fits the application Low 796 High 1596 Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 to 45096 of full load current Slow Running Current Allows the user to program the required current to operate the motor slow speed setting 0 to 45096 of full load current Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 to 40096 of full load current Allbraking stopping current settings in the range of 1 100 will provide 100 braking current to the motor Braking Control is not offered for standard use in MV applications Please consult factory for further assistance 1560E UM051A EN P TBA 2005 Options 6 5 Note Options that control the stopping of the motor Soft Stop Pump Stop Linear Speed Braking require the self powered gate drivers to be pre charged by the current loop power supply If this supply is not present an alarm symbol will appear at the upper right corner of the control module display and the options will be inhibited When the motor is stopped it will coast If the supply is restored the alarm symbol
141. o 5A core balanced ground fault protection with the option of enabling Ground Fault Trip Ground Fault Alarm or both a core balance CT can be provided with 1562E units Ground Fault Trip The MV SMC Flex will trip with a ground fault indication if No trip currently exists Ground fault protection is enabled GF Inhibit Time has expired GF Current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay Parameter 75 Gnd Inh Time allows the installer to inhibit a ground fault trip from occurring during the motor starting sequence and is adjustable from to 250 seconds 1560E UM051A EN P September 2005 1 14 Product Overview Protection and Diagnostics cont 1560E UM051A EN P September 2005 Ground Fault Trip cont Parameter 74 Gnd Delay allows the installer to define the time period a ground fault condition must be present before a trip occurs It is adjustable from 0 1 to 25 seconds Parameter 73 Gnd Fit Level allows the installer to define the ground fault current at which the MV SMC Flex will trip It is adjustable from 1 0 to 5 0 A Important The ground fault inhibit timer starts after the maximum phase of load current transitions from 0 A to 30 of the device s minimum FLA Setting or the GF Current is greater than or equal to 0 5 A The MV SMC Flex does not begin monitoring for a ground fault condition until the Gnd Inh Time expires Ground Fa
142. o or bottom two within a phase Measured between terminals Cathode on SPGD Boards top to bottom within a phase Measured between line and load terminals within a phase Note The actual resistance value depends on the ohmmeter used the particular brand rating of SCR and external circuit influences It is impossible to accurately measure the condition of the SCR when it is unclamped 3 Ifashort circuit is suspected the SCR must be isolated from all surrounding circuitry 1 6 unplug gate and cathode leads and remove snubber and resistor circuit leads from the driver boards Measure resistance to confirm state of the SCRs If the SCRs are not shorted proceed to snubber and resistor circuit testing following this procedure 4 Ifafaulty device is found the entire heatsink assembly must be removed For heatsink assemblies containing four or more SCRs the entire matched set shall be replaced Devices connected in series must have performance specifications matched for proper operation Failure to use matched sets may result in damage to the devices 1560E UM051A EN P September 2005 9 12 Troubles hooting 1560E UM051A EN P September 2005 5 Complete heatsink assemblies with matched SCRs are available as a renewal part see Appendix D In most cases the assembly can be dismantled to replace the SCRs SCR Replacement Procedure Note This procedure applies to 180A and 360A units lt 5000V only Important Refe
143. of the Stop option The start signal for this scheme cannot be a slave of the main contactor since it must remain closed to accomplish the option stop maneuver The SMC Flex module can be used to control the main contactor such that it will close when a start 15 initiated and remain closed until it has sensed the motor has stopped following an option stop maneuver 1560E UM051A EN P September 2005 1 30 Product Overview Functional Description cont Bulletin 1560E Control Controlled Start only The control scheme shown in Figure 1 25 allows the MV SMC Flex to be controlled using DPI This special usage of DPI includes provisions for a Local mode of control as well With the Local Off Remote selector switch in the Remote position and closure of the existing starter main contactor terminal 18 is energized allowing a start command to be executed via DPI Aux 4 serves as an interlock with the main contactor or breaker in the existing starter As with the other control schemes the SMC Flex module closes Aux 1 energizing B IV as the motor approaches rated speed Local control is enabled with the selector switch in the Local position Closure of the Start relay from the existing starter allows the unit to initiate motor soft starting 1560E UM051A EN P September 2005 TD f INTERFACE N XX 5 BOARD
144. on Stall protection is user adjustable from 0 0 to 10 0 seconds enabled only after the programmed start time expires An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing e Jam detection allows the user to determine the jam level up to 1000 of the motor s full load current rating and the delay time up to 99 0 seconds for application flexibility 60096 Full Load Current Percent lt Programmed Start Time Stall gt Time seconds Figure 1 11 Stall Protection Product Overview 1 13 Percent User Programmed Full Load Trip Level Current 600 Running gt lt Jam gt Time seconds Figure 1 12 Jam Detection Detection is disabled during slow speed and braking operation Ground Fault In isolated or high impedance grounded systems core balanced current sensors are typically used to detect low level ground faults caused by insulation breakdowns or entry of foreign objects Detection of such ground faults can be used to interrupt the system to prevent further damage or to alert the appropriate personnel to perform timely maintenance The MV SMC Flex s ground fault detection capabilities consist of using a core balance current transformer for 1 t
145. onic and electrical equipment They are to be kept as dust free as possible A scheduled program of inspection will reduce the possibility of problems Servicing energized industrial control equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Recommended practice is to disconnnect and lock out control equipment from power sources and allow any stored energy in capacitors to dissipate If it is necessary to work in the vicinity of energized equipment the safety related work practices of NFPA 70E Electrical Safety Requirements for Employee Workplaces must be followed Note For OEM supplied components refer to documentation provided by the OEM for recommended periodic maintenance procedures 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 or 4 months after installation is suggested Applicable parts of the following guidelines should be used Contamination If inspection reveals that dust moisture or other contamination has reached the control equipment the source must be eliminated This could indicate an incorrect or ineffective enclosure unsealed enclosure openings conduit or other or incorrect operating procedures Dirty wet or contaminated parts must be replaced unless they ca
146. or Circuit Testing 9 26 Voltage Sensing Ri erem densi ede 9 27 Snubber Resistor Replacement eee 9 29 Warme Diagrams eret tette esee reet er oe eL ete tona 9 30 Maintenance Chapter 10 Safety and Preventative 5 re easet Ere GERE E CERE ERES Ree 10 1 Periodic Inspection 10 1 10 1 Vacuum Bottles eerte 10 2 Terminals 10 2 COIS meee 10 2 Solid State Devices reU rtr eer i dre eine 10 3 Static Sensitive 10 3 Overload Maintenance After Fault Condition 10 3 Pinal Check 10 3 Keep Good Maintenance Records 10 4 Power Components eor eed cest 10 4 Control Components Electronic 10 4 purse 10 4 10 4 10 4 Environmental Considerations eee 10 5 Hazardous Materials rrt hr ren 10 5 DISPOSAL costes debe tues 10 6 1560E UM051A EN P September 2005 vi Table of Contents MV Dialog Plus Medium Voltage Controller User Manual Appendix A Appendix B Appendix C Appendix D Appendix E 1560E UM051A EN P September 2005 1560E 156
147. or ID 104 0 65535 0 Motor Data CT Ratio 105 1 1500 MV Ratio 9 106 1 10000 Refer to Chapter 3 Commissioning Procedures to determine the appropriate setting 1560E UM051A EN P September 2005 4 Parameter Information Table 1 Parameter List cont Group Parameter Description Parameter Number Units Min Max Default Settings User Settings Basic Set Up Aux 1 Config 9 107 Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Up To Speed Aux 3 Config Aux 4 Config 108 109 Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Alam Normal Aux 2 Config 110 Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Fault Language All Language Parameter Mgmt 111 115 English French Spanish German Portuguese Mandarin Ready Load Default English Ready Basic Set Up Backspin Timer 116 SEC 0 999 This parameter does not appear for MV applications 1560E UM051A EN P September 2005 Table B 1 Parameter List cont Parameter Information B 5
148. ow Speed 222511 The jog button is not active for P reset Slow Jog Speed Slow Speed cannot be operated via the HIM 1560E UM051A EN P TBA 2005 6 2 0 ptions Human Interface Module con Option Action Operation Pump Control Pump Control The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button when pressed will initiate a pump stop maneuver lt Q Braking Control Smart Motor Braking The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button when pressed will initiate a Jog brake stop Accu Stop The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault With a stopped status the jog button when pressed will initiate slow speed motor operation From an at speed condition the jog button when pressed will initiate braking to slow speed operation The controller will maintain slow speed operation as long as the jog button is pressed lt Slow Speed with Braking The green start button when pressed will commence motor acceleration to
149. p C The equipment must be kept clean Dust build up inside the enclosure inhibits proper cooling and decreases the system reliability The equipment should not be located where liquid or solid contaminants can drop onto it Controllers with ventilated enclosures in particular those with fans must be in a room free of airborne contaminants D Only persons familiar with the function of the controller should have access to it E The losses in the controller produce a definite heat dissipation depending on the unit size that tends to warm the air in the room Attention must be given to the room ventilation and cooling require ments to ensure that the proper environmental conditions are met F Operational altitude is 3 300 feet 1 km maximum without derating Higher altitudes may require optional components Please consult Rockwell Automation factory G The area of the controller should be free of radio frequency interference such as encountered with some welding units This may cause erroneous fault conditions and shut down the system An incorrectly applied or installed controller can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or ambient tempera tures above or below the specified temperature range may result in malfunction of the controller Mounting The 1503 1560E and 1562 are designed to be mounted in the ve
150. p Description Option Display Overload Class Disable 10 15 20 9 Pit 44 Class The factor default setting disables 30 Class overload protection To enable it enter the desired trip class in this parameter Service Factor 0 01 to 1 99 F Gla pias Service Factor Enter the value from the motor s nameplate MotorFLC 1 0 to 2200A m Pf 46 Enter the value from the motor s Amps nameplate Overload Reset Manual Auto pus PEU Allows the user to select either a manual Manual or auto reset after an overload Motor Connection Line Delta DENEN Ps 15 Enter the type of motor being connected to the SMC Flex Line or Delta Line Voltage 1 to 10 000 V F P 16 Line Voltage Volt Referto the SMC Flex controller nameplate for maximum ratings Exceeding these could result in damage to the controller Found in Basic Set Up programming group Found Overload programming group Only one location needs to be programmed This is not to indicate how the motor windings are configured Do not select Delta for MV applications Caper D Overview Viewing Metering Data While the SMC Flex controller operates your motor it also monitors several different parameters providing a full function metering package To access the metering information follow the procedure below Desaiption Display
151. plication requirements Unbalanced feedback Check voltage sensing module Overvoltage 20 Supply voltage is greaterthan user Check power system and correct if necessary programmed value Correctthe user programmed value Undervoltage 21 Supply voltage is less than user Check power system and correct if necessary programmed value Correctthe user programmed value The delay time is too short for the Extend the delay time to match the application application requirements Overload 22 Motoroverloaded Check motor overload condition Overload parameters are not Check programmed values for overload class and matched to the motor motor FLC Underload 23 Broken motor shaft Repair or replace motor Broken belts tool bits etc Check machine Pump cavitation Check pump system 24 Motor current has exceeded the Correctsource of jam user programmed jam level Check programmed time value Stall 25 Motor has not reached full speed by Correctsource of stall the end ofthe programmed ramp time 1560E UM051A EN P September 2005 9 4 Troubleshooting Table 9 Fault Display Explanation cont Display Fault Code Possible Causes Possible Solutions Phase Reversal 26 Incoming supply voltage is not in Check power wiring the expected ABC sequence Disable protection if not needed Comm Loss 27 28 29 Communication disconnection at Check for a communication cable disco
152. points marked with an asterisk in Figure 3 1 This will ensure the unit is isolated from the line and the motor The line and the motor may be tested separately to locate problem areas If a 1503E is being tested consult OEM documentation After completing the test remove all semiconductor jumpers and test the devices with a multimeter to ensure no damage has occurred from the insulation test Reconnect the system as it existed prior to this section Perform the power supply and resistance checks in the following sections ATTENTION Failure to reconnect all wires and cables correctly may result in equipment damage personal injury or death wn 2 2 Commissionin 12 007 iN33302 2 amp 3SVHd 519201 ri Svr 4007 1
153. pplications some of the I O are assigned to specific functions Please refer to Notes related to Status Indication page 1 20 for additional details A serial interface port DPI is provided as standard which allows connection to the Bulletin 20 HIM LCD human interface modules DPI Figure 1 14 DPI Location Two peripheral devices can be connected to the DPI The maximum output current through the DPI is 280 mA Product Overview 1 19 Programming Setup is easy with the built in keypad and three line sixteen character backlit LCD Parameters are organized in a three level menu structure using a text format for straightforward programming Port5 DPI Communications Port2 Ports 2 and 3 when two HIMs are connected with a splitter Figure 1 15 Built in Keypad and LCD Status Indication Four programmable hard contact outputs are provided as standard All auxiliary contacts are programmed for the following states Normal N O N C Up to Speed N O N C e Alarm N O N C e Fault N O N C Network Control N O N C External Bypass N O 11 12 13 14 15 16 17 18 19 20 21 2 Opt Input Input npu Start Aux l SMC Flex Input Control Terminals 3 24 25 5 27 28 29 30 31 32 33 34 bae ENSE 551 1 1 Y Y Y PTC TACH Ground Aux 2 Au
154. ption 2 function Input 0 No Action Bits 5to 10 5 X Aux 1 Use Aux 1 to Aux 4 Enable 0 Ignore Aux 1 to Aux 4 1 Aux 1 Active 5 0 Aux 1 Inactive 1 Aux 2 Active 0 Aux 2 Inactive 1 Aux 3 Active AUX i 0 Aux 3 Inactive 1 Aux 4 Active 5 0 Aux 4 Inactive Reference Feedback The SMC Flex does not offer the analog Reference feature The analo g g Feedback feature is supported and will provide Parameter 1 Current in Phase A automatically as the feedback word Parameter Information A complete listing of the SMC Flex parameters is located in Appendix B Scale Factors for PLC The parameter values stored and produced by the SMC Flex through Communication communication are unscaled numbers When reading or writing values from a PLC image table it is important to apply the proper scaling factor which is based on the number of decimal places Read Example Parameter 11 Power Factor The stored value is 85 Since this value has two decimal places the value should be divided by 100 The correctly read value 1 0 85 1560E UM051A EN P September 2005 8 10 Communications Display Text Unit Equivalents Configuring DataLinks 1560E UM051A EN P September 2005 Write Example Parameter 46 Motor FLC The value which is to be written to the SMC is 75 A Since this value has one decimal place the value should be multiplied by 10 The correctly written value is 750 Some parameters have
155. r more than one motor the Overload Class parameter must be programmed to OFF and separate overload relays must be supplied for each speed motor 2 Automatic reset of an overload fault requires the start input to be cycled in a 2 wire control scheme 3 The trip rating is 117 of the programmed FLC Figures 1 9 and 1 10 provide the overload trip curves for the available trip classes 1560E UM051A EN P September 2005 1 10 Product Overview Protection and Diagnostics cont Class 10 Class 15 Class 20 Class 30 10000 0 10000 0 5 5 s 5 s 5 s Trip Time seconds Trip Time seconds 8 Approodmate Trip Time seconds 5 Approsdmate Trip Time seconds 5 10 10 1 2 3 4 567890 1 2 3 4 5678910 1 2 3 4 5678910 1 2 3 4 5 6 7890 Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC Approximate trip time for 3 phase balanced Approximate trip time for 3 phase balanced condition from cold start condition from hot start Figure 1 9 Overload Trip Curves 100000 1000 100 S Class 10 Class 15 Class 20 Auto Reset Times 1 1 Class 10 905 Class 15 1355 Class 20 1805 Class 30 2705 0 10096 100096 Percent
156. r to OEM documentation for SCR stack location in 1503E A Remove SCR Stack from Unit For all types of SMCs the stack requiring new SCRs must first be removed from the unit as follows 1 Remove all power from the equipment To avoid shock hazard ensure main power has been disconnected before working on the controller motor or control devices Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Service to phase A module may require removing the medium voltage door and swinging out the low voltage panel for 36 inch wide two high cabinet only see the low voltage panel Fig 9 4 3 Remove current loop cable see page 9 9 4 Unplug all fibre optic cables from the gate driver board Unplug gate lead connectors and thermistor connectors Remove leads from the left side of the circuit board The grey fibre optic cables can be damaged if struck or bent sharply They have a locking feature which requires pinching the tab on the connector and gently pulling straight out The component on the printed circuit board should be held to prevent damage 5 Remove gate driver board by compressing the locking tabs of the nylon circuit board supports and carefully pulling the board off the supports 6 Disconnect the power cables from the terminals on the left side of the heatsink assembly Use care not to damage components T
157. rcuit With Stop Control C 8 Bul 1560E Relay Control Circuit With DeviceNet C 9 Spare Parts Replacement SCRs Table D 1 see D 1 Complete Power Stacks Table 02 D 1 Snubber Capacitor Snubber Resistor Table D 3 D 1 Common Parts Table D 4 sese D 2 Accessories Table D5 nitri dS D 2 Accessories Accessories Table tereti E 1 Service Procedure For your convenience the Rockwell Automation Global Manufacturing Solutions GMS 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 MV SMC Flex 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 1560E UM051A EN P September 2005 Preface 1560E UM051A EN P September 2005 Manual Objectives Documentation Description Chapter 1 Product Overview This manual is intended for use by personnel familiar with Medium Voltage and solid state power equipment The manual cont
158. riate CEC or NEC regulations to determine correct power wiring If assistance is needed contact your area Rockwell Automation Sales Office Hinged doors and panels which provide access to medium voltage components must be mechanically interlocked to ensure circuit isolation If a combination MV SMC Flex 1562E is purchased from Rockwell Automation all medium voltage compartments will be mechanically interlocked such that they cannot be opened unless the isolating switch for the unitis open Each medium voltage door is interlocked to the isolating switch handle To open the doors move the isolating switch to the OFF position and loosen the two retaining bolts on the main power cell door Once this door is open the other doors may be opened in sequence depending on the specific interlock scheme provided The retrofit type MV SMC Flex 1560E is intended to be added to an existing motor controller and has no isolating means included For 1503E and 1560E it is the responsibility of the installer user to ensure the equipment interlocking scheme is in place and functional before energizing the equipment Inadequate interlocking could expose personnel to energized parts which could result in severe burns injury or death NOTE Rockwell Automation can assist with the selection of an appro priate interlocking method which may include mechanical modifications to the cabinet s or key type lock systems NOTE An auxiliary cabinet may be attac
159. ring Controllers consisting of two or more sections will require that the power and control wiring be connected per the schematic drawings provided Control Cables Control cable entry exit should be located near the terminal blocks customer s connections are to be routed along the empty side of the terminals Nylon cable tie loops are provided at the left front corner of the cabinet to route control cables safely behind the low voltage panel hinges Cables should be routed so they do not interfere with the swing of the low voltage panels Fibre Optic Cables The small gray fibre optic cables are fragile and must be protected during installation from sharp bends and impact 1560E UM051A EN P September 2005 2 14 Installation Installation cont 1560E UM051A EN P September 2005 Power Factor Correction Capacitors The controller can be installed on a system with power factor correction capacitors The capacitors must be located on the line side of the controller This is required to prevent damage to the SCRs in the MV SMC Flex controller A separate switching contactor is recommended to apply the capacitors only after the bypass contactor has closed and to remove them when the bypass contactor opens See Figure 2 7 for two different acceptable connection methods NOTE Consult the factory if there are any capacitors on the same branch circuit as the MV SMC Flex When discharged a capacitor has essentially zero impedance
160. rmal capacity calculations Soft Stop is not intended to be used as an emergency stop Such usage may result in severe injury or death Refer to the applicable standards for emergency stop requirements Protection and Diagnostics Product Overview 1 9 The MV SMC Flex controller is capable of providing the following protective and diagnostic features Overload The SMC Flex controller meets applicable requirements as a motor overload protection device Thermal memory provides added protection and is maintained even when control power is removed The built in overload algorithm controls the value stored in Parameter 12 Motor Thermal Usage see Chapter 4 Programming An Overload Fault will occur when this value reaches 100 parameters below provide application flexibility and easy setup Parameter Range Overload Class Disable 10 15 20 30 Overload Reset Manual Auto Motor FLC 1 0 2200 amps Service Factor 0 01 1 99 Important During slow speed operations current waveforms exhibit non sinusoidal characteristics These non sinusoidal characteristics inhibit the controller s current measurement capability To compensate for additional motor heating that may result the controller uses motor thermal modeling which increments motor thermal usage This compen sation takes place when the Preset Slow Speed option is used Notes 1 Ifthe MV SMC Flex is used to control a multi speed motor o
161. roubleshootin Circuit Board Replacement The replacement of printed circuit boards is straightforward however there are a number of precautions which must be considered when handling the boards Some circuit boards may contain CMOS components which can be destroyed by static charges generated by friction of materials made with synthetic fibres Use of damaged circuit boards may also damage related components grounding wrist strap is recommended for handling sensitive circuit boards 1 Remove all power from the equipment To avoid shock hazard ensure the main power has been disconnected before working on the controller motor or control devices Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Carefully detach all wires cables and connectors noting their location and orientation For the interface board remove the control module see page 9 6 The fibre optic cables can be damaged if struck or bent sharply They have a locking feature which requires pinching the tab on the connector and gently pulling straight out The component on the printed circuit board should be held to prevent damage 3 For boards mounted with hardware remove the hardware taking care not to drop anything onto other circuits For boards with nylon stand off posts squeeze the section above the board and carefully pull the board up and off t
162. roup provides a limited parameter set allowing quick start up with minimal adjustments If the user is planning to implement some of the advanced features i e Dual Ramp Unbalance Level etc then the Linear List programming group should be selected It provides all the Basic Setup parameter set plus the advanced set Parameter Option SMC Option Displays the type of controller This is factory set and not adjustable Standard Motor Connection Line or Delta Displays the location of the SMC in relation to the motor windings Line Voltage Displays the system line voltage the unitis connected to MV Ratio 11010000 S cales the output from the Voltage Sensing Board to display correct line voltage See Table 3 B Input Voltage Ranges Starting Mode Soft Start Current Limit Full Voltage Allows the user to program the S MC Flex controller for the type of starting that best fits the application Linear S peed Ramp Time This sets the time period during which the controller will ramp the output voltage 0to 305 Initial Torque 0 The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter 0 to 90 96 locked rotor torque Current Limit Level The current limit level that is applied for the Ramp time selected 50 to 60096 FLC Starting Mode must be programmed to S oft Start to obtain access to the Initial Torque parameter e
163. rtical position Standard cabinet drawings with certified dimension drawings can be obtained by contacting your local Rockwell Automation Sales office for the 1560E 1562E Please refer to OEM documentation for the 1503E Refer to drawings for mounting requirements 1560E UM051A EN P September 2005 2 4 Installation Installation Site cont Recommended Torque Values 1560E UM051A EN P September 2005 Grounding Practices The purpose of grounding is to A Provide safety for Personnel B Limit dangerous voltages to ground on exposed parts C Facilitate proper overcurrent device operation under ground fault conditions D Provide for electrical interference suppression Important Generally grounding should be in accordance with the Canadian Electrical Code CEC or National Electrical Code NEC and other local codes Each power feeder from the substation transformer to the controller must be equipped with properly sized ground cables Simply utilizing the conduit or cable armour as a ground is not adequate The conduit or cable armour and ground wires should be bonded to ground at both ends Each enclosure and or frame must be bonded to ground at a minimum of two locations Each AC motor frame must be bonded to grounded building steel within 20 feet 6 1 m of its location and tied to the controller s ground bus by ground wires within the power cables and or conduit The conduit or cable armour should be bonded to groun
164. scription 1514312110987 1 Control Power Applied Enabled 0 No Control Power 1 Power Applied to Motor Running 0 Power not Applied to Motor 1 ABC Phasing Phasing 0 CBA Phasing Phasing 1 3 phase is valid Active 0 No valid 3 phase is detected Starting 1 Performing a Start Maneuver Accel 0 Not performing a Start Maneuver Stopping 1 Performing a Stop Maneuver Decel 0 Not performing a Stop Maneuver 1 Alarm Present Alam 0 No Alarm Present 1 Fault Condition Exists Fault 0 No Fault Condition At 1 Full Voltage Applied Speed 0 NotFull Voltage Applied X Start 1 Start lsolation Contactor Enabled Isolation 0 Start lsolation Contactor Disabled 1 Bypass Contactor Enabled Bypass 0 Bypass Contactor Disabled 1 Ready Ready 0 Not Ready X Option 1 1 Input Active Input 0 Input Inactive X Option2 1 InputActive Input 0 Input Inactive Bits 14 and 15 NotUsed 1560E UM051A EN P September 2005 Table 8 H Logic Command Word Control Communications 8 9 Bit Status Description 15 14 13 12 11 10 87654302100 1 Stop Inhibit 5 stop 0 No Action 1 Start 5 0 No Action X Option 1 1 Stop Maneuver Inhibit Input 0 No Action X Clear 1 Clear Faults Faults 0 No Action X Option 42 1 Perform O
165. ses faulty firing e g open SCR gate or faulty gate driver Open Gate has been sensed during the start sequence The SMC Flex controller will attempt start the motor total of three times before the controller shuts down Power Pole The power pole temperature in each phase is monitored If the temperature rises above the predetermined level Overtemperature the unit will fault to protect the power pole A reset can be performed once the temperature falls below this level P This fault may also representloss of gate driver power during gating MV applications only Motor PTC motor PTC can be connected to terminals 23 and 24 If the PTC parameter is enabled and the PTC trips S MC Flex will trip and indicate a Motor PTC fault pen Bypass Power Pole bypass contacts are monitored for proper operation In the event of a contact failure the SMC Flex will pen Syp indicate an Open Bypass fault No Load The SMC Flex can determine if a load connection has been lost and No Load fault will be indicated Line Unbalance amp Voltage unbalance is detected by monitoring the three phase supply voltages The formula used to calculate the percentage voltage unbalance is as follows Vu 2100 Va Va Vu Percent voltage unbalance Va Maximum voltage deviation from the average voltage Va Average voltage The controller will shut down when the calculated voltage unbalance reaches the user programmed trip percentages Overvol
166. ss Reference Fault Code Fault Code Line Loss A 1 Stall 25 Line Loss B 2 Phase Reversal 26 Line Loss C 3 Coms Loss P2 2 Shorted SCR A 4 Coms Loss P3 28 Shorted SCR B 5 Coms Loss P5 29 Shorted SCR C 6 Network P2 30 Open Gate A 1 Network P3 31 Open Gate B 8 Network P5 32 Open Gate C 9 Ground Fault 33 PTC PwrPole 10 Excess Starts Hour 34 SCR Overtemp 11 Power Loss 35 Motor PTC 12 Power Loss B 36 Open Bypass A 13 Power Loss C 37 Open Bypass B 14 Hall ID 38 Open Bypass C 15 NVS Error 39 No Load A 16 No Load 40 No Load B 17 Line Loss A 41 No Load C 18 Line Loss B 42 Line Imbalance 19 Line Loss C 43 Overvoltage 20 V24 Loss 45 Undervoltage 21 V Control Loss 46 Overload 22 Input 1 48 Underload 23 Input 2 49 Jam 24 System Faults 128 209 Notapplicable in MV applications Fault and Alarm Auxiliary contacts can be programmed for Fault or Alarm N O or N C Auxiliary Indication indication Parameter setup can be found in the Parameter Motor Protection group when modifying parameters in the Program Mode 1560E UM051A EN P September 2005 7 4 Diagnostics Fault Definitions Table 7 B Fault Definitions for the SMC Flex Fault Description Line Loss F1 F2 F3 The SMC Flex can determine if a line connection has been lost and will indicate this accordingly Shorted SCR Shorted SCRs will be detected and starting will be prohibited by the SMC Flex Open gate indicates that an abnormal condition that cau
167. t Extract SCR To Insert New SCR Apply thin film of electrical joint compound to surfaces of SCR Install SCR so that itis seated in locating pin of heatsink note orientation of SCR Pry heatsinks to close gap ensuring that SCR is seated properly in both its locating pins Rotate SCR so that all leads have same direction Proceed to replace SCR s matched pair SCR2 Note You must replace both SCRs of a matched set SCR 4 Shorting Bar Hardware Shorting Bar Hardware Heatsink 5 Figure 9 10 Removal of SCR2 and SCR4 3300 to 4160 V 180 360 1560E UM051A EN P September 2005 Troubleshootin 9 21 55 Q lt Line connection 5 9 4 Load connection 9 4 Line connection D 9x G S 9 5 lt Load connection Board Mounting Frame Figure 9 12 Power Module Assembly one phas
168. t are displayed on the SMC Flex can be modified to show you desired values by accessing Main Menu Preferences 1560E UM051A EN P September 2005 Chapter Options Overview The SMC Flex controller offers a variety of unique control programming and communication options that provide enhanced capabilities See Chapter 1 for brief descriptions of each option Note Only one option can reside in a controller Human Interface Module The control buttons available with the Bulletin 20 HIM Human interface modules are compatible with the SMC Flex controller s control options The following table details the functionality of each button with regards to each option Notes 1 The logic mask port must be enabled prior to initiating control commands to the SMC Flex controller Refer to Control Enable on page 2 16 for instructions 2 The control terminals must be wired according to Figure 3 10 on page 3 10 and Figure 3 16 on page 3 16 Option Action Operation Standard EB The green start button when pressed will commence motor acceleration to full speed SoftStop Current Limit a he red stop button when pressed will Full Voltage provide a coast stop and or reset a fault Linear Speed Jog The jog button when pressed will initiate the programmed maneuver EE The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will Preset Sl
169. tage and Undervoltage Protection amp Overvoltage and undervoltage protection are user defined as a percentage of the programmed line voltage The SMC Flex controller continuously monitors the three supply phases The calculated average is then compared to the programmed trip level Underload Underload protection is available for undercurrent monitoring The controller will shut down when the motor current drops below the trip level This trip level a percentage of the motor s full load current rating can be programmed Overload Protection Overload protection is enabled in the Motor Protection group by programming the Overload class Overload reset Motor FLC Service factor Refer to Chapter 5 for more information on Motor Protection Phase Reversal Phase reversal is indicated when the incoming power to the SMC Flex controller is in any sequence other than ABC This pre start protective feature can be disabled The SMC Flex controller disables control through the serial communication port as the factory default To enable control the Logic Mask found in the Communication programming group must be set to 4 With Series B human interface modules this can also be accomplished by enabling control logic through the Control Status programming Coms Loss group If a Bulletin 20 HIM Human interface module or Bulletin 1203 communication module is disconnected from the S MC Flex controller when control is enab
170. tant For retrofit units Bul 1560E the CEC and NEC require that branch circuit protection of the AC line input to the controller be provided by a circuit breaker or motor starter This function is included with a Bulletin 1562E Important The control and signal wires should be positioned at least six 6 inches 150 mm from power cables Additional noise suppression practices including separate steel conduits for signal leads etc are recommended Bulletin 1503E For 1503E refer to applicable documentation from OEM for installation grounding interlocking and wiring This manual should be utilized in conjunction with the OEM supplied documentation and is suitable for commissioning programming calibration metering serial communica tions diagnostics troubleshooting and maintenance of a standard solid state controller 1560E UM051A EN P September 2005 2 12 Installation Power Wiring Interlocking 1560E UM051A EN P September 2005 The wire sizes must be selected individually observing all applicable safety and CEC or NEC regulations The minimum permissible wire size does not necessarily result in the best operating economy The minimum recommended size for the wires between the controller and the motor is the same as that used if a main voltage source connection to the motor was used The distance between the controller and motor may affect the size of the conductors used Consult the wiring diagrams and approp
171. tation and is suitable for commissioning programming calibration metering serial communications diagnostics troubleshooting and maintenance of a standard solid state controller It is the responsibility of the user to thoroughly inspect the equipment before accepting the shipment from the freight company Check the item s received against the purchase order If any items are damaged it is the responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill Should any concealed damage be found during unpacking it is again the responsibility of the user to notify the freight agent The shipping container must be left intact and the freight agent should be requested to make a visual inspection of the equipment The Canadian Electrical Code CEC National Electrical Code NEC or other local codes outline provisions for safely installing electrical equipment Installation MUST comply with specifications regarding wire type conductor sizes branch circuit protection interlocking and disconnect devices Failure to do so may result in personal injury and or equipment damage After unpacking the material check the item s received against the bill of lading to ensure that the nameplate description of each item agrees with the material ordered Inspect the equipment for physical damage as stated in the Rockwell Automation Conditions of Sale Remove all packing material wedges or braces
172. telliV AC Control Circuit With Stop Control 1 35 Bul 1560E Intelli V AC Control Circuit With DeviceNet 1 36 Installation Chapter 2 2 1 Safety COMES i E 2 1 Unpacking and Inspection cnt ette 2 1 General Precautions 2 2 Transportation and 2 2 Installation Site uiderit ret rientra ete to earn ere inanes 2 3 2 3 Grounding Practices etre eet tiet 2 4 Recommended Torque Values esee 2 4 Power COMNECHONS 2 5 Bulletin 1562E 1 oerte 2 5 Bulletin 1560 reet 2 8 Bulletin 5036 2 11 Powet i 2 12 Interlocking oec ose 2 12 Installation te ee terr eet e 2 13 Physical Location eerte ee be eie be cte nro 2 13 2 13 Ground Bus B t intime Pace cades 2 13 Power and Control Wiring 2 13 Control Cables reet 2 13 Fibre Optic Cables iieii 2 13 Power Factor Correction 2 14 1560E UM051A EN P September 2005 Table of Contents MV Dialog Plus Medium Voltage Controller User Manual iii Installation cont Chapter 2 Page Surge Arrestor Protection 2 16 Motor Overload Protection
173. the switch and the three yellow LEDs on the left side of the Interface board should be lit Note They may appear dim depending on ambient light conditions Red LED ON when test pulses active SW2 Figure 3 3 Interface PCB 1560E UM051A EN P September 2005 3 8 Commissioning P rocedures Power Supply Tests cont 6 Since the gate driver circuits normally receive power from the snubber circuits when the SMC is operating an alternate source must be used for testing Locate the Portable Test Power Supply that was included with the equipment and verify that the rating corresponds to the available power system i e 110 120 VAC or 220 240 VAC Plug the unit into the power source and plug the green connector into J1 on each of the gate driver boards See Figure 3 4 Gate signal Temperature signal fibre optic receiver fiber optic receiver Yellow LED Plug in test Current loop CT power supply 5V test point Thermistor connector V n 5 3 Snubber J terminal 4 Cathode n terminal zl 1 TP2 O 1 T HL Gate signal test point
174. thirty seconds maximum for each operation A stopping operation counts as a start for purposes of thermal capacity calculations Note Options that control the stopping of the motor Soft Stop Pump Stop Linear Speed Braking require the self powered gate drivers to be pre charged by the current loop power supply If this supply is not present an alarm symbol will appear at the upper right corner of the control module display and the options will be inhibited When the motor is stopped it will coast If the supply is restored the alarm symbol will be cleared and the module will perform the programmed sequence 1560E UM051A EN P September 2005 4 12 Programming Preset Slow Speed the motor This control mode may be configured to allow slow speed operation of Parameter Slow Speed Select Allows the user to program the Slow speed that best fits the application Option Low 7 Forward 10 Reverse High 15 Forward 20 Reverse Slow Speed Direction This parameter programs the Slow speed motor rotational direction Forward Reverse Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 to 45096 of full load current Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting 0 to 45096 of full load current Basic Setup The Basic Setup programming g
175. three power modules one for each phase Each power module consists of incoming and outgoing terminals for cables SCRs heatsink and clamp assembly The SCRs are connected in inverse parallel and in series for 12 or 18 SCR assemblies to form a three phase AC line controller configuration Each power module includes a snubber circuit to limit the rate of rise in voltage across each SCR pair The module also includes patented current loop gate driver circuits which derive their power primarily from the snubber circuit Voltage sharing resistors are connected across each SCR pair to provide static voltage balance for series connected SCRs These resistors are tapped to provide a reference for overvoltage protection circuitry on the gate driver board A voltage sensing board is used to reduce the line side and load side voltages to lower levels that can be measured by the SMC Flex control module Current Loop Gate Driver CLGD Board This board provides the turn on capability for SCR devices The board also provides optical fibre isolation between itself and the gating source logic It is primarily powered by recovering energy from the snubber circuit so it is fully isolated from the control and logic circuits The board also receives short term power from the current loop power supply The SMC Flex has three heatsinks fitted with a thermistor to monitor temperature rise The circuitry on the gate driver board accepts the thermistor
176. tify fault and correct Check for shorted SCR replace if necessary Ensure power terminals are secure Motor coasts when option stop is programmed Option not programmed Current loop power supply not active Incorrect control logic Verify the option parameter settings and correct if necessary Verify currentloop power supply see Chapter 3 Power Supply Tests Verify connections to module terminals 16 and 17 see Chapter 1 Functional Description Various faults may occur if Parameter 15 is set to Delta It must be set to Line for all MV applications NOTE For Pump Stop issues please refer to Pump Application Considerations on page 1 21 1560E UM051A EN P September 2005 9 6 Troubleshootin Control Module Removal The control module is not intended for field repair The entire module must be replaced in the event of failure The following procedure must be followed before unplugging the control module 1 Remove all power from the equipment To avoid shock hazard ensure the main power has been disconnected before working on the controller A motor or control devices Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Make sure that the wires are properly marked and that the program parameters are recorded 3 Disconnect all control wires to control module 4 Loosen the four co
177. ting To Remove SCR Remove shorting bar hardware Pry opposing Heatsinks apart Extract SCR To Insert New SCR Apply thin film of electrical joint compound to surfaces of SCR Install SCR so that itis seated in locating pin of heatsink note orientation of SCR Pry heatsinks to close gap ensuring that SCR is seated properly in both its locating pins Rotate SCR so thatall leads have same direction SCR 2 SCR 1 Shorting Bar Hardware Heatsink 3 E p Heatsink 1 Heatsink 2 Locating Pin Figure 9 7 Removal of SCR 1000 to 2400 V 180 360 A 1560E UM051A EN P September 2005 Troubleshooting 9 19 0 Heatsink 1 SCR 1 Heatsink 2 SCR 2 Heatsink 3 L SCR 3 e Heatsink 4 SCR4 1 5 Heatsink 5 Note SCR 1 SCR 3 a matched set SCR 2 and SCR 4 are a matched set Figure 9 8 Power Module Assembly one phase 3300 4160 V 180 360 Do not loosen Centre Nut Locking Nut Do not adjust Indicating Washer To remove clamp pressure loosen lower center nut so that gap between the clamp surface and the heatsink is Do notloosen approximately 6 mm 0 25 Figure 9 9 Heatsink Clamp 1560E UM051A EN P September 2005 9 20 Troubleshooting To Remove SCR4 Remove shorting bar hardware Pry Heatsinks 4 and 5 apar
178. trolled or coast stop is achieved by opening the connection to terminal 17 This contact should remain open to ensure all hold in contacts clear to prevent a re start If the motor has started the unit is in the bypass mode and a trip occurs within the SMC Flex module or from an external protection relay Aux 4 will open the line contactor immediately and Aux 1 will remain closed for 10 seconds A trip due to an overload or fault condition will result in a coast stop Bulletin 1562E DPI Control Controlled Start only The control scheme shown in Figure 1 22 allows the MV SMC Flex to be controlled using DPI Drive Programming Interface This special usage of DPI includes provisions for a Local mode of control as well With the Local Off Remote selector switch in the Remote position terminal 18 of the SMC Flex module is energized allowing a start command to be executed via DPI The Aux 4 contact closes energizing both M IV and When the motor approaches rated speed the SMC Flex module closes Aux 1 energizing B IV which closes the bypass contactor To run in Local mode the CR contact is used to initiate a start sequence similar to Figure 1 20 A stop command can be generated via DPI or by opening depending on the control mode Product Overview 1 29 Bulletin 1560E Basic Control Controlled Start Only The Bulletin 1560E is intended for addition to an existing motor controller
179. troller parameter values stored in the EEPROM are copied to RAM RAM is volatile and the values stored in this area are lost when the controller is powered down Read only Memory ROM The SMC Flex controller comes with factory default parameter values These settings are stored in nonvolatile ROM and are displayed the first time you enter the Program mode Electrically Erasable Programmable Read only Memory EEPROM The SMC Flex controller provides a nonvolatile area for storing user modified parameter values in the EEPROM Programming 4 7 Using Parameter Management with DPI HIM Note SMC Flex will automatically save any parameter changes made during the programming process Memory Storage and Parameter Management perform the same function of resetting to defaults Description Action Display Recalling Defaults After parameter values have been modified factory default settings can still be re initialized 1560E UM051A EN P September 2005 4 8 Programming Parameter Modification parameters are modified using the same method The basic steps to performing parameter modification are described below Notes 1 Parameter values modified while the motor is operating are not valid until the next start sequence begins 2 Ifthe password is set parameters cannot be adjusted without logging in 3 Use the Sel key to highlight a single digit
180. type of control present and is not user programmable Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 400 of full load current Allbraking stopping current settings in the range of 1 100 will provi ide 100 braking currentto the motor Braking Control is not offered for standard use in MV applications Please consult factory for further assistance 1560E UM051A EN P TBA 2005 6 4 0 ptions Programming Parameters cont Option Parameter Range Braking Control cont Accu Stop SMC Option This parameter identifies the type of control present and is not user programmable Braking Control Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 High 15 Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 to 450 of full load current Slow Running Current Allows the user to program the required current to operate the motor at slow speed operation 0 to 400 of full load current Braking Current amp Allows the user to program th intensity of the braking applied to the motor D 0 to 40096 of full load current Stopping Current Allows the user to program the intensity of the braking current applied to the motor from slow Speed operation 0 t
181. ules the Option 2 input defaults to Emergency Run for MV applications 1560E UM051A EN P September 2005 4 14 Programming Motor Protection 1560E UM051A EN P September 2005 While the Basic Set Up group allows the user to get started with a minimum number of parameters to modify the Motor Protection group allows full access to the SMC Flex controller s powerful parameter set Following is a listing of the additional setup parameters provided Note The majority of parameters have a Fault and an Alarm setting Parameter Option Overload Trip Class Service Factor Allows the user to select the operation of the Motor FLC Overload Reset overload Overload Alarm Level Underload Underload Fault Level Determines the trip level as a percentage of the motor s FLA and the delay period Underload Fault Delay Underload Alarm Level Underload Alarm Delay Undervoltage Determines the trip level as a percentage of line voltage and delay period Undervoltage Fault Level Undervoltage Fault Delay Undervoltage Alarm Level Undervoltage Alarm Delay Overvoltage Overvoltage Fault Level Determines the trip level as a percentage of line Overvoltage Fault Delay voltage and delay period Overvoltage Alarm Level Overvoltage Alarm Delay Unbalance Unbalance Fault Level Allows the user to setthe current unbalance trip level and delay period Unbalance Fault Delay Unbalance Alarm Level
182. ult Alarm The MV SMC Flex will indicate a Ground Fault Alarm if No warning currently exists Ground fault alarm is enabled GF Inhibit Time has expired GF Current is equal to or greater than the Gnd Fit A Lvl Parameter 77 Gnd A Lvl allows the installer to define the ground fault current at which an alarm will be indicated It is adjustable from 1 0 to 5 0 A Parameter 78 Gnd Fit A Dly allows the installer to define the time period a ground fault alarm condition must be present before a trip occurs It is adjustable from 0 1 to 25 seconds Thermistor PTC Protection The MV SMC Flex provides terminals 23 and 24 for the connection of positive temperature coefficient PTC thermistor sensors PTC sensors are commonly embedded in motor stator windings to monitor the motor winding temperature When the motor winding temperature reaches the PTC sensor s temperature rating the PTC sensor s resistance transitions from a low to high value Since PTC sensors react to actual temperature enhanced motor protection can be provided to address such conditions as obstructed cooling and high ambient temperatures The following table defines the MV SMC Flex PTC thermistor input and response ratings Product Overview 1 15 Table 1 A PTC Input Ratings Response Resistance 34000 1500 Reset Resistance 16000 1000 Short circuit Trip Resistance 250 100 Maximum Voltage at PTC Terminals 4 15V
183. ult in personal injury and or equipment damage Trans portation and Handling The controller must be transported on a pallet or via use of the lifting angles supplied as part of all 90 inch 2 3 m high cabinets or frame units Ensure that the load rating of the lifting device is sufficient to safely raise the controller sections Failure to do so may result in severe injury and or equipment damage Refer to the packing slip enclosed with shipment for shipping weights Round rollers can be used to assist in moving the controller to the instal lation site Once at the final site the pipe rolling technique can be used to place the cabinet in the desired position Care must be exercised when using either a forklift or the pipe rolling technique for positioning purposes to ensure that the equipment is not scratched dented or damaged in any manner Always exercise care to stabilize the controller during handling to guard against tipping and injury to personnel 1560E UM051A EN P September 2005 Installation Site Installation 2 3 Consider the following when selecting the installation site The operating ambient temperature should be between 0 C and 40 C 32 F and 104 F for NEMA Type 1 or 12 enclosures For higher ambient conditions please consult Rockwell Automation factory B Therelative humidity must not exceed 95 non condensing Excessive humidity can cause electrical problems from corrosion or excessive dirt build u
184. utomatically switches to full voltage and the bypass contactor is closed 600 Percent Full Load Current 50 gt Time seconds Figure 1 3 Current Limit Start Kickstartis also available with Current Limit Start Dual Ramp Start and Linear Acceleration 1560E UM051A EN P September 2005 Product Overview 1 5 Dual Ramp Start This starting mode is useful for applications that have varying loads and therefore varying starting torque requirements Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings Percent Voltage 100 1 Initial Torque 2 Le Initial Torque 1 amp gt Runt gt lt 501 0 lt Time seconds Figure 1 4 Dual Ramp Start DualRamp Startis available only with the standard controller Full Voltage Start This starting mode is used for applications requiring across the line starting The output voltage to the motor will reach full voltage within second 100 Percent Voltage Time seconds Figure 1 5 Full Voltage Start 1560E UM051A EN P September 2005 1 6 Product Overview Starting Modes cont 1560E UM051A EN P September 2005 Preset Slow Speed This option can be used in applications that require a slo
185. voltage Current Limit Level 50 to 60096 full load current This parameter provides adjustability for the reduced output voltage level provided to the motor Kickstart Time 0 0to 2 05 A boost of current is provided to the motor for the programmed time period Kickstart Level 0 to 90 96 locked rotor torque Adjusts the amount of current applied to the motor during the kickstart time ifthe controller senses that the motor has reached full speed before completing the Current Limit Start it will automatically switch to providing full voltage to the motor 1560E UM051A EN P September 2005 4 10 Programming Dual Ramp Start 1560E UM051A EN P September 2005 The SMC Flex controller provides the user with the ability to select between two Start settings The parameters below are available in the Set Up programming mode obtain Dual Ramp control Ramp 1 is located in the Basic Set Up and Ramp 2 is located in the Option 2 Input Dual Ramp Parameter Option SetUp The user must select the Set Up programming mode to obtain access to the Dual Ramp parameters Basic Set Up Starting Mode Set up as stated in previous pages Option 1 Input Dual Ramp This allows the user the option to choose between two Soft Start profiles defined by 1 Start Mode Ramp Time Initial Torque and 2 Start Mode 2 Ramp Time 2 Initial Torque 2 When this feature is turned on the ramp time initial torque comb
186. w speed jog for general purpose positioning Preset Slow Speed provides either 7 of base speed low or 15 of base speed high settings in the forward direction Reverse can also be programmed and offers 10 of base speed low and 2046 of base speed high settings Forward 15 High _ 7 Time seconds lt Start gt gt 10 Low 20 High Reverse Figure 1 6 Preset Slow Speed Option Important Slow speed running is not intended for continuous operation due to reduced motor cooling The two starts per hour limitation also applies to slow speed operation This option employs a cycle skipping scheme which produces limited torque Applications should be checked with the factory Product Overview 1 7 Linear Speed Acceleration and Deceleration The SMC Flex has the ability to control the motor speed during starting and stopping maneuvers A tachometer signal 0 to 5V DC is required to perform this start mode The start time is selectable from 0 to 30 seconds and determines the time the motor will ramp from 0 speed to full speed Kickstart is available with this option 100 Motor Speed lt gt lt Run lt Stop Time seconds Figure 1 7 Linear Speed Acceleration Linear deceleration does not need to be used even if linear acceleration is used The stop time can be programmed for 0 to 120 seconds Linear dec
187. will result in a coast stop Bulletin 1562E Control Controlled Start only Refer to Figure C 3 and description on page 1 27 1560E and 1560E Relay Control C 3 Bulletin 1560E Basic Control Controlled Start Only The Bulletin 1560E is intended for addition to an existing motor controller which provides circuit isolation motor switching and overload and overcurrent protection When wired as shown in Figure C 4 the controller operates as follows When a start is initiated in the existing motor controller and the contactor or breaker closes a contact must be supplied to tell the 1560E to start also A contact will apply control voltage to terminal 17 of the SMC Flex module When stopping the motor the contactor in the existing controller will open removing power from the motor and then the CR relay The bypass hold in rung will keep the bypass contactor closed for a short time The Fault contact on the SMC Flex module should be wired into the existing controller to trip the main contactor or breaker in the event of a fault condition sensed by the SMC Flex module If possible it is better to have the SMC Flex module control the main contactor directly In this case the control circuit would look like and function like the descriptions above for the Bulletin 1562E Bulletin 1560E Basic control With Controlled Stop When wired as shown in Figure C 5 the controller operates much the s
188. with bypass Starting Torque 0 to 9096 of motor torque Thermal Capacity 60096 10 seconds 45096 30 seconds Ramp Time 0 to 30 seconds Consult Factory for Longer Time Acceleration Kick 550 for 0 0 to 2 0 seconds Approvals Safety 92 59 EEC Directive 061 1198 Certificate Ref BSEN 61010 1 1993 BSEN 60204 1 1997 89 336 EEC 92 31 EEC 93 68 EEC Directives T703ALB1 Certificate Ref EN 61000 6 4 2001 EN 61000 6 2 2001 UL E102991 CSA LR 12235 pending 1560E UM051A EN P September 2005 2 Specifications Table A 1 Specifications cont Electrical Ratings cont UL CSA NEMA IEC Short Circuit Protection The power electronics unit must be protected by current limiting fuses to be included by customer in existing starter with 1560E The combination controller includes appropriate fusing coordinated with motor 2400 V 200 MVA Sym Fault Level Withstand as a Fused E2 4160 V 350 MVA Sym Controller NEMA E2 4600 V 400 MVA Sym 6900 V 570 MVA Sym Control Circuit Rated Operation Voltage 120 240 V AC 15 410 110 230V 15 410 Dielectric Withstand 1600 V AC 2000 V Operating Frequency 50 60 Hz 50 60 Hz Enclosure Enclosure Type NEMA Type 1 16 12 and 3R IP 10 21 52 and 34 Overload Characteristics Control Module Type Solid state thermal overload with phase loss Curre
189. x 3 Aux 4 Input Input Fault Figure 1 16 Control Terminals 1560E UM051A EN P September 2005 1 20 Product Overview Status Indication cont Control Options 1560E UM051A EN P September 2005 Note The Aux 1 contact is always programmed for Up to speed N O to control the bypass contactor in MV applications The Aux 2 contact is typically programmed for fault indication in MV applications it can be configured for The Aux 3 contact is typically programmed for alarm indication in MV applications it can be configured for The Aux 4 contact is always configured as Normal N O to control the line contactor for MV applications Network inputs can be obtained through proper programming of Option Input 1 and Option Input 2 The MV SMC Flex controller offers the control options described below Important The options listed in this section are mutually exclusive and must be specified when ordering An existing controller may be upgraded to another control option by replacing the control module and possibly other components Consult your nearest Rockwell Automation sales office Pump Control Option This option reduces surges during the starting and stopping of a centrifugal pump by smoothly accelerating and decelerating the motor The micro processor analyzes the motor variables and generates commands that control the motor and reduce the possibility of surges occurring in th
190. x independent channels which convert voltages up to 10800 V 7 2 kV 1 5 pu down to low voltage levels which can be used by the SMC Flex control logic Table 3 B shows the input voltage ranges for each of the input terminals on the voltage sensing module This module has been designed to operate at a nominal input voltage of up to 7200 V with a continuous 40 overvoltage The output voltages are scaled to provide close to 10 V peak for a 14096 input voltage at the high end of each of the voltage ranges Each of the channels has four taps to provide a range of input voltages and software will be used to scale the output to show the correct value on the SMC Flex front panel display See Parameter 106 MV Ratio Table 3 B Input Voltage Ranges Tap Voltage Range MV Ratio D 800 1449 V 1020 C 1450 2499 V 390 B 2500 4799 V 165 4800 7200 V 105 The MV ratios shown above are nominal values and may be fine tuned to achieve better accuracy on the display of the SMC Flex control module While running the motor in bypass mode compare the voltage displayed on the control module to a known accurate meter connected to the same source voltage as the motor the MV SMC Flex is controlling Parameter 106 MV Ratio may be changed up or down to match the Flex display to the external meter A small change in ratio can make a large change in the display so 5 units at a time is recommended Increasing the ratio will decr

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