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1560E-UM051 - Rockwell Automation

1. Phase 1 Line Connections Phase 1 Power Stack Assembly Voltage Sensing Module Phase 2 I Line Connections 7 pr Phase Ea n Power Stack Assembly P BEN Load Connections ILE top exit shown Phase 1 front through 3 back 12 b 2 ET E EJ Current Transformers 8 Phase 3 Power Stack Assembly Phase3 r Mes Line Connections Bypass Vacuum Contactor 60 Rockwell Automation Publication 1560E UM051G EN P March 2015 Power Wiring Interlocking Installation Chapter2 IMPORTANT For retrofit units Bul 1560E the CEC and NEC require that branch circuit protection of
2. ani M IV tec M i 3 WW 917221 AMB N MAIN CONTACTOR M N 4 11 6 M TO SMCLEXIB TB6 E r ENS E lt gt 4 u del ba 4 B IV 1 4 M EC 2 3 A BB N 2 ENS avy o E G gt BYPASS CONTACTOR B P 5 4 4 L c DA M IV B IV START BH Ha alo o o gt 4 CONTROL RELAY CR MODULE MODULE M IV R LS STATUS STATUS 5H 16 CONTACTOR STATUS OFF B V s MOX LOCAL REMOTE BYPASS CONTACTOR t 15H AUXILIARY RELAY BCX BCX CR CONTACIR BV 9 o FROM SMC CLOSE 3 5 16117 18 19 20 2 22 DENT ADAPTER SMC Flex CONTROL TERMINALS AUX Mm bel EXTERNAL BYPASS EE raul AUX 2 AUX3 AUXA 52 TODEVICENET PIC Tach NORMAL 80 0 NETWORK INPUT INPUT FAULT 11 11 port o MOD 4
3. Rockwell Automation Publication 1560E UM051G EN P March 2015 Troubleshooting Chapter 9 Figure 70 Typical 6900V Module Wiring 180 360 600 A GATE DRIVER BOARDS 61 2 GD1 al ov gt C o a RS1 0 1 RR1 053 THERMISTOR 51 52 G2 G1 07 y l a oC Q HS2 RS2 0 2 62 7 LINE 92 HS3 3 4 53 5 G3 q THERMISTOR G c y BE sy oC G G 0 3 RR 2454 0 4 G4 E 5 64 o H 5 o oC a 0V4 G5 C5 LOAD 5 G HS6 52294 G G gt C G 015 s 0 5 6 RR3 0 6 57 C6 dns LEGEND 56 G6 RR SHARING RESISTOR oy 06 7 RS SNUBBER RESISTOR C6 CS SNUBBER CAPACITOR 076 HS HEATSINKS G WHITE C CATHODE LEAD RED 155 Chapter9 Troubleshooting Notes 156 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 Safety and Preventative Periodic Inspection Chapter 10 Maintenance The Maintenance Technician should become familiar with the layout and be a
4. Gate Driver Boards Gate Driver Snubber Circuit and Sharing Resistor Frame Assembly Rockwell Automation Publication 1560E UM051G EN P March 2015 147 Chapter9 Troubleshooting Figure 65 Power Module Assembly one phase 5500 6900V 600A Heatsink Assembly Line connection Gate Driver Boards Gate Driver Snubber Circuit and Sharing Resistor Frame Assembly 148 Rockwell Automation Publication 1560E UM051G EN P March 2015 Troubleshooting Chapter 9 Snubber and Resistor Circuit If the resistance checks from the Thyristor testing section were abnormal and the Testin g thyristors checked out OK there may be a problem in the snubber or resistor circuits 1 Remove all power from the equipment 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 SHOCK HAZARD To avoid shock hazard ensure main power h
5. normal operation to SMC Flex control module Current underneath control module feedback test points y FL idi os I 18 q VoM El a _ LED Yellow ON Ribbon connector Phase A when Phase ps to Voltage Fibre Optic gate signal active h T P Sensing Board Transmitters send E oltage gatesignalsto al ER TPA Phase A T feedback NEB driver boards ICOM gate signal test points LOAD B n m ES Module common 5 Current loop E __ 8 Common for L Donat connetto power supply Gate Pulse TPs F VoM sensor input L this terminal NN p r TB6 4 Hi _ LED Yellow ON k Es M m when Phase B LED Green gate signal active ON when current 185 Phase Fg 5 loo 1 B p power FibreOptic LPS TP11 Phase B supply is present B Current Transmitters 3 gate signal transformer M B connections a Ls 4 LED Yellow ON a GATE when Phase C ws C Ec INS gate signal active 11 a TP13 Phase C Pm o gate signal ase Fibre Optic E gt m LED Green Transmitters LL TP15 Common for Green a Gate Pulse TPs ON when Fg power is 1 18 19 20 present zo Power supply test c
6. 12 _ Hef ro K aS l I ww x A B B N C rm B 551 BYPASS CONTACTOR 8 SN ux e 1 2 A 5 L1 e 4 START STO SIGNAL FROM EXISTING STARTER id BH Hu CONTROL RELAY CR MODULE STATUS BAV EN 15H 16 BYPASS CONTACTOR CONTACTOR AUXILIARY RELAY BCX STATUS T BAV 1 319 D CLOSE FROM SMC FlexIB J3 4 u z2 s m s s v s s e a z SMC Flex CONTROL TERMINALS AUX 1 EXTERNAL BYPASS AUX2 AUX3 AUXA nap AARM NORMAL PICINPUT INPUT E E 232 2 2 2 2 2 2 gt 3 2 3 SMCFlexIB INPUTPOWER LIN 46 Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 Figure 25 Typical Bulletin 1560E IntelliVAC Control Circuit With Stop Control BV 1 4 M 21 3 A BB N ml c NS x o Spo tu e es START STOP 7 SIGNAL FROM EXISTING STARTER BV BCX BH Hu Ae T V STATUS COAST STOP 5
7. TIP During an arc fault the plenum will be subjected to a brief high pressure shock wave The Extension Elbow assembly may experience dynamic loading It is important to account for dynamic loading when selecting supporting means and materials 198 Rockwell Automation Publication 1560E UM051G EN P March 2015 Appendix E ArcShield Chimney Installation Instructions The following instructions are provided to ensure the proper installation and function of chimney supplied with ArcShield enclosures Refer to Appendix C for additional information related to ArcShield chimney before attempting to follow these instructions Recommended Torque 1 4 20 Thread Fasteners 7 5 Nem 6 lbeft Values 5 16 18 Thread Fasteners 14 Nem 11 Ibeft Figure 101 Chimney Exhaust Label A DANGER A DANGER ARC FLASH HAZARD HAZARD D ARC LECTRIQUE PRESSURE RELIEF EXIT SORTIE DE L EVENT R GION TRE AREAS TO BE INACCESSIBLE AUX PERSONNEL INACCESSIBLE TO PERSONNEL PENDANT GUE D QUIPEMENT WHILE EQUIPMENT ENERGIZED EST SOUS TENSION FREE OF OBSTRUCTIONS D MUNI D OBSTRUCTIONS REFER TO USER MANUAL R F RER AU MANUEL SEVERE INJURY OR RISQUE DE BLESSURES DEATH MAY RESULT CORPORELLES GRAVES OU M ME LA MORT General Plenum Layout for e example Hi a general Er io is Figure E ArcShield
8. 115V BOSCH H4 ee MV r 1 4 Sh F gt X ow 0 AM B N Mov MAIN CONTACTOR M y y 4 6 TO SMCLEXIB TBG _ R 5 NP AUX cco 5 lt 2 gt 4 u fel 0 7 B IV n ABB N CN EE BYPASS CONTACTOR B 12 5 4 4 E G EA 4 B V anso START BH 1 ww e CONTROL RELAY CR MODULE MODULE CR STATUS STATUS 15 16 CONTACTOR STATUS COAST STOP B V s alo BYPASS CONTACTOR MOX 15H 16 AUXILIARY RELAY BCX CONTACTOR SINUS BOX CR B V E F 3 9 10_ 4 CLOSE FROM SMC 3 4 1 15 6 07 09 2 2 SMC Flex CONTROL TERMINALS AUX EXTERNAL BYPASS DPI AUX2 AUX3 AUXA nO GROUND jus ALARM NORMAL INPUT INPUT FAULT 11 E 2 251512 2 20 90 31 2 3 55 MAIN CONTACTOR 1 AUXILIARY RELAY MO FROM GFCT MN OPTIONAL 9 155 3 CLOSE SMC FlexlB INPUT POWER L2 N Rockwell Automation Publication 1560E UM051G EN P March 2015 43 Chapter1 Product Overview Figure 22 Typical Bulletin 1562E IntelliVAC Control Circuit without Stop control With DeviceNet or DPI Communication and Optional Local Off Remote
9. Rockwell Automation Publication 1560E UM051G EN P March 2015 36 Product Overview Chapter 1 Functional Description The following functional descriptions and associated control circuits are for units using IntelliVAC contactor control modules For units with electromechanical relay control refer to Appendix B 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 ATTENTION The control circuit schematics shown below assume that control Bulletin 1562E Basic Control Controlled Start only When wired as shown in Figure 20 the controller operates as follows Pressing the Start button initiates the start sequence Relay CR closes and applies control power to terminal 17 ofthe SMC Flex module The Aux 4 Normal closes energizing M IV and MCX 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 Ext Bypass aux
10. 93 Stop TAA tes 93 Preset Slow Speed 94 Lut as avo Suwa 94 Motor 96 h asan t uM 97 Wadervoltates ats as apt 97 Overvoltage 1 Imt Reese f UND 97 E E 97 Sa Sony ahs Lapsana 97 Motor Information 98 Motor Data ss sun E aeo UR EAT ROC 98 Chapter 5 oodd BERS Ss m evene HER oie etus 99 Viewing Metering Data ia d sa qo ECHO EURO S ERE S 99 Rockwell Automation Publication 1560E UM051G EN P March 2015 7 Table of Contents Options Diagnostics Communication Troubleshooting Chapter 6 OVERVIEW iii id ooh acd Mewes Ra nade Seda PH e Human Interface Module Programming Parameters 55562594 0310 asd Control WINE oireita bns ri pep eee e ber Tae e Roos dne e En Chapter 7 OVekVIeW sv een en a Sa Geb Sees e dsl he ER UE HE RAE Protection Fault SEED C leap en A o ul P stare uit l
11. TIP Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place STEP 2 Align ment of Side Plenums mounted side by side must fastened together through the aligning by Si de Plenums holes using 5 16 inch supplied hardware see Figure 91 Figure 91 Aligning Side by Side Plenums IMPORTANT unused holes must be filled with thread forming screws i e Lifting Lug holes All Gaps must be sealed and filled with silicone 194 Rockwell Automation Publication 1560E UM051G EN P March 2015 STEP 3 Sequence of Final Assembly End Cover Plate STEP 4 Closing the Front of the Plenum Sections Figure 93 Top Plate ArcShield Plenum Installation Instructions Appendix D All Plenums in a Line up must be mounted to the top of each enclosure and to the Plenum directly beside it before the front duct sections are re attached see Figure 87 Figure 92 Sequence of Final Assembly The End Cover Plate must be mounted on the closed end of the Line up at this time during the assembly using 5 16 inch hardware see Figure 92 Left side After the first stage of the Plenum assemblies have been mounted the Plenums can then be closed up by replacing the front duct sections as shown in Figure 93 to Figure 95 Figure 94 Bottom Plate Figure 95 Front Closing Plate IMPORTANT re
12. D A n5 3 ISH i WOLSIWH3H L FEE LAO 9 avol e D 5 Sd O N Jo m 7 O D A0 jo 5 10 5 IS 4 1 WOLSIWEGHL sq8vog AIO 31 9 153 Rockwell Automation Publication 1560E UM051G EN P March 2015 Troubleshooting Chapter 9 Figure 69 Typical 3300 4160V Module Wiring 180 360 600 A 034 0V31300H V 7 GLHM qva13lv9 9 SANISLVJH SH 80127472 9399105 52 80151538 8388 5 SY 80151534 DNIHVHS 013931 SSH p Y y D YAO ENO 9 Y 5 o ESH o D A 710 YOLSIWYHL 70 z t a D D A i5 o SH qu CSH 6 15 154 n Twp n 9 S ENO w 3 5 070 Ol D lap 3 0 5 170 D D 19 BAN YOLSTNUSHL 504 08 IVO Rockwell Automation Publication 1560E UM051G EN P March 2015 154
13. 115V QT TO SMCLEXIB 6 7 Mov W 1 i 8 ork BC BE BE D RECTIFIER 1 lt n gt BYPASS CONTACTOR B RECMOVIZ i 1 ABB CS CN SIGNAL FROM BC EXISTING STARTER P z MASTER CONTROL CR COAST OFF cr STOP LOCAL REMOTE 55 Ni BYPASS CONTROL BC E en FROM SMC FlexIB J3 4 1 22 Bl 4 5 26 7 38 39 2 2 22 DEVICENET SMC Flex ADAPTER CONTROL TERMINALS AUX 1 EXTERNAL BYPASS pe bal AUX2 8210 TODEVICENET MO ALARM NORMAL 88 71 NETWORK INPUT FT 1H I 23 24 25 26 7 2B 29 391 2 B HA NOTE LINECONTACTOR OR BREAKER MUST REMAIN CLOSED DURING THE OPTION STOP PERIOD IT IS RECOMMENDED THAT THE LINE CONTACTOR BE CONTROLLED BY THE AUX 4 NORMAL CONTACT SMC FlexlB INPUT POWER 1 CCand HC and their wiring into the control circuit part of the Rockwell Automation relay control panel 1503E CXXX This control panel ensures reliable operation of the contactor within its published specification Rockwell Automation Publication 1560E UM051G EN P March 2015 181 AppendixB 1560 1562E Relay Control Notes 182 Rockwell Automation Publication 1560E UM051G EN P March 2015 Overview Appendix C Ar
14. BYPASS CONTACTOR B MASTER CONTROL CR ZELLE i FROM SMC FlexIB J3 4 BYPASS CONTROL BC NY FROM GFCT OPTIONAL ADAPTER AUX 1 EXTERNAL BYPASS AUX2 g GROUND PUT ALARM NORMAL 5511 INPUT INPUT FAUT pH 23 24 34 NtA TO DEVICENET NETWORK MAIN CONTROL MC SMC DIN 1 specification NOTE EXTRA CONTACTS FROM STOP BUTTONS SHOULD BE MONITORED BY THE CONTROLLING PLC FOR REMOTE OPERATION TO ENSURE UNIT WILL STOP WHEN COMMANDED Rockwell Automation Publication 1560E UM051G EN P March 2015 CCand HCand their wiring into the control circuit are part of the Rockwell Automation relay control panel 1503E CXXX This control panel ensures reliable operation of the contactor within its published 177 AppendixB 1560 1562E Relay Control Figure 75 400 Amp Bulletin 1560E Relay Control Circuit Without Stop Control 115V TO SMCLEX MV 186 E BC BE LU 0 o LA HH PM EH HHI BYPASS CONTACTOR 8 REC MOVI2 lt BE START STOP Gu M SIGNAL FROM EXISTING STARTER BC E T NL MASTER CONTROL CR
15. 21 2 2 2 3 5 4 2 3 mao MAIN CONTACTOR 5 PILOT RELAY MCX S 224 PROM GECT i i OPTIONAL 9 o SMC FlexIB CLOSE INPUT POWER L1 L2 N 44 Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 Figure 23 Typical Bulletin 1562E IntelliVAC Control Circuit with Stop control With DeviceNet or DPI Communication and Optional Local Off Remote 115V TRA IR AA 1 4 M 2 TCO 3 MOV o A N C MAIN CONTACTOR TO SMCLEXIB TB6 Tes LG gt 12 5 d u e L B IV 1 4 M 2 3 A BB N 2 Noon s lt lt gt 1 M BYPASS CONTACTOR B n ES M IV BAV OPTION STOP START BH oto a
16. 5223 E28 115 230V 3 El E amp 5 8 5 5 5 5 5 5 2 p lt 5 2 PO 2 7t 7 5 s 55 ss g 2 89849 Bo Bos 8 8 So 9 s 5 Sc 9 9 8 8 8 8 8 8 8 8 8 E se 5 amp Zo of of of 5 4 9 x Li 5 aj s NS alo xz N 2 2 8 8 2 8 s 2 5 5 5 1 uX 115 230V AC 50 60Hz pd 03 VOLTAGE SENSING BOARD o4 not x o5 GND2 o6 74 Rockwell Automation Publication 1560E UM051G EN P March 2015 SW2 When ON up provides test pulses to gate driver circuits NOTE Must be OFF down for Figure 37 Connection and Test Information for Interface Board LED Red ON when test pulses on SMC Flex control module Commissioning Procedure Ribbon connectors to connect Chapter 3
17. All auxiliary contacts can be programmed as NO or NC for the following states except External Bypass which can only be programmed as NO Normal Normal NC The contact state changes when the unit receives a Start Stop signal Up to Speed Up to Speed NC The contact state changes when the motor approaches rated speed Alarm Alarm NC The contact state changes when an Alarm condition is detected Fault Fault NC The contact state changes when a Fault condition is detected Network Control Network Control NC The contact state is controlled over the network Refer to Table 16 on page 121 which describes logic command word to control auxiliary outputs External Bypass This contact controls the Bypass contactor for MV applications TIP Thetag name without a suffix indicates a NO state e g Normal On the other hand a tag name followed by NC indicates a normally closed state e g Normal NC Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 Figure 16 Control Terminals GTSTSTSTSTSESTSTS TS Te T Opt Opt Stop Input Input Start Input Input Aux 1 External SMC Flex Controller Terminals Bypass TACH Ground Input Input Fault Aux2 Aux3 Aux4 Fault Alarm Normal Contact Contact Note The Aux 1 contact is always programmed for External Bypass NO to control the bypass contactor in MV applications The Aux 2 contact
18. Input 12 Control Power 24 Input 13 Control Enable Input 25 Tach Input 14 Control Module Ground 26 Tach Input 15 Option Input 90 27 Ground Fault Transformer Input 16 Option Input 1000 28 Ground Fault Transformer Input 1 Start 29 Aux Contact 2 18 Stop Input 30 Aux Contact 2 19 Aux Contact 1 Ext Bypass 99 31 Aux Contact 437 20 Aux Contact 1 Ext Bypass 99 32 Aux Contact 437 21 Not Used 33 Aux Contact 4 Normal 9 22 Not Used 34 Aux Contact 4 Normal 9 1 RCsnubbers are required on inductive loads connected to auxiliary 2 Do not connect any additional loads to these terminals These result in false starting and stopping parasitic loads may cause problems with operation which may 3 Aux Contact 1 is always programmed for Ext Bypass NO to control the bypass contactor in MV applications 4 Aux Contact 4 is always programmed for Normal NO to control the isolation contactor in MV applications Note The OFF state leakage current for a solid state device connected to an SMC Flex input must be less than 6 mA 68 Rockwell Automation Publication 1560E UM051G EN P March 2015 Chapter 3 Commissioning Procedure Prelimin ary Setup 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
19. 57 81 AE R35 AE R36 TVS6 L1 L2 n Rockwell Automation Publication 1560E UM051G EN P March 2015 T Troubleshooting Chapter 9 Measure across R25 R27 R29 R31 R33 and R35 located at the bottom of each leg of the module The resistance should be 11 3 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 Table 28 on page 203 in Appendix F and refer to procedure on page 132 boards Failure to do so may result in injury death or damage to ATTENTION Grounds must be reconnected the voltage sensing equipment TIP 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 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 are securely connected to the ground bar in the low voltage panel or ground bus Failure to do so may resul
20. CONTROL RELAY CR CR STATUS STATUS 1 sH CONTACTOR STATUS OFF i COAST STOP LOCAL REMOTE ES BH His 4 BYPASS CONTACTOR AUXILIARY RELAY BCX o o o o STATUS X o o MOX o X BCX CR T 1 B V 9 10 _ FROM SMC CLOSE 3 1 12 13 14 15 16 17 18 19 20 21 22 DEVICENET SMC Flex ACAPTE CONTROL TERMINALS AUX 1 EXTERNAL BYPASS r ze W EE DT DX uw OH FRU ALARM NORMAL 8 _ PICINPUT INPUT FAULT 1 i PORT Hay BLK MAIN CONTACTOR 23 24 25 26 27 28 29 30 3l 32 33 3A PILOT RELAY MCX ES NE FROM GFCT OPTIONAL M IV 9 1o SMC FlexlB CLOSE INPUT POWER 1 L2 N NOTE EXTRA CONTACTS FROM STOP BUTTONS SHOULD BE MONITORED BY THE CONTROLLING PLC FOR REMOTE OPERATION TO ENSURE UNIT WILL STOP WHEN COMMANDED Rockwell Automation Publication 1560E UM051G EN P March 2015 45 Chapter1 Product Overview Figure 24 Typical Bulletin 1560E IntelliVAC Control Circuit Without Stop Control 115V BS M dr 7 xi 0 6V X2 TO SMCLEXIB TB6 D B IV
21. s points LED Green ON when signal present I ANS at temperature feedback fibre optic detect temperature DEFEAT awa p feedback channels TempA Temperature ty Feedback Temps C Fibre Optic Receivers C mod UL LNG LN Serial __ Replacement Control Power Power out to Number Part Number 110 240V AC SMC Flex Notes 1 is the common connection for Gate and Pulse test points 2 VCOM is the common connection for Current and Voltage feedback test points Do not connect J2 VCOM to earth ground do not connect ICOM and VCOM together either directly or through test probes meter or scope common Rockwell Automation Publication 1560E UM051G EN P March 2015 75 Chapter3 Commissioning Procedure Power Supply Tests 76 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 ATTENTION Servicing energized industrial control equipment can be Isolate incoming power Open the door s providing acc
22. 2 H an aan an nn xi 0 6V X2 9 TO SMCLEXIB TBG 42 i B V 1 4 M mu mind mim a 24K 10 r3 TEES SII LUC B A BB N L C BYPASS CONTACTOR B NSO B gt AUX 0 2 12 5 L1 G L2 N m START STOP T SIGNAL FROM BOX EXISTING STARTER P BH 4 CONTROL RELAY CR N 2 157 STATUS OFF BV S LOCAL REMOTE BYPASS CONTACTOR nl 5H Fre AUXILIARY RELAY BCX STATUS i 98 1 BV 9 19 O CLOSE FROM SMC FlexIB J3 4 1 1 15 16 17 18 19 20 2 22 DEVICENET ADAPTER SMC Flex CONTROL TERMINALS AUX 1 A D EXTERNAL BYPASS E iw AUX 2 AUX3 AUXA ES TODEVICENET PIC TACH GROUND FAULT ALARM NORMAL dem NETWORK INPUT INPUT FAULT f PORT O MOD O 24V 3 a2 2 3 z 33 39 a 2 3 34 SMCFlexlB INPUT POWER ul L2 N 48 Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 Figure 27 Typical Bulletin 1560E IntelliVAC Control Circuit with Stop Control With DeviceNet or DPI Communication and optional Local Off Remote
23. When the motor approaches rated speed the SMC Flex module closes Aux 1 energizing BC which closes the bypass contactor When a Stop is executed the unit opens Aux 1 which drops the BC relay and opens the bypass contactor The unit initiates a controlled stop sequence followed by opening of Aux 4 which opens the main contactor An uncontrolled or coast stop can be achieved via DPI or by opening the connection on terminal 18 i e by pressing Coast Stop button When using the optional HIM pressing the Jog button will initiate the optional stop maneuver and pressing the O button will initiate a coast stop To run in Local mode the CR contact is used to initiate a start and stop sequence similar to Figure 72 An uncontrolled or coast stop is achieved by opening the connection on 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 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 to protect the power electronics from any voltage transients due to opening the motor circuits A trip due to an overload or fault condition will result in a Coast stop Bulletin 1560E Basic Control Controlled Start only The Bulletin 1
24. 10096 Motor Speed lt Start gt lt lt Run gt gt lt Stop Time seconds Linear deceleration does not need to be used even if linear acceleration is used The stop time can be programmed for 0 120 seconds Linear deceleration cannot brake the motor load and reduce the stop time IMPORTANT Consult factory if settings over 30 seconds are required The base rating ofthe 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 Stop Such usage may result in severe injury or death Refer to the applicable Linear Deceleration is not intended to be used as an emergency standards for emergency stop requirements Rockwell Automation Publication 1560E UM051G EN P March 2015 19 Chapter1 Product Overview 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 0 120 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 Figure 8 Soft Stop Option Percent Voltage 10096 Coast to rest Soft Stop Initial Torque lt Start gt lt Run gt lt lt Soft Stop Time seconds TIP
25. Down key Continue the process until all desired settings are entered The SMC Option advises the user if any control modified by the user F Ramp Time P 18 Secs ion i e Pump Control is resident This parameter is factory set and cannot be The display will indicate that the second line is now active by highlighting the first character If the LCD display does not provide a highlighted cursor then the controller is in the Display mode 90 Rockwell Automation Publication 1560E UM051G EN P March 2015 Programming Chapter 4 Soft Start Current Limit 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 Soft Start Ramp Time 0 3052 Programs the time period that the controller will ramp the output voltage up to full voltage from the initial Torque level programmed Initial Torque The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter 0 90 locked rotor torque Kickstart Time 0 0 2 05 A boost of current is provided to the motor for the programmed time period Kickstart Level 0 90 locked rotor torque Adjusts the amount of current applied to the motor during the kickstart time 1 Ifthe controller senses that the motor has reached full speed before completing t
26. Overload protection is enabled in the Motor Protection group by programming the e 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 Coms Loss 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 group If a Bulletin 20 HIM Human interface module or Bulletin 1203 communication module is disconnected from the SMC Flex controller when control is enabled a Comm Fault will occur Network Network faults are faults generated on the network external to the SMC Flex and are annunciated on the LCD display 1 Phase loss overvoltage and undervoltage protection are disabled during braking operation 2 Jam detection and underload pro ection are disabled during slow speed and braking operation Additional details regarding fault definitions can be found in Chapter 1 Product Overview Rockwell Automation Publication 1560E UM051G EN P March 2015 Diagnostics Chapter 7
27. To Remove SCR 4 Remove shorting bar hardware Pry Heatsinks 4 and 5 apart Extract SCR To Insert New SCR Apply thin film of electrical joint compound to surfaces of SCR Install SCR so that it is 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 SCRs matched pair SCR 2 Note You must replace both SCRs of a matched set SCR 4 Shoring Bar Hardware Shoring Bar Hardware Heatsink 5 Rockwell Automation Publication 1560E UM051G EN P March 2015 143 Chapter9 Troubleshooting Figure 57 Power Module Assembly one phase 5500 6900V 180 360A S3 52 Line connection Gate Driver Boards S3 2 0 Load connecti oad connection Board Mounting Frame 144 Rockwell Automation Publicatio
28. requirements that pertain to their respective job assignments A A TIP TIP IMPORTANT ATTENTION 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 qualified personnel using appropriate local safety work practices and precautionary measures ATTENTION 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 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 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 representativ
29. Rockwell Automation Publication 1560E UM051G EN P March 2015 Installation Chapter2 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 Fiber Optic Cables The small gray fiber optic cables are fragile and must be protected during installation from sharp bends and impact 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 34 for two different acceptable connection methods TIP 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 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
30. 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 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 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 A continuous bare copper ground bus Power electronics A bypass vacuum contactor Three current transformers A low voltage control panel complete with microprocessor based control module Top and bottom plates to accommodate power cables TIP Refer to Interlocking on page 61 of Chapter 2 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 current limiting power fuses for NEMA Class E2 operation Three cu
31. Fastened at the opening of the last Fastened at the opening of the last Connected at the exhaust end of the component on the exhaust end Plenum in the line up opposite the Plenum or Extension exhaust end to seal Plenum end General Plenum Layout for An example of a general Plenum assembly configuration is shown in Figure 86 Plenums of varying widths are mounted directly over the MV enclosures of the ArcShield Line up corresponding width A 0 9 m 36 in Exhaust extension assembly is shown mounted on the extreme right side Plenum of the equipment Line up can alternatively exhaust to the left Engineered systems can be made site specific Rockwell Automation Publication 1560E UM051G EN P March 2015 191 AppendixD ArcShield Plenum Installation Instructions Sealed end 36 Exhaust extension Exhaust end Plenum exhaust can be on the left or right hand end of the line up Pictures and figures in this procedure are shown for a right hand exhaust exit direction Also shown is an optional vertical top direction exhaust extension see Figure 100 IMPORTANT Plenum components not directly mounted to the tops of the MV enclosures must have additional mounting support This includes the Extension components and 90 Elbow Sections refer to STEP 7 Additional Mounting Support on page 198 STEP 1 Mounting a Single Before mounting a sing
32. If the indicator washer becomes too loose no friction back the center nut off slowly until the washer is loose with some friction Replace the shorting bar Torque hardware to 30 Nem 20 lbeft For 3 8 in hardware in the T slots of aluminum heatsinks the recommended torque is 22 Nem 16 Do not overtorque these connections as the slots will be damaged and the connection will be compromised C Install Refurbished Stack Inspect all connections on the module Inspect wire insulation and components for damage Install the module in the cabinet Watch for power cables and fiber 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 Nem 20 Ibeft Install gate driver board ensuring that the locking tabs on the 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 fiber optic cables Replace current loop cable see Figure 49 Tighten the terminals at the current loop power supply to 5 6 Nem 50 Make sure all connections are secure Perform resistance checks according to instructions on Thyristor SCR Testing page 135 and test gate drive circuits by performing power supply tests in Chapter 3 page 76 Rockwell Automation Publication 1560E UM051G EN P March 2015 Troubleshooting Chapter 9 Fig
33. 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 che Basic Setup parameter set plus the advanced set Parameter SMCOption Displays the type of controller This is factory set and not adjustable Option Standard Motor Connection Displays the location of the SMC in relation to the motor windings Line or Delta Line Voltage Displays the system line voltage the unit is connected to MV Ratio Scales the output from the Voltage Sensing Board to display correct line voltage 1 10000 Refer to Table 4 in Chapter 3 Starting Mode Allows the user to program the SMC Flex controller for the type of starting that best fits the application Soft Start Current Limit Full Voltage Linear Speed Ramp Time This sets the time period during which the controller will ramp the output voltage 0 305 Initial Torque The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter 0 90 locked rotor torque Current Limit Level The current limit level that is applied for the Ramp time selected 50 600 FLC 1 Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter 2 Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Le
34. Pressthe Enter key to access the Preferences menu Preferences Change Password User Dspy lines 4 Scroll with the Up Down keys until the Change Password option is highlighted Preferences Change Password User Dspy lines 5 Press the Enter key 6 Press the Up Down keys to enter the desired Prefs Password number If you are modifying the password make a New Code 83 note of it as displayed Verify 83 7 Verification of the new password is required Press the Enter key eu 8 Press the Enter key after you have completed Preferences modifying the password 1 Change Password User Dspy lines 1 programming system To complete the programming process re enter the Main Menu mode to log out This will eliminate unauthorized process to TIP 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 87 Chapter4 Programming Parameter Management 88 Before you begin programming it is important to understand how the controller memory is e structured within the SMC Flex controller used on power up and during normal operation Refer to Figure 44 and explanations below Figure 44 Memory Block Diagram EEPROM RAM 4 ROM
35. clamp bars They must remain as they are to maintain squareness See Figure 52 Figure 55 and Figure 61 2 Loosen the clamp by rotating the center nut below the indicator washer at the top end of the clamp Refer to Figure 52 Figure 55 and Figure 61 As the center 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 3 The heatsinks may now be spread apart to allow removal of the SCRs 4 Applyathin film of Electrical Joint Compound supplied to both faces of the new SCRs S Placethe 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 Figure 53 Figure 56 and Figure 62 6 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 7 Advance the center 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 137 Chapter 9 138 Troubleshooting 8 Tighten the center 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
36. terminal 18 ofthe SMC Flex module is energized allowing start and stop maneuvers to be executed via DPI When a Start is executed the Aux 4 contact closes which 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 When a Stop is executed the unit opens Aux 1 The bypass contactor opens and the unit initiates a controlled stop sequence followed by opening of Aux 4 which opens the main contactor or breaker in the existing starter When using the optional HIM pressing the Jog button will initiate the optional stop maneuver and pressing the O button will initiate a coast stop An uncontrolled or coast stop can be achieved via DPI or by opening the connection on terminal 18 i e by energizing Coast Stop relay in the existing starter To run in Local mode the CR contact is used to initiate a start and stop sequence similar to Figure 25 Closure of the Start relay from the existing starter allows the unit to initiate motor soft starting Likewise opening of Start relay from the existing starter will initiate a controlled stop An uncontrolled or coast stop is achieved by opening the connection on terminal 17 i e by energizing Coast Stop relay in the existing starter This contact shoul
37. 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 disposed of according to local regulations and must not be disposed of with general landfill refuse Chromate Plating Sheet steel and fasteners may be plated with zinc and sealed with a chromate based dip gold or silver colored 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 161 Chapter10 Maintenance 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
38. 173 Rockwell Automation Publication 1560E UM051G EN P March 2015 9 Table of Contents ArcShield Unit Information ArcShield Plenum Installation Instructions ArcShield Chimney Installation Instructions Spare Parts Accessories Index Appendix C AreShield Designs ayasa Exhaust Systems Chimney or Plenum Plenum Information Plenum Exhaust Considerations Additional Notes staged Ueda he et Sx CC ae Chimney Information crocs cae Chimney Exhaust Considerations Appendix D Recommended Torque Values Plenum Brading zu ni tes et p oun ts pasaba ad Molo General Plenum Layout for ArcShield STEP 1 Mounting a Single Plenum Cabinet Preparation ber Plenum Placement on STEP 2 Alignment of Side by Side Plenums STEP 5 Sequence of Final Assembly STEP 4 Closing the Front of the Plenum Sections STEP 5 Extension and Elbow STEP 6 Mounting Extension Elbow to Plenum Line up STEP 7 Additional Mountin
39. 24 Random Access Memory RAM This is the work area of the controller after it is powered up When you modify parameters in the Setup mode the new values are stored in RAM When power is applied to the controller 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 Programming Chapter4 Electrically Erasable Programmable Read Only Memory EEPROM The SMC Flex controller provides a nonvolatile area for storing user modified parameter values in the EEPROM Using Parameter Management with DPI HIM TIP The 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 Display Memory Storage Reset to Defaults Recalling Defaults After parameter values have been modified factory default settings can still be re initialized Rockwell Automation Publication 1560E UM051G EN P March 2015 89 Chapter4 Programming Parameter Modification All parameters are modified using the same method The basic
40. 4 b 55 BYPASS CONTROL BC R 4 1 FROM 5 T 3 Ze ON p 11 2 13 14 15 16 17 18 19 20 21 2 SMC Flex CONTROL TERMINALS AUX 1 EXTERNAL BYPASS DPI AUX2 AUX3 AUXA pO ALARM NORMAL INPUT INPUT FAULT L I 2 24 5 6 2 8 9 WD 1 2 2 3 A SMC FlexIB u LIN 1 CCand HC and their wiring into the control circuit are part of the Rockwell Automation relay control panel 1503E CXXX This control panel ensures reliable operation of the contactor within its published specification 178 Rockwell Automation Publication 1560E UM051G EN P March 2015 1560E and 1562E Relay Control Appendix B Figure 76 400 Amp Bulletin 1560E Relay Control Circuit With Stop Control 115V TO SMCLEX Mov 4 TB6 M BW no 2 1 BC BC BE BE BE BE C D JU ES EC LC ELM I i OA OB C RECTIFIER 1 1 re rt lt KEKR gt BYPASS CONTACTOR 8 REC MOV 2 PN i CO START STOP SIGNAL FROM EXISTING STARTER BC MASTER CONTROL CR COAST STOP 55 4 BYPASS CONTROL BC FROM SMC FexIB J3 4 e c 11 12 13 14 15 16 17 18 19 20 21 22 SMC Flex CONTROL TERMINALS AUX 1 EXT
41. 8 7 6 5 4 3 2 1 0 X Stop 1 Stop Inhibit 0 No Action X Start 1 Start 0 No Action X Option 1 Input 1 Stop Maneuver Inhibit Option Stop 0 No Action X Clear Faults 1 Clear Faults 0 No Action X Option 2 Input 1 Perform Option 2 function 0 No Action Bits 5 10 Not Used X Aux Enable 1 Use Aux 1 Aux4 0 Ignore Aux 1 Aux 4 X Aux 1 1 Aux 1 Active 0 Aux 1 Inactive X Aux2 1 Aux 2 Active 0 Aux 2 Inactive X Aux3 1 Aux 3 Active 0 Aux 3 Inactive X Aux4 1 Aux 4 Active 0 Aux 4 Inactive Reference Feedback The SMC Flex does not offer the analog Reference feature The analog Feedback Parameter Information Scale Factors for PLC Communication feature is supported and will provide Parameter 1 Current in Phase A automatically as the feedback word A complete listing of the SMC Flex parameters is located in Appendix A The parameter values stored and produced by the SMC Flex through 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 is 0 85 Rockwell Automation Publication 1560E UM051G EN P March 2015 121 Chapter8 Communication Display Text Unit Equ
42. C 51 Underload F Lvl 96 Data Out A1 7 Watt Meter 52 Underload F Dly 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 Meter Reset 55 Undervolt F Lvl 100 Data Out C1 11 Power Factor 56 Undervolt F Dly 101 Data Out C2 12 Mtr Therm Usage 57 Undervolt A Lvl 102 Data Out D1 13 Motor Speed 58 Undervolt A Dly 103 Data Out D1 14 SMC Option 59 Overvolt F Lvl 104 Motor ID 15 Motor Connection 60 Overvolt F Dly 105 CT Ratio 16 Line Voltage 61 Overvolt A Lvl 106 MV Ratio 17 Starting Mode 62 Overvolt A Dly 107 Aux Config 18 Ramp Time 63 Unbalance F Lvl 108 Aux3 Config 19 Initial 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 Timed Start 23 Kickstart Level 68 Jam F Dly 113 Shutoff Level 24 Option 2 Input 69 Jam A Lvl 114 UTS Level 25 Starting Mode 2 70 Jam A 115 Parameter Mgmt 26 Ramp Time 2 7 Stall Delay 116 Backspin Timer 27 Initial Torque 2 72 Gnd Fit Enable 117 V Shutoff Level 28 Cur Limit Level 2 73 Gnd Fit Level 118 OL Reset Level 29 Reserved 74 Gnd Fit Delay 119 Ambient Temp 30 Kickstart Time 2 75 Gnd Flt Inh Time 120 Notch Position 31 Kickstart Level 2 76 Gnd Flt A Enable 121 Notch Maximum 32 Stop Mode 77 Gnd Flt A Lvl 122 Start Delay 33 Stop Time 78 Gnd Fit A Dly 123 Bypass Delay 34 Pump Pedestal 79 PTC Enable 12
43. 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 thermal capacity calculations usage may result in severe injury or death Refer to the applicable standards for ATTENTION Soft Stop is not intended to be used as an emergency stop Such emergency stop requirements 20 Rockwell Automation Publication 1560E UM051G EN P March 2015 Protection and Diagnostics Product Overview Chapter 1 The MV SMC Flex controller is capable of providing the following protective and diagnostic features Overload The MV 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 Refer to Chapter 4 Programming An Overload Fault will occur when this value reaches 10096 The parameters below provide application flexibility and easy setup Parameter Overload Class Range Disable 10 15 20 30 Overload Reset Manual Auto Motor FLC 10 2200 amps Service Factor 0 01 1 99 IMPORTANT During slow speed operations current waveforms exhibit non sinusoidal characteristics These non sinusoidal characterist
44. Dual Ramp Start Starting Mode 17 Programming 92 EMC Compliance 66 Enclosure 66 Wiring 66 Excessive Starts Hour 28 Exhaust Systems Options 184 Rockwell Automation Publication 1560E UM051G EN P March 2015 209 Fan Installation 62 Fans Maintenance 160 Fault Buffer 108 Codes 109 Fault Codes 109 Fault Definitions 110 Fault Display Diagnostics 107 Fault Indication 109 Faults Codes 109 Definitions 110 Indication 109 Faults Clearing 108 Fiber Optic Cables Installation 63 Firmware Updating 123 Full Voltage Start Starting Mode 18 Programming 93 Functional Description 37 G General Precautions 52 Ground Bus Bar Installation 62 Ground Faults 24 Hardware Description 33 Current Loop Gate Driver CLGD Board 34 Interface Board 34 Power Module 33 Hazardous Materials 161 HIM Human Interface Module Communication 114 Connecting to Controller 116 Options 101 HIM Control Enable 116 Hi Pot and Megger Test 73 Human Interface Module Communication 114 Connecting to Controller 116 Options 101 1 0 29 Default Configuration 119 Variable Configuration 119 Inspection 51 Installation 51 62 Control Cables 63 Control Wiring 62 Fan 62 Fiber Optic Cables 63 Ground Bus Bar 62 Physical Location 62 Power Factor Correction Capacitors 63 Power Wiring 62 Site Selection 52 Grounding Practices 53 Mounting 53 Interlocking 61 Interlocks Maintenance 160 J Jam Detection 24 Jams Example Settings 97 K
45. Fault Description Ground Fault Ground faults are based on feedback from the user supplied 825 CT detecting ground fault currents Ground 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 111 Chapter7 Diagnostics Notes 112 Rockwell Automation Publication 1560E UM051G EN P March 2015 Overview Communication Ports Chapter 8 Communication The SMC Flex provides advanced communications capabilities that allow it to be started and stopped from multiple sources as well as provide 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 Hex Standard DPI co
46. Figure 10 Restart Trip Curves after Auto Reset 100000 1000 ru 100 1 J 5 9 g Class 10 lass15 b s Rawa Class 20 le Class 30 4 Auto Reset Times 1 4 Class 10 905 Class 15 1355 Class 20 1805 Class 30 2705 0 100 100 Percent Full Load Current Setting 4 Underload Utilizing the underload protection of the MV SMC Flex controller motor operation can be halted if a sudden drop in current is sensed The MV SMC Flex controller provides an adjustable underload trip setting from 0 99 of the programmed motor full load current rating Trip delay time can be adjusted from 0 99 seconds 4 Underload protection is disabled during slow speed and braking operations 22 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 Product Overview Chapter 1 Undervoltage 5 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 99 of the programmed motor voltage Trip delay time can be adjusted from 0 99 seconds TIP For medium voltage applications undervoltage protection should be set from 80 99 An alarm pre fault indicat
47. Keypad Communication 114 Overview 83 Programming 83 L Line Faults 27 Linear Speed Acceleration Starting Mode 19 Programming 93 Linear Speed Deceleration Stopping Mode 19 M Maintenance 157 After Overload Fault 159 Barriers 160 Coils 158 Contamination 157 Control Components 160 Environmental Considerations 161 Fans 160 Final Check Out 159 Hazardous Materials 161 Interlocks 160 Keeping Records 160 Periodic Inspection 157 Power Components 160 Preventative 157 Safety 157 Solid State Devices 159 Static Sensitive Items 159 Terminals 158 Vacuum Bottles 158 Metering 28 Overview 99 Viewing Data 99 Rockwell Automation Publication 1560E UM051G EN P March 2015 Motor Information Programming 98 Motor Overload Protection 65 Multi motor Protection 65 Two speed Motors 65 Motor Protection Programming 96 Multi motor Protection 65 0 Open Gates 27 Options Control Wiring 105 Exhaust Systems 184 HIM Human Interface Module 101 Overview 101 Overloads 21 Overtemperatures 28 Overview Hardware 33 Current Loop Gate Driver CLGD Board 34 Interface Board 34 Power Module 33 Overviews 1503E OEM Controller 14 1560E Retrofit Controller 14 1562E Combination Controller 14 ArcShield Unit 183 Commissioning 69 Communication 29 113 Control Options 32 Braking 33 Pump 32 Diagnostics 107 Functions 37 General Precautions 52 1 0 29 Inspection 51 Installation 51 Site Selection 52 Keypad 83 Metering 28 99 O
48. 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 then be sent to local recycling facilities In addition all disposal precautions mentioned above must also be taken for those particular materials 162 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 Table 25 Parameter List Parameter Information Appendix A Group Parameter Description Parameter Units Min Max Default User Number Settings Settings Metering Volts Phase A B 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 A Watt Meter 7 KW MW Kilowatt Hours 8 KWH MWH Elapsed Time 9 Hours Meter Reset 10 NO NO ETM Reset KWH Reset Power Factor 11 0 00 0 99 Mtr Therm Usage 12 96 0 100 Motor Speed 13 96 0 100 BasicSet Up SMC Option 14 Standard Brake Pump Control Motor Connection 15 Line Delta Line w Line Voltage 16 V 0 10000 480 Starting Mode 1 Full Voltage Soft Start Current Limit Soft Start Linear Speed Pump Start Ramp Time 18 SEC 0 30 10 Initial Torque 19 96 LRT 0 90 70 Cur Limit Level 20 96 FLC 50 600 350 Kickstart Time 22 SEC 0 0 2 0 0 0 Kickstart Level 23 96 LRT 0 90 0 Option 2 Input 24 Di
49. aqna cette edd 22 Undervoltageu aa as oae 23 Overvoltage gt anes UU A ador P NN 23 IU nbalances aza ceo a Spree i Ha ssl a SE rS ebd 23 Stall Protection and Jam Detection 24 Groutid Pallio rec yayay d du ile Solet int b dial 24 Thermistor PTC Protection 26 Open Gate u coeptae ree REN e CHR apan taie 27 cwok vie wi dd ete het oll cise tall ie ts ae hnc rie 27 Excessive Starts Hour 28 Overte nm peratures siet Sher hat aska uh 28 E 28 DAC aha e ni 29 Communication 29 Programming 55 hema adore eared Turis iret segete 30 Status o Len 30 Control equ td e tertiae 32 Pump Control Option 32 Braking Control Options e e Etre heer dees Funds 33 Hardware Description sere yates cotra dd LIE I 33 Power Module 33 Current Loop Gate Driver 34 Interface BOSE A ci xu ool Leodii eval Gua dei 34 Rockwell Automation Publication 1560E UM051G EN P March 2015 5 Table of Contents Functional Descriptio
50. complete Check for any damaged components and verify that electrical clearances have not been reduced while installing power cables Verify Incoming Power System Grounding Floating Solid Ground Resistive Ground and determine if Vcom on the interface board should be connected to a ground reference or not refer to Resistance Checks on page 80 Check if there are any Power Factor Correction Capacitors refer to Power Factor Correction Capacitors on page 63 of Chapter 2 for correct installation requirements of these capacitors Check if Surge Capacitors and or Surge Arrestors are installed at the motor Open motor junction box and verify it by yourself These must be disconnected from the circuit refer to Surge Arrestor Protection Devices on page 64 of Chapter 2 Verify fiber optic cables are connected at the right location FO cables on Phase A power pole go to Phase A on the Interface board Phase B of power pole to Phase B on the Interface board and Phase C of power pole to Phase C on the interface board and the connectors are fully seated in their sockets Verify that circuit board plug connectors are installed and fully inserted in their sockets Verify that the cooling fan if supplied is secured and the rotor is not obstructed Complete device resistance checks per user manual refer to Resistance Checks on page 80 of Chapter 3 Complete Power Supply Tests refer to Power
51. exhaust piece that extends beyond either the left or right ends of the line up The other end of the plenums is capped with an end cover Extensions can be added to the plenum to allow the arc flash energy to be directed further away from the ArcShield line up to an area where safe venting of the plasma gases can occur Figure 79 Elements of ArcShield Plenum Rockwell Automation Publication 1560E UM051G EN P March 2015 ArcShield Unit Information Appendix C Figure 80 Cross section of plenum extension dimensions in mm inches 584 23 EM o 633 25 Y i Plenum Exhaust The following options for locating the plenum exhaust are presented Considerations 1 Plenum ducted to an area of the control room where arc gases are permitted to escape with plenum extensions see Figure 81 Figure 82 and Figure 83 2 Plenum duct to outside of control room see Figure 81 and Figure 82 Plan the location where the plenum will exhaust Ensure that There is no access to personnel while equipment is energized Area is free of flammable material or vapors Ensure that adequate space is provided around the plenum exhaust as outlined in Figure 81 through Figure 83 IMPORTANT aware that equipment in the area of the plenum exhaust point will be damaged or destroyed Rockwell Automation Publication 1560E
52. familiar with Medium Voltage and solid state power equipment The manual contains 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 TIP This user manual pertains to units with Series letter K or later and firmware release 4 xxx or later See Appendix C Appendix D and Appendix E for arc resistant cabinets The following Rockwell Automation publications provide pertinent information for the MV SMC Flex and components e MVB 5 0 General Handling Procedures for MV Controllers e 1500 UM055_ EN P Controllers 200 400A Two High Cabinet Standard and Arc Resistant Enclosure e 1502 UM050 EN P 400 Amp Medium Voltage Contactor Series D e 1502 UM052_ EN P Medium Voltage 400A Contactor Series E e 1502 UMO051 EN P Medium Voltage Contactor 800A Series D and E 1560E SRO22 EN P Medium Voltage Smart Motor Controllers Specification Guide e 1503 UMO051 EN P IntelliVAC 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 13 Chapter1 Product Overview
53. for maximum ratings Exceeding these could result in damage to the controller This is not to indicate how the motor windings are configured Do not select Delta for MV applications Overview Viewing Metering Data Metering Chapter 5 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 Description Action Display W Amps Vo uru 1 Press any key to access the Main menu Main Menu Memory Storage 2 Scroll with the Up Down keys until the Parameter Main Menu option is shown Memory Storage 3 Press the Enter key to access the Parameter option e 4 Scroll with the Up Down keys until the Monitoring GP File option is displayed vy z Set Up 5 Press the Enter key to access the Monitoring group i 6 Press the Enter key to access the Metering group P Metering 1 Referto Metering on page 28 of Chapter 1 or Figure 43 on page 85 of Chapter 4 for details on the metering functions Rockwell Automation Publication 1560E UM051G EN P March 2015 99 Chapter5 Metering Description Action Display 7 Scroll through the Metering parameters with the Fal 1 Up Down k
54. hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death SHOCK HAZARD To avoid shock hazard ensure main power has been 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 Figure 50 3 Remove current loop cable see Figure 49 Unplug all fiber optic cables from the gate driver board Unplug gate lead connectors 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 ATTENTION The gray fiber optic cables can be damaged if struck or Disconnect the power cables from the terminals on the left side of the heatsink assembly Use care not to damage components The sharing resistors are fragile Remove two 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 fiber optic cables and wiring so they will not be damaged as the module is removed from the cabinet Pull module out slowly and slide onto a platform lift or lift the module out of the cabinet greater To avoid injury always use two people to remove and handle ATTENTION The heatsink assembly is heavy approx 25 55 Ib or t
55. install the front duct section of the last Plenum on the exhaust side of the Line up at this time refer to STEP 6 Mounting Extension Elbow to Plenum Line up on page 197 for more information TIP Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place Rockwell Automation Publication 1560E UM051G EN P March 2015 195 AppendixD ArcShield Plenum Installation Instructions STEP 5 Extension and Elbow The 36 Extension components and 90 Elbow Section are to be attached using Ass embly 5 16 inch hardware in the following sequence Step 5A See Figure 96 Step 5B See Figure 97 Step 5C See Figure 98 TIP The Screen Cover Plate is attached in Figure 97 Figure 96 90 Elbow Section Assembly Step 5A Front View Figure 97 90 Elbow Section Assembly Step 5B Front View Screen Cover Plate 36 Extensions 2 piece 90 deg Elbow Section Screen Cover Plate The Extension components are attached to the Elbow Section using 5 16 inch Hardware 36 Extensions Figure 98 illustrates what the Extension Elbow Assembly Should resemble when finished TIP Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place 196 Rockwell Automation Publication 1560E UM05 1G EN P March 2015 ArcShield Plenum Installation Instructions Appendix D STEP 6 Mounting As referred to in STEP 4 Closin
56. ipsa vn 61 P 62 Physical Location ince oobis esp tel Decet te oie leu 62 E DUM HM 62 Ground Bus eric bep SEU 62 Power and Control Wiring 62 Control Cables ss esee deter ve up papay 63 Fiber Optic Cables cs Sareea qe 63 Power Factor Correction 63 Surge Arrestor Protection 64 Motor Overload Protection 65 SET sn qa ote timete bs hawa sh pida 65 Multi motor Protectioliz el ve eee sotalol 65 EMC GConmplialiGez cus Casa RAN E ore REA d RU S SS 66 Enclosure tins pasnya sya ina a E 66 pon E UIT 66 Control LL ep ATTE 67 Control Voltage Su dieing eee 67 Control Witing oy hex wes ease eat bna Y e e beets 67 Control Terminal Designations 245 s dede e toda nal stratis 68 6 Rockwell Automation Publication 1560E UM051G EN P March 2015 Commissioning Procedure Programming Metering Table of Contents Chapter 3 Preliminary Setup eo o asa iie eR 69 System Characteristic o wel overuc ewes pase RUN 70 Important Commiss
57. is typically programmed for fault indication in MV applications it can be configured for NO NC The Aux 3 contact is typically programmed for alarm indication in MV applications it can be configured for NO NC The Aux 4 contact is always configured as Normal NO to control the line contactor for MV applications Network inputs can be obtained through proper programming of Option Input 1 and Option Input 2 refer to page 163 and page 167 for available options MV applications have special requirements for isolation and bypass contactors or circuit breakers For Firmware up to and including 5 001 the following issues must be considered 1 AUX1 must be used to control the fully rated bypass contactor Parameters 107 will not be displayed and defaults to Ext Bypass 2 AUX4 must be used to control the isolation contactor Parameter 109 must be set to Normal For Firmware 6 001 and later the definitions of all AUX relays will be the same and for MV applications will perform with the modified MV functionality 1 AUXI should be used for bypass contactor control and must be set for Ext Bypass 2 AUX4 should be used for isolation contactor control and must be set for Normal Rockwell Automation Publication 1560E UM051G EN P March 2015 31 Chapter1 Product Overview Control Options The MV SMC Flex controller offers the control options described below IMPORTANT The options listed in
58. location of voltage sensing board ATTENTION Solid state devices be destroyed by high voltage Use jumper voltage testing is potentially hazardous and may cause severe burns injury or death Where appropriate the case of the test equipment should be connected to ground ATTENTION Use caution when performing the HI POT or Megger Test High Insulation may be tested from phase to phase and phase to ground The recommended level for AC HI POT testing is 2 X VLL Volts where VLL 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 a 1560E is being tested it is recommended that the input and output cables be disconnected for each phase If a 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 points marked with an asterisk in Figure 36 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
59. m B V log M 2 3 MOV gt ABB N Nn 17 BYPASS CONTACTOR B 12 5 n L G nm M IV B IV STOP START BH Haat ole CONTROL RELAY CR MODULE MODULE R STATUS STATUS 5H Hs 11 CONTACTOR STATUS MOX B V lt BYPASS CONTACTOR 15H AUXILIARY RELAY BCX BCX CR CONTACTOR N BV 9 10 CLOSE FROM SMC 3 g 12 s 34 15 16 7 3 39 2 2 2 SMC Flex CONTROL TERMINALS AUX EXTERNAL BYPASS O AUX 2 AUX3 AUXA TACH GROUND FAULT NORMAL INPUT INPUT FAULT 1 l 32 2 2 2 2 2 2 gt 3 2 3 3 55 MAIN CONTACTOR t AUXILIARY RELAY MCX FROM GFCT OPTIONAL 9 o CLOSE SMC FlexiB INPUT POWER L1 L2 N 42 Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 Figure 21 Typical Bulletin 1562E IntelliVAC Control Circuit With Stop Control
60. on each gate driver board as described in step 4 above The voltage should be 10 12V DC If the voltage is less than 5V then you have a bad gate drive board Do not leave the Portable Test Power Supply connected to a bad gate driver board The power supply adapter will burn up if the gate driver board is shorted more detailed check is performed by verifying the actual gate pulses by connecting an oscilloscope between TP1 and TP3 see Figure 39 To check gate pulses the pulse generator must be enabled i e SW2 toggled up and the Portable Test Power Supply should be connected to J1 The pulse should appear as shown in Figure 40 and Figure 41 Rockwell Automation Publication 1560E UM051G EN P March 2015 77 Chapter3 Commissioning Procedure Figure 40 Gate Pulse Detail Typical SCR ABB Volts 6 00 5 00 4 00 3 00 2 00 0 00 2 00 1 00 0 00 1 00 2 00 3 00 4 00 5 00 6 00 T 00 Microseconds Figure 41 Gate Pulse Test Waveform 10 11 T T T T T T T T t 20 15 10 05 0 0 05 10 15 20 25 3C Milliseconds If no pulse is observed and the yellow LED is lit check for a shorted 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 fiber optic connector and carefully pull it straight out of the receiver The end of the connector sh
61. or chimney must be used to direct the arc flash energy to a suitable location Failure to do so voids the arc resistant integrity Refer to Appendix D for plenum installation instructions Refer to Appendix E for chimney installation instructions All wiring between the low voltage panel and the power cell must be routed through a suitable gland to ensure flames and gases are not transmitted into this area as fitted from factory Themedium voltage power cell doors must be properly secured using both the handle mechanism and the door bolts refer to instruction label on the power cell door and in Chapter 2 Failure to do so voids the arc resistance integrity 1 50 KA is only for specific configurations Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 183 AppendixC ArcShield Unit Information Exhaust Systems Chimney or Plenum Information Plenum Option 184 A plenum can be provided for each unit and is to be field mounted on the top of the unit structure some incoming units may not have a plenum if top cable entry is required The purpose of the plenum is to direct the hazardous flames and gases away from the top of the arc resistant enclosure Unit plenums are secured to the top of the unit structure and to adjacent plenums creating a continuous conduit for release of the arc flash energy Refer to Appendix D for plenum installation instructions Each plenum based ArcShield line up includes a plenum
62. seconds to protect the power electronics from any voltage transients due to opening the motor circuits 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 22 allows the MV SMC Flex to be controlled using DPI Drive Programming Interface Table 16 on page 121 for Logic Command Word bits assignment for DPI control 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 ofthe SMC Flex module is energized allowing a start command to be executed via DPI When a Start is executed the Aux 4 contact closes energizing both M IV and MCX The line contactor closes and the unit initiates a start sequence 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 20 A stop command can be generated via DPI or by opening CR depending on the control mode Bulletin 1562E DPI Control With Controlled Stop The control scheme shown in Figure 23 allows the MV SMC Flex to be controlled using DPI Drive Programming Interface Table 16 on page 121 for Logic Command Word bits assignment for DPI control This spec
63. start If the motor has started the unit is in 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 to protect the power electronics from any voltage transients due to opening the motor circuits trip due to an overload or fault condition will result in a Coast stop 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 24 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 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits 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 modu
64. 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 If the password is set parameters cannot be adjusted without logging in 3 Use the Sel key to highlight a single digit Description Action Display Amps vo MTU 1 Press the ESC key to go from the status display to the Main menu 2 Scroll with the Up Down keys until the Main Menu Preferences option is highlighted VOU Memory Storage 3 Press the Enter key to access the GP Fil Parameter menu SHE e Set Up 4 Scroll with the Up Down keys until the File option you want to use Monitoring Motor Protection etc is highlighted For Motor Protection this example Set Up will be used 5 Press Enter to select the Set Up group 6 Scroll to Basic Set Up and press Enter Fu Pz Group Basic Set Up 7 Scroll to the Starting Mode parameter by Fab Parameter using the Up Down keys and press Enter A Starting Mode Ramp Time 8 Press Enter to select the option Scroll to F ala P 17 the option of your choice by using the Up FU Down keys For this example we will choose Current Limit 9 Press the Enter key to accept the new setting 10 Scroll to the next parameter by using the
65. supply supplied 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 69 Chapter3 Commissioning Procedure System Characteristics Job Name Job Number Rated Voltage Rated Current Actual Motor Load Load Type Fan Pump Conveyor Compressor Mixer Other Constant Torque or Variable Torque Actual Motor Data Motor HP Motor Rated Speed Motor F L A Motor 5 Motor L R A Frequency Phases 70 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 S F Commissioning Procedure Chapter3 Important Commissioning Checks important checks are completed For more details follow the commissioning ATTENTION When commissioning a MV SMC Flex it is critical that following guidelines that follow this page Inspect the equipment for any signs of physical damage Verify SMC Flex physical installation is complete Verify the integrity and operation of all safety interlocks Verify that motor mechanical installation is complete Verify that Incoming Power wiring to SMC Flex is complete and all connections are tight Verify that Motor cabling to SMC Flex is complete and that all connections are tight Verify that Control wiring to SMC Flex is
66. 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 communications diagnostics troubleshooting and maintenance of a standard solid state controller 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 appropriate 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 me
67. 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 IMPORTANT Stop commands override all start commands and can be initiated from the hardwired inputs or any port regardless ofthe 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 SMC Flex itself The SMC can be used wit
68. the capacitor conductors This can be accomplished 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 replaced and securely fastened before energizing equipment Failure to do so ATTENTION Any covers or barriers removed during installation must be may result in severe burns injury or death Rockwell Automation Publication 1560E UM051G EN P March 2015 63 Chapter 2 Surge Arrestor Protection Devices 64 Installation Figure 34 Typical One Line Diagram Showing 2 Different Styles of Power Factor Capacitor Connections Power Bus Isolation Switch Isolation Switch Fuse i Fuse Contactor Isolation Contactor E di dt Inductor di dt Inductor Capacitor Contactor T PEE X Power Factor X Correction Capacitor Bypass Contactor AX Motor Rockwell Automation highly 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
69. 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 microprocessor analyzes the motor variables and generates commands that control the motor and reduce the possibility of surges occurring in the 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 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 The Pump Stop option functions only f
70. timer starts after the maximum phase of load current transitions from 0A to 30 of the devices 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 Fit Inh Time expires Ground Fault 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 Gad Fit A Lvl Parameter 77 Gad Fit A Lvl allows the installer to define the ground fault current at which an alarm will be indicated It is adjustable from 1 0 5 0 A Parameter 78 Grd Flt A Dl allows the installer to define the time period ground fault alarm condition must be present before a trip occurs It is adjustable from 0 1 25 seconds Rockwell Automation Publication 1560E UM051G EN P March 2015 25 Chapter1 Product Overview 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 sensors resistance transitions from a low to high value Since P TC sensors react to actual temperature enhanced motor protection can be provided to address such conditions a
71. 189 Basic Setup Programming 94 C Chimney Exhaust Considerations 188 Information 188 Circuit Board Replacement 134 Commissioning Control Function Tests 79 Hi Pot and Megger Test 73 Power Supply Tests 76 Preliminary Check 72 Preliminary Setup 69 Procedure 69 Programming 72 Resistance Checks 80 Start Up 81 Voltage Sensing Module 80 Communcation Data Links Configuring 122 Communication 29 DataLinks Rules 122 Documentation 113 Failure 118 Human Interface Module 114 Keypad 114 Overview 113 PLC Scale Factors 121 Ports 113 Conrollers 1562E Combination 14 Control Cables Installation 63 Control Function Tests 79 Control Module Removal 131 Index Control Options 32 Braking 33 Pump 32 Control Power 67 Conrol Voltage 67 Control Wiring 67 Control Terminal Designations 68 Control Voltage 67 Control Wiring 67 Installation 62 Options 105 Controller Connecting Human Interface Module 116 Controllers 1503E 14 1560E Retrofit 14 Relay Control 169 1562 Combination Relay Control 169 Current Limit Start Starting Mode Programming 91 Starting Modes Current Limit Start 16 Current Loop Power Supply 133 D Data Links Configuring 122 DataLinks Rules 122 Diagnostics Alarm Auxiliary Indication 109 Clearings Faults 108 Fault Buffer 108 Fault Codes 109 Fault Definitions 110 Fault Display 107 Fault Indication 109 Overview 107 Documentation Rockwell Automation 13 Communication 113
72. 2015 Rockwell Automation Inc All rights reserved Printed in Canada
73. 25 20 27 21 29 40 53 43 57 60 90 64 84 KOhms 2 3 3 Cathode to Gate 10 40 10 40 10 40 10 40 10 40 10 40 10 40 10 40 Ohms 1 Measured between terminals Cathode on CLGO Boards upper two or between two within a phase 2 Measured between terminals Cathode on CLGO Boards top to bottom within a phase 3 Measured between line and load terminals within a phase 3 Ifabnormal readings are obtained refer to Power Circuit Troubleshooting on page 135 of Chapter 9 The voltage sensing module consists of a voltage sensing board and mounting plate refer to Figure 48 on page 132 The voltage sensing board has six independent channels with different sized resistors base on voltage range which convert voltages up to 10800V 7 2 kV 1 5 pu down to low voltage levels which can be used by the SMC Flex control logic Table 4 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 7200V with a continuous 40 overvoltage The output voltages are scaled to provide close to 10V peak for a 140 input voltage at the high end of each of the voltage ranges Rockwell Automation Publication 1560E UM051G EN P March 2015 Start Up Commissioning Procedure Chapter 3 Software will be used to scale the output to show the correct v
74. 28 Cabinet Layout 1562E 180 360A 2400V to 4160V with LV panels not shown Non arc resistant cabinet shown Power Stack Assembly Terminal Block Assembly Bypass Vacuum Contactor Voltage Sensing Module Non Load Break Isolation Switch Load Cable Connection Point top exit Current Transformers Line Vacuum Contactor 1 6900 arc resistant and 600 A models available 56 Rockwell Automation Publication 1560E UM051G EN P March 2015 Installation Chapter2 Figure 29 Incoming Line Cable Connections viewed from the rear with power bus access cover removed Non Arc resistant cabinet shown Power Cable Lugs Ground Bus Lug Figure 30 Bottom Cable Exit Configuration with LV panel swung open Non Arc resistant cabinet shown Cable Duct Barrier Cable Duct Boot Motor Cable Terminals Rockwell Automation Publication 1560E UM051G EN P March 2015 57 Chapter2 Installation Bulletin 1560E Figure 31 Power Connections 1560E 180 360A 2400 4160V Not available in an Arc resistant design Phase 2 Power Stack Assembly Phase 1 Power Stack Assembly Phase 3 Power Stack Assembly Load Connections Voltage Sensing Module top exit Shown Phase 1 front through 3 back Line Connections Phase 1 top through 3 bottom Current Transformers 58 Rockwell Automation Publication 1560E UM051G EN P March 2015 Installation Cha
75. 4 Fault 1 35 Braking Current 80 Phase Reversal 125 Fault 2 36 Braking Time 81 Starts Per Hour 126 Fault 3 37 Load Type 82 Restart Attempts 127 Fault 4 38 High Eff Brake 83 Restart Delay 128 Fault 5 39 Slow Speed Sel 84 Line Fault 129 Start Time E 40 Slow Speed Cur 85 Emergency Run 130 Start Time 2E 41 Slow Accel Cur 86 Current Loss 131 Stop Time E 42 Slow Running Cur 87 Logic Mask 132 Option 1 Input 43 Stopping Current 88 Data In A1 133 Stop Input 44 Overload Class 89 Data In A2 134 Elapsed Time 2 45 Service Factor 90 Data In B1 1 Pump Control module only see Troubleshooting section for guidance 2 Do not change these parameters from the default settings 3 Brake module only Consult factory 86 Rockwell Automation Publication 1560E UM051G EN P March 2015 Password Programming Chapter 4 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 Amps EWWIICIIEIGkFZIUI II II PE o 1 Press the ESC key to go from the status display to the 5 Main Menu Main menu Diagnostics Parameter 2 Scroll with the Up Down keys until the Preferences option is highlighted Preferences Diagnostics 3
76. 560E 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 75 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 AUX1 contact is held closed for 10 seconds to keep the bypass contactor closed for a short time Rockwell Automation Publication 1560E UM051G EN P March 2015 171 Appendix B 172 1560E and 1562E Relay Control 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 76 the controller operates much the same as described above for the Standard module The control signal uses terminal 16 instead of 17 an
77. C Flex module closes Aux 1 contact energizing which closes the bypass contactor To run in Local mode the CR contact is used to initiate a start sequence similar to Figure 71 A stop command can be generated via DPI or by opening CR depending on the control mode 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 to protect the power electronics from any voltage transients due to opening the motor circuits A trip due to an overload or fault condition will result in a coast stop Rockwell Automation Publication 1560E UM051G EN P March 2015 1560E and 1562E Relay Control Appendix B Bulletin 1562E DPI Control With Controlled Stop The control scheme shown in Figure 74 allows the MV SMC Flex to be controlled using DPI Drive Programming Interface Refer to Table 16 page 121 for Logic Command Word bits assignment for DPI control 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 ofthe SMC Flex module is energized allowing start and stop maneuvers to be executed via DPI When a Start is executed the Aux 4 contact closes energizing which closes the main contactor
78. Circuit Tests 131 Selectable Kickstart Starting Mode 16 Voltage Sensing Board Replacement 132 SMC Flex Bit Identification 120 Voltage Sensing Module 80 SMC Flex Control Module 15 Snubber Replacement 151 Troubleshooting 149 Soft Start Starting Mode 15 Programming 91 Soft Stop Stopping Mode 20 Spare Parts Power Stacks 203 Specifications Torque 54 Stall Protection 24 Staring Modes Linear Speed Acceleration 19 Starting Modes 15 Dual Ramp Start 17 Full Voltage Start 18 Preset Slow Speed 18 Selectable Kickstart 16 Soft Start 15 Status Indication 30 Stop Control Programming 93 Stopping Modes Linear Speed Deceleration 19 Soft Stop 20 Surge Arrestor Protection Devices 64 T Thermistor 26 Torque Recommended Values 54 Transportation and Handling 52 Troubleshooting Circuit Board Replacement 134 Control Module Removal 131 Current Loop Power Supply 133 General Notes 125 Power Circuit 135 Resistor Circuit Testing 149 Snubber Testing 149 Voltage Feedback Circuit 131 Voltage Sensing Board Replacement 132 Warnings 125 Two speed Motors 65 U Unbalances 23 Underloads 22 Example Settings 97 Undervoltages 23 Example Settings 97 Unpacking 51 212 Rockwell Automation Publication 1560E UM051G EN P March 2015 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical an
79. Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www ab com mvb Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page www rockwellautomation com Power Control and Information Solutions Headquarters 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 NV Pegasus Park De Kleetlaan 12a 1831 Diegem 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 Tel 852 2887 4788 Fax 852 2508 1846 Publication 1560E UM051G EN P March 2015 Supersedes Publication 1560E UMO5 TF EN P June 2013 Copyright O
80. Dly Unbalance A Lvl Unbalance Parameter Mgt Starts Per Hour Restart Attempts 4 Restart Dly Parameter Mgt 4 1 2 3 4 Steps back one level Communications lt q Logic Mask arameter Mgt 4 ata In A1 ata In A2 ata In B1 ata In B2 ata In C1 ata In C2 ata In D1 ata In D2 ata Out A1 ata Out A2 ata Out B1 ata Out B2 ata Out C1 ata Out ata Out D1 ata Out D2 arameter Mgt 4 For further information on parameters refer to Appendix A For further information on parameter management refer to Parameter Management on page 88 t All parameters Parameter Mgt 4 Linear Lls Language Parameter Mgt 4 Motor Data Motor Motor ID CT Ratio MV Ratio Parameter Mgt 4 Depending upon SMC option selected some parameters may not appear in product display Rockwell Automation Publication 1560E UM051G EN P March 2015 85 Chapter 4 Programming Table 6 Parameter Linear List Parameter No Description Parameter No Description Parameter No Description 1 Volts Phase A B 46 Motor FLC 91 Data In B2 2 Volts Phase B C 47 Overload Reset 92 Data In C1 3 Volts Phase C A 48 OL Shunt Time 93 Data In Q 4 Current Phase A 49 OL Trip Enable 94 Data In D1 5 Current Phase B 50 Overload A Lvl 95 Data In D2 6 Current Phase
81. EH He S Go CONTACTOR STATUS BV CR t F CLOSE FROM SMC HexlB J3 ei 2 1 5 6 7 18 19 2 2 2 SMC Flex CONTROL TERMINALS AUX 1 EXTERNAL BYPASS bet AUX2 AUX3 AUXA e FAULT ALARM NORMAL PTC INPUT INPUT FAULT 1 3 z2 25 3 2 33 2 9 u1 2 3 o NOTE LINE CONTACTOR OR BREAKER MUST REMAIN CLOSED DURING THE OPTION STOP PERIOD IT IS RECOMMENDED THAT THE LINE CONTACTOR BE CONTROLLED BY THE AUX 4 NORMAL CONTACT SEE 1562E CONTROL SCHEME L2 N Rockwell Automation Publication 1560E UM051G EN P March 2015 BYPASS CONTACTOR B CONTROL RELAY CR BYPASS CONTACTOR AUXILIARY RELAY BCX 47 Chapter1 Product Overview Figure 26 Typical Bulletin 1560E IntelliVAC Control Circuit without Stop Control With DeviceNet or DPI Communication and optional Local Off Remote 115V 7
82. EN P March 2015 Troubleshooting Chapter 9 Power Circuit Thyristor SCR Testing Troubleshooting If a power semiconductor is suspected of malfunctioning it may be checked as follows 1 Remove all power from the equipment 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 SHOCK HAZARD To avoid shock hazard ensure the main power has 2 Measure DC resistance per the following chart Table 24 SCR Resistance Measurements Location of 1000V 1300V 1500V 2300V 3300V 4160V 5500V 6900V Probes Cathode to Cathode 22 30 23 31 21 29 24 32 KOhms Cathodeto Cathode 17 23 19 25 20 27 21 29 40 53 43 57 60 90 64 849 KOhms Cathode to Gate 10 40 10 40 10 40 10 40 10 40 10 40 10 40 10 40 Ohms 1 Measured between terminals Cathode on CLGO Boards upper two or between two within a phase 2 Measured between terminals Cathode on CLGO Boards top to bottom within a phase 3 Measured between line and load terminals within a phase TIP 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
83. ERNAL BYPASS DPI AUX 2 AUX3 AUX4 pO FUU ALARM NORMAL INPUT INPUT FAULT 11 11 23 2 25 26 27 8 9 3 3 3 Bl A 51 NOTE LINE CONTACTOR OR BREAKER MUST REMAIN CLOSED DURING THE OPTION STOP PERIOD IT IS RECOMMENDED THAT THE LINE CONTACTOR BE CONTROLLED BY THE AUX 4 NORMAL CONTACT SEE 1562E CONTROL SCHEME SMC FlexlB INPUT POWER u LIN 1 CCand HC and their wiring into the control circuit are part of the Rockwell Automation relay control panel 1503E CXXX This control panel ensures reliable operation of the contactor within its published specification Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 179 AppendixB 1560 1562E Relay Control Figure 77 400 Amp Bulletin 1560E Relay Control Circuit Without Stop Control With DeviceNet or DPI Communication and Optional Local Off Remote 115 ar 8 12 TO SMCLEXIB m TB6 _ So M 8 II BC B B C D LA B K RECTIFIER HH 1 lt lt Y 2 BYPAS
84. IW W sii 5 40 WIWININ V Bd 519015 OML WNWIXYW Y ELXL sal ax LXI gt XC 5409 OLXL 991 61 8XL 99 COND LOND 9X1 95 SXL N6rvL 008 0 Le 90 166 0912 8 A66Lv 00SC d XL m gj 85A a al uL ash gno 8 08 9NISN3S 39VIT0A IWS Quv09 DVN3INIX H WS WS 01 N POWER OUT HASEC CTINPUTS HASEB GATE TRANSMITTERS PHASE A DH D Pe m a gt i b op lal val Dp dpa D D 0D ig 0D OD gg OD 4s 7701 ESTA Iz OTSTAOT AOT T t 5 ta J M 5 o tsa is 198 700 no ES cuu 1 gt 100 NID 14 14 1 4 gt bh 1008 w 8 2 14 Y ini T po NI my 5
85. LUVIS N33ALISG SALANIW E 40 WDWINIW V SINVISOMLWAWIXYW E sal o ux ID Wows 4 E Xs 981 _ 8 El au TES S iml Lg T 95 61 008 1 ec sXL A66 2 0SbL D g N66Lt 00SC 4 002 008 n v aS SSA au gl 181 xL 95A gad 4 08 9NISN3S 39VIT0A INS Quv08 IWS n LINDY 1081802 OL v z 4 P 4 b Pit 7 esi ZZ 12 b ape io P ups ES Tn D D m SHY x 8210 AL A 0D yoy 0D jy 0D jy 090 mm hasce alsmi Dsi Disk 5 s Tao IH 1 4 MOCV u S351 ABVWINd 5 U 9 0 FT M SISMA 30d an H 4 14 bt H gt H bero JXOTEINIIOOG 9 001 240906 DV 0019 8 35 Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Figure 19 Typical MV SMC Flex Power System Bulletin 1560E 3300 4160V shown Chapter 1 5 z LI J f 181 1N3WdIf 103 31038 4972 SQuvOg YIAING 31 9 JHL ozn NO 5 JHL HONOYHL 5544 540121002 4001 1 388402 81 Pas 23SVHd 403 NMOHS SNOLLD3NNOO v p 8x 8 803540103880 2 LXL V 3SVHd 803 SNOLD3NNO 4 SLX SINVIS S2LAN
86. 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 1 Not applicable in MV applications Auxiliary contacts can be programmed for Fault or Alarm NO or NC indication Parameter setup can be found in the Parameter Motor Protection group when modifying parameters in the Program Mode Rockwell Automation Publication 1560E UM051G EN P March 2015 109 Chapter7 Diagnostics Fault Definitions 110 Table 8 Fault Definitions for the SMC Flex Fault Line Loss F1 F2 F3 Description 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 Open gate indicates that an abnormal condition that causes faulty firing 0 open SCR gate or faulty gate driver has been sensed during the start sequence The SMC Flex controller will attempt to start the motor a total of three times before the controller shuts down Power Pole PTC Overtemperature The power pole temperature in each phase is monitored If the temperature rises above the predetermined level the unit will fault to protect the power pole A reset can be performed once the temperature falls below this level This fault may also represent loss of gate driver power during gating MV appl
87. Line up imneys of varying widths are mounted directly over the enclosures of the corresponding width Rockwell Automation Publication 1560E UM051G EN P March 2015 199 AppendixE ArcShield Chimney Installation Instructions Figure 102 ArcShield Line ups Cabinet Preparation In preparation for mounting a chimney remove 1 4 20 fasteners from the Relief vent on the top of the MV enclosure Leave the 4 corner fasteners in place see Figure 104 Figure 103 Relief Vent Fasteners top view Figure 104 Relief Vent Relief Vent olo r not remove olo 4 corner fasteners e O Q Q Remove Fasteners w 1 0 The chimneys are designed to fit over the fastener heads at the 4 corners of the Relief vent The corner fasteners are required to secure the Relief vent during installation 200 Rockwell Automation Publication 1560E UM051G EN P March 2015 ArcShield Chimney Installation Instructions Appendix E Chimney Placement on Structure Once the Chimney has been lifted in place directly over the relief vent shown in Figure 104 all 1 4 20 fasteners removed in Cabinet Preparation on page 200 are replaced to attach the chimney to the top of the enclosure Figure 105 Chimney Placement Use reco
88. Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt P Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information New and Updated This table contains the changes made to this revision Information Topic Page Replaced diagrams 35 36 Added footnote 56 Updated Ground Bus Bar dimensions 62 Changed all R values 151 Added Important table 169 footnote Added Bulletin 1562E Relay Control Circuit e Without Stop Control With DeviceNet 17 or DPI Communication and Optional Local Off Remote footnote Added Bulletin 1562E Relay Control Circuit With Stop Control With DeviceNet or 17 DPI Communication and Optional Local Off Remote footnote Added Bulletin 1560E Relay Control Circuit Without Stop Control footnote 178 Added Bulletin 1560E Relay Control Circuit With Stop Control footnote 17 Added Bulletin 1560E Relay Control Circuit e Without Stop Control With DeviceNet 180 or DPI Communication and Optional Local Off Remote footnote Added Typical Bulletin 1560E Relay Control Circuit With Stop Control With 181 DeviceNet or DPI Communication and Optional Local Off Remote footnote Updated to Type 2B acces
89. R Universal 80187 245 51 R 1 per controller Current loop transformer 50VA 115 230 0 6V 80022 133 01 3 per controller Current loop cable assembly 5ft 80018 246 55 6ft 80018 246 51 Tft 80018 246 52 8ft 80018 246 53 9ft 80018 246 54 1 per controller Current loop sense CT 80022 163 01 1 per controller Ribbon cable from VSB to Interface Board 80026 146 56 2 per controller Ribbon cable from Control Module to Interface Board 6 pin 80174 201 01 3 per controller Ribbon cable from Control Module to Interface Board 8 pin 80174 201 02 1 Refer to Table 26 for an explanation of the number of SCRs per controller which is voltage dependant 2 Different lengths are used for the various configurations The current loop total length must equal 21 ft for proper operation Table 30 Accessories Qty per Description Part Number controller 1 Control Module Standard W4139145401S1FX Control Module Pump Control W4139145401B1FX 1 Fan 120 80025 248 01 R Fan 240v 80025 248 02 1 Frequency to voltage converter for Tachometer 2Hz 10kHz 80026 427 01 feedback 0 100 kHz 80026 427 02 Power Supply for frequency to voltage converter 80026 433 01 Fuse Extractor 1 Optional equipment 204 Rockwell Automation Publication 1560E UM051G EN P March 2015 80144 491 02 Spare Parts Appe
90. RMAL INPUT INPUT l 1 23 24 25 26 27 28 29 30 31 32 33 34 Ws MAIN CONTROL MC FROM GFCT SS OPTIONAL SMC FlexlB INPUT POWER u LIN 1 CR1 and CR2 and their wiring into the control circuit are part of the Rockwell Automation relay control panel 1503C XXXX or 1503E CXXX This control panel ensures reliable operation of the contactor within its published specification Rockwell Automation Publication 1560E UM051G EN P March 2015 175 AppendixB 1560 1562E Relay Control Figure 73 400 Amp Bulletin 1562E Relay Control Circuit Without Stop Control With DeviceNet or DPI Communication and Optional Local Off Remote 115V MASA x1 0 6V X2 TO SMCLEXIB I TB6 W i 43 gt gt e ees MC MC ME ME ME C p D 8 _ RECTIFIER 4 LM HHHH H EIE S Gr it REC MOVET 4 ss qu A MB lt o Y MOV MOV BC BCO BE BE BE C E D RECTIFIER LM PH 4 414 BYPASS CONTACTOR B REMOVE M AO lt OA em
91. S CONTACTOR B REC MOV 2 mori N GO A BB Eel CN BE START STOP SIGNAL FROM BC EXISTING STARTER P CR 4 MASTER CONTROL CR OFF ain ae BYPASS CONTROL BC LT 4 CR EE 9 t E 9 1 FROM SMC 3 4 I 12 13 14 15 16 17 18 19 20 21 22 DEVICENET SMC Flex ADAPTER CONTROL TERMINALS AUX 1 EXTERNAL BYPASS ss BRR DPI AUX2 AUX3 AUA EE DV topeviceneT Gu ALARM NORMAL 58 5 NETWORK INPUT INPUT FAULT l l 241 23 24 2 26 27 28 29 39 31 2 33 34 NetA WIRETO MAIN CONTACTOR SMC FlexiB INPUT POWER ul LIN 1 CCand HCand their wiring into the control circuit are part of the Rockwell Automation relay control panel 1503E CXXX This control panel ensures reliable operation of the contactor within its published specification 180 Rockwell Automation Publication 1560E UM051G EN P March 2015 1560E and 1562E Relay Control Appendix B Figure 78 Typical 400 Amp Bulletin 1560E Relay Control Circuit With Stop Control With DeviceNet or DPI Communication and Optional Local Off Remote
92. START m 1 a Lo 5 CR MASTER CONTROL CR MC CR M OFF LOCAL REMOTE 55 MC XJ Lol BYPASS CONTROL BO C CR amp 4 o FROM SMC 3 2 13 5 16 7 38 39 2 2 2 DEVICENET SMC Flex ADAPTER CONTROL TERMINALS AUX 1 EXTERNAL BYPASS s Dn NX2 P F to pevicener ALARM NORMAL ESL NETWORK INPUT INPUT FAULT I m op qur 8 23 22 25 26 27 28 29 30 3 3 B3 3A netao MAIN CONTROL MC FROM GFCT 55 OPTIONAL SMC POWER NOTE EXTRA CONTACTS FROM STOP BUTTONS SHOULD MONITORED BY THE CONTROLLING PLC FOR REMOTE OPERATION TO ENSURE UNIT WILL STOP WHEN COMMANDED 1 CCand HCand their wiring into the control circuit are part ofthe Rockwell Automation relay control panel 1503E CXXX This control panel ensures reliable operation of the contactor within its published specification 176 Rockwell Automation Publication 1560E UM051G EN P March 2015 1560E and 1562E Relay Control Appendix B Figure 74 400 Amp Bulletin 1562E Relay Control Circuit With Stop Control With DeviceNet or DPI Communication and Optional Local Off Remote TO SMCLEXIB TB6 RECTIFIER REC MOV 1 RECTIFIER REC MOV 2 OPTION STOP MAIN CONTACTOR M
93. Supply Tests on page 76 of Chapter 3 Rockwell Automation Publication 1560E UM051G EN P March 2015 71 Chapter3 Commissioning Procedure e Program the module with correct parameter settings Start the unit and record scope waveforms line voltage motor voltage and motor current Preliminary Check ATTENTION Ensure that all sources of power are isolated and locked out before N 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 B Verify power fuse ratings and condition C Verify control fuse ratings and condition D Check that power cable installation has not damaged components and that electrical spacings have not been reduced E Check that fiber optic cables are fully seated in their connectors F Check that circuit board plug connectors are installed and fully inserted in their sockets G Check that the cooling fan if supplied is secured and the rotor is not obstructed H Verify integrity and operation of all interlocks I In the case of the 1503E verify wiring and perform all tests in conjunction with OEM documentation Programming MV SMC Flex Module Refer to Chapter 4 for programming procedures The default factory parameter settings are as shown in Appendix A Settings may be different o
94. TO SMCLEXIB TB6 4 B IV ae 1 4 M EC TO n 2 3 poA e A B B N va BYPASS CONTACTOR B gt a EKO 12 5 n T TI G DA START STOP T SIGNAL FROM BCX EXISTING STARTER hp TBH Hu 2 4 CONTROL RELAY CR MODULE STATUS COAST OFF T STOP LOCAL REMOTE an o o BH 80 BYPASS CONTACTOR EG CONTACTOR AUXILIARY RELAY BCX c STATUS o B V h m CLOSE FROM SMC 3 5 u 2 ms ma s a mz s a 2 z 2jnbucmnr ADAPTER SMC Flex CONTROL TERMINALS AUXT li EXTERNAL BYPASS BE lw AUX2 AUX3 AUXA EZ TO DEVICENET it sm sidus FAULT n 55 NETWORK INPUT INPUT FAULT 1 E 23 2 25 2 z z3 2 38 au o2 3 23 w 9 NOTE LINE CONTACTOR OR BREAKER MUST REMAIN CLOSED DURING THE OPTION STOP PERIOD IT 15 RECOMMENDED THAT THE LINE CONTACTOR BE CONTROLLED BY THE AUX 4 NORMAL CONTACT SEE 1562E CONTROL SCHEME SMC FlexlB INPUT POWER u L2 N Rockwell Automation Publication 1560E UM051G EN P March 2015 49 Chapter1 Product Overview Notes 50 Rockwell Automation Publication 1560E UM051G EN P March 2015 Receiving Safety and Codes Unpacking and Inspection Chapter 2 Installation ATTENTION Perform the installation duties correctly Errors may cause commissioning delays equipment damage or personal i
95. UM051G EN P March 2015 185 AppendixC ArcShield Unit Information Figure 81 Plenum Exit Left with Extension s to Internal Controlled Access Area Top View Z Personnel Access Barriers lt X gt Figure 82 Plenum Exit Left with Extensions to Internal Controlled Access Area Front View lt gt Personnel Access Barriers o CH AUO AH BMD EM E Minimum H 3 5 m 138 inches Minimum L 1 2 m 47 inches Minimum Volume of space required for safe pressure relief X Y H 11m 390 cubic feet 186 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 ArcShield Unit Information Appendix Figure 83 Chimney Exhaust Space Requirements Minimum H1 1 7m 67 Minimum H 1m 37 Rockwell Automation Publication 1560E UM051G EN P March 2015 187 AppendixC ArcShield Unit Information Additional Notes Chimney Information Chimney Exhaust Considerations 188 The walls of the plenum exit area must be capable of withstanding the pressure generated Any painted surfaces which face direct contact with the arc products may ignite Flame suppression is recommended The exit point can also be outside the building Ensure exit area can not be blocked by ice snow vermin nests Access ba
96. User Manual Allen Bradley Medium Voltage SMC Flex Motor Controller for Series K or later Bulletin 1503E 1560E and 1562E Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with resp
97. ace board NVS Error 39 Data entry error Check user data and perform a User Store function Replace control module Line Loss 41 42 43 e Line Distortion Check supply voltage for capability to start stop High impedance connection motor Verify system grounding refer to Resistance Checks on page 80 of Chapter 3 Check for loose connections on line side or motor side power wires V24 Loss 45 Internal power supply problem Cycle control power to reset the control module f Fault persists replace control module V Control Loss 46 Internal sense circuit problem Cycle control power to reset the control module f Fault persists replace control module Option Input 1 48 External Fault Check programming of Parameter 132 e Check status of device connected to Input 1 Option Input 2 49 External Fault Check programming of Parameter 24 Check status of device connected to Input 2 System Faults 128 209 Control module internal fault Cycle control power to reset the control module 1 Prestart fault indication 128 Rockwell Automation Publication 1560E UM051G EN P March 2015 e If fault persists replace control module Table 19 Motor Will Not Start No Output Voltage to the Motor Display Fault displayed Possible Causes See fault description Troubleshooting Chapter 9 Possible Solutions See Table 18 addressing fault conditions Display is blank Control voltage is ab
98. ad Underload F Lvl 51 FLC 0 99 0 Underload F Dly 52 SEC 0 99 0 Underload A Lvl 53 96 0 99 0 Underload A Dly 54 SEC 0 99 0 Undervoltage Undervolt F Lvl 55 0 99 80 7 Undervolt F Dly 56 SEC 0 99 1 Undervolt A Lvl 57 V 0 99 0 Undervolt A Dly 58 SEC 0 99 0 Overvoltage Overvolt F Lvl 59 96V 0 199 0 Overvolt F Dly 60 SEC 0 99 0 Overvolt A Lvl 61 96V 0 199 0 Overvolt A Dly 62 SEC 0 99 0 Unbalance Unbalance F Lvl 63 96 0 25 0 Unbalance F Dly 64 SEC 0 99 0 Unbalance A Lvl 65 0 25 0 Unbalance A Dly 66 SEC 0 99 0 Jam 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 A Dly 70 SEC 0 99 0 Stall Stall Delay 71 SEC 0 0 10 0 0 1 Pump option modules default to Pump Stop 2 Brake module only 3 Donotset below 70 164 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 Parameter Information Appendix A Group Parameter Description Parameter Units Min Max Default User Number Settings Settings Ground Fault Gnd Fit Enable 72 Disable Disable Enable Gnd Fit Level 73 A 1 0 5 0 2 5 Gnd Fit Delay 74 SEC 0 1 250 0 0 5 Gnd Fit Inh Time 75 SEC 2 25 10 Gnd Fit A Enable 76 Disable Disable Enable Gnd Fit A Lvl 7 A 1 0 5 0 2 0 Gnd Fit A Dly 78 SEC 0 250 10 PTC PTC Enable 79 Disable Disable Enable Phase Reversal Pha
99. alue on the SMC Flex front panel display See Parameter 106 MV Ratio Table 4 Input Voltage Ranges Module Rated Voltage Voltage Range MV Ratio 1500 800 1500 1200 2500 1501 2500 580 4800 2501 4800 324 7200 4801 7200 195 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 five units at a time is recommended Increasing the ratio will decrease the displayed voltage and visa versa Remove any temporary jumpers or grounding devices used during commissioning 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 Check that all barriers or covers removed during installation or commissioning have been securely mounted b ly ted Close and secure all doors and verify function of all interlocks that prevent access to medium voltage compartments when the unit is energized The controller is ready to power the motor Rockwell Aut
100. any stored energy in capacitors to dissipate The safety related work practices of NFPA 70E Electrical Safety Requirements for Employee Workplaces must be followed if it is necessary to work in the vicinity of energized equipment ATTENTION Servicing energized industrial control equipment can be 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 79 Chapter3 Commissioning Procedure Resistance Checks Voltage Sensing Module 80 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 appropriate voltage measuring device Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment ATTENTION Verify that all circuits are voltage free using a hot stick or 2 Measure DC resistance per the following chart Table 3 Power Circuit Resistance Measurements Location of Probes 1000V 1300V 1500V 2300V 3300V 4160V 5500V 6900V Cathode to Cathode 22 30 23 31 21 29 24 32 KOhms Cathode to Cathode 17 23 19
101. as been 2 Check the snubber components and sharing resistors by isolating them and measuring values as follows See Figure 67 to Figure 70 RS 600 180 A and 360 A 30 Q 660 CS 0 5 or 0 68 uF 180 A and 360 A 1 0 uF 600A RRx 32 5 total taps at 2 5 from each end x 1 2 or 3 Replace any out of spec components See Table 28 on page 203 in Appendix 3 Ifthe snubbers and sharing resistors are within tolerances check the resistance of the voltage sensing module refer to Figure 66 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 66 Rockwell Automation Publication 1560E UM051G EN P March 2015 149 Chapter 9 Troubleshooting Figure 66 Voltage Sensing Board 150 V rated Tap 1 3 5 1 5 kV 1 9M 25kV 37M 48kV 6 6M 72kV 112 Values 2 Measure 11 3 Tap 2 4 6 2 8M 5 6M 10 0 16 9M m gt To Interface Board A Ground Connections VOLTAGE FEEDBAC 24 RATED VOLTAGE kV MADE IN LU DU SERIAL AWA NUMBER R25 TVS1 TVS8 R27 TVS2 AL ES TVS3 A 54 USA iios GND1
102. ated 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 can be cleaned effectively by vacuuming or wiping Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 157 Chapter 10 Maintenance 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 ATTENTION Allen Bradley magnetic starters contactors and relays are Some parts of other devices are factory lubricated if lubrication during use 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 ope
103. ater than zero when Undervoltage Overvoltage and Unbalance are enabled 2 For Jam and Underload detection to function the Motor FLC must be programmed the Motor Protection group See Motor Information on page 98 3 See details in Ground Fault page 24 4 details in Thermistor PTC Protection on page 26 Rockwell Automation Publication 1560E UM051G EN P March 2015 Programming Chapter 4 Example Settings Undervoltage With Line Voltage programmed for 4160V and the Undervoltage level programmed for 80 the trip value is 3328V Overvoltage With Line Voltage programmed for 3300V and the Overvoltage level programmed for 115 the trip value is 3795V Jam2 3 With Motor FLC programmed for 150 Amps and the Jam level programmed for 400 the trip value is 600 Amps Underload 2 With Motor FLC programmed for 90 Amps and the Underload level programmed for 60 the trip value is 54 Amps 1 The average value of the three phase to phase voltages is utilized 2 largest value of the three phase currents is utilized 3 The SMC Flex will self protect Rockwell Automation Publication 1560E UM051G EN P March 2015 97 Chapter4 Programming Motor Information 98 The Basic Setup 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 control
104. cShield Unit Information ArcShield units have a robust arc resistant enclosure design that has been tested per IEEE C37 20 7 2001 Each ArcShield structure was tested to withstand the effects of an arc flash at 40 kA or 50 for 0 5 5 ArcShield units provide an enhanced Type 2B Accessibility level ArcShield Design ArcShield units typically include a pressure relief vent on the roof of the structure some incoming units may not have a pressure relief vent if top cable entry is required Under arc flash conditions the pressure relief vent will open allowing hazardous flames and gases to exit the enclosure via plenum or chimney system The low voltage panel area is sealed to prevent flames and gases from entering however suitable personal protective equipment PPE must be used whenever working on live circuits ATTENTION To ensure Arc resistant integrity it is important to ensure that the following rules are followed pressure relief vent may not be tampered with and it is not to be used as a step e Noalterations be made to the ArcShield structure e covers plates and hardware removed for installation or maintenance purposes must be re installed and properly secured Failure to do so voids the arc resistant integrity e Power cable entry points are be treated as the boundary between a hazardous location and sealed accordingly Failure to do so voids the arc resistant integrity A plenum
105. chanically 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 unit is 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 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 ATTENTION 1503E and 1560E itis the responsibility of the installer user to Rockwell Automation Publication 1560E UM051G EN P March 2015 61 Chapter2 Installation Installation 62 TIP Rockwell Automation can assist with the selection of an appropriate interlocking method which may include mechanical modifications to the cabinet s or key type lock systems TIP An auxiliary cabinet may be attached to the main structure It will be ram interlocked with the main power cell door which will not allow
106. cond Figure 5 Full Voltage Start 10096 Percent Voltage Time seconds Preset Slow Speed This option can be used in applications that require a slow speed jog for general purpose positioning Preset Slow Speed provides either 796 of base speed low or 1596 of base speed high settings in the forward direction Reverse can also be programmed and offers 1096 of base speed low and 2096 of base speed high settings Figure 6 Preset Slow Speed Option Forward 15 High N 796 Low Time seconds Start c Run 1096 L ow 7 N i 20 High _ Reverse 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 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 5V DC is required to perform this start mode The start time is selectable from 0 30 seconds and determines the time the motor will ramp from 0 speed to full speed Kickstart is available with this option Figure 7 Linear Speed Acceleration
107. 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 Motor Overload Protection Installation Chapter2 e 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 voltage withstanding ratings or surge arrester rating or cause distorted voltage signals whic
108. d a coast stop can be achieved by opening the connection to terminal 17 It is 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 is initiated and remain closed until it has sensed the motor has stopped following an option stop maneuver Bulletin 1560E DPI Control Controlled Start only The control scheme shown in Figure 77 allows the MV SMC Flex to be controlled using DPI Drive Programming Interface Refer to Table 16 on page 121 for Logic Command Word bits assignment for DPI control 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 of the SMC Flex module is energized allowing a start command to be executed via DPI The Aux 4 contact closes and 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 contact energizing BC to close the bypass contactor as the motor approaches rated speed Local control
109. d application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a
110. d remain open to ensure all hold in contacts clear to prevent a re start It is 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 is initiated and remain closed until it has sensed the motor has stopped following an option stop maneuver Rockwell Automation Publication 1560E UM051G EN P March 2015 41 Chapter 1 Product Overview Figure 20 Typical Bulletin 1562E IntelliVAC Control Circuit Without Stop Control MV M 1 E A MB N MAIN CONTACTOR M NS ate eS MES pA H 2 11 G lm
111. d wrench is required Indicating Washer c LN Do not loosen Gap Figure 62 Removing and Replacing SCR 1 SCR 2 and SCR 5 To Remove SCR 1 Remove shorting bar hardware Pry Heatsinks 1 and 2 apart SCR 1 Extract SCR Heatsink 3 Heatsink 2 To Insert New SCR Apply thin film of electrical joint compound to surfaces of SCR Install SCR so that it is 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 Heatsink 6 Locating Pin Proceed to replacement of other SCRs in the matched set SCR 2 and SCR 5 Shoring Bar Note You must replace all three SCRs of a matched set Heatsink 5 Heatsink 1 Locating Pins Shoring Bar 146 Rockwell Automation Publication 1560E UM051G EN P March 2015 Troubleshooting Chapter 9 Figure 63 Power Module Assembly one phase 2300V 600A Heatsink Assembly F Line connection Load connection Gate Driver Boards L Gate Driver Snubber Circuit and j Sharing Resistor Frame Assembly Figure 64 Power Module Assembly one phase 3300 4160V 600A Heatsink Assembly S n H 8 2 46 Line connection lt Load connection e o
112. e 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 125 Chapter 9 126 Troubleshooting IMPORTANT Inthe case of the 1503E refer to applicable documentation from OEM for troubleshooting or repair This manual should be utilized in conjunction with the OEM 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 Figure 47 Troubleshooting Flowchart Fault Displayed Define Nature of Trouble Motor will not Motor rotates but Motor stops Irregular Miscellaneous start no output does not accelerate while running Starts situations voltage to motor to full speed See Table 23 See Table 22 See Table 19 See Table 18 Rockwell Automation Publication 1560E UM051G EN P March 2015 Table 18 Fault Display Explanation Troubleshooting Chapter 9 Display Fault Code Possible Causes Possible Solutions Line Loss with phase indication 1 2 3 Missing supply phase Check for open line e g blown line fuse Motor not connected properly e Check for open load lead Improper or missing current or voltage Check current transfo
113. e al heehee hod ol ced Chapter 9 General Notes and Control Module Removal Voltage Feedback Circuit Tests Voltage Sensing Board Replacement Current Loop Power Supply Rockwell Automation Publication 1560E UM051G EN P March 2015 Maintenance Parameter Information 1560E and 1562E Relay Control Table of Contents Circuit Board Replacement 134 Power Circuit Troubleshooting 135 Thyristor SCR Testing 135 SCR Replacement Procedure 136 Snubber and Resistor Circuit 149 Snubber Resistor Replacement 151 Chapter 10 Safety and Prevent tv so dud ass Sole edad eS as ETUR 157 Periodic Inspection nos T e beoe eR ds 157 Contamination vu oco uerit eq ene aged dele gere c das 157 Vacu m Bottles du deo too OR eue edis 158 Terminals eee ub edet e EMI aa Br 158 OUS ee to rta 158 Solid State DeVICes euius s s up aetate uud 159 Static Sensitive ERA UE S QUE IR 159 Overload Maintenance After a Fault Condition 159 Final CheclcOUtu
114. e reverse order for removal TIP 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 The most straightforward means of checking the feedback circuits is to perform the snubber and resistor testing procedure found on page 149 Another possible test involves measuring the feedback voltages at the interface board see Figure 37 on page 75 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 approximately 1 volt rms It is important that the level in each phase is the same as the other phases within 1 If any voltage is well outside this range there may be a 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 131 Chapter9 Troubleshooting Voltage Sensing Board Replacement 132 Ensure there is no power to the equipme
115. e 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 fiber 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 MV SMC Flex has three heatsinks fitted with a thermistor to monitor temperature rise The circuitry on the gate driver board accepts the thermistor and drives a fiber 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 signaled to stop gating and initiate a temperature fault 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 fiber optic transmitters The gating signals are sent to the gate driver circuit board via fiber optic cables The interface board also receives temperature feedback from the gate driver board via fiber optic cable s If the heatsink temperature rises above a se
116. ecessary Failed control module Replace control module Starting Two or three power phases are missing Check power system Table 22 Irregular Starts Symptom Bypass contactor closes before motor is up to speed Failed control module Possible Causes Ramp time too short Motor characteristics cause Up to Speed sensing too early Check voltage sensing module and connections Replace control module Possible Solutions Increase ramp time parameter 18 Adjust parameter 114 higher no more than 5 at a time Motor is up to speed but bypass contactor is delayed in closing or does not close at all Ramp time too long Motor characteristics cause Up to Speed sensing too late or not at all Decrease ramp time Adjust parameter 114 lower no more than 5 at a time Rough start erratic current growling from the motor may see Line Faults Poor grounding of the power system or controller Poor power quality electrical noise harmonics VFD line notching Resolve ground issues Adjust parameter 117 higher Typical settings are 35 or 40 Not recommended to exceed 75 or go below 25 During a Pump Stop the motor takes more than 5 seconds to begin to decelerate or takes longer than the programmed stop time Rockwell Automation Publication 1560E UM051G EN P March 2015 Motor or pump characteristics do not match the default setting TIP Adjust param
117. ect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence P P IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARCFLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal
118. ed 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 Figure 45 Fault Display Faulted Fault 427 COMS LOSS P2 TIP 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 TIP 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 Corrective action must be taken before resetting the fault Rockwell Automation Publication 1560E UM051G EN P March 2015 107 Chapter7 Diagnostics Clear Fault Fault Buffer 108 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 Ifa human interface module is connected to the controller press the Stop button TIP A stop signal from the HIM will always stop the motor and dear the fault regardless of Logic Mask configuration Logic Mask parameter 87 equals o Ifa RESET push button is present the NO push button auxiliary contact can be connected to Option Input 2 terminal 15 Option Input 2 must be programmed for Clear Fault Cycle control p
119. eplate 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 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 20 75 C 4 167 F with a maximum humidity of 9596 non condensing to guard against damage to temperature sensitive components in the controller Rockwell Automation Publication 1560E UM051G EN P March 2015 51 Chapter2 Installation General Precautions Transportation and Handling Installation Site In addition to the precautions listed throughout this manual the following statements which are general to the system must be read and understood ATTENTION The controller contains ESD electrostatic discharge sensitive A 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 ATTENTION An incorrectly applied or installed controller can damage A components or reduce product life Wiring or application errors such as undersizin
120. er to Chapter 4 for the parameter settings and refer to 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 outputs are Aux 1 Aux 2 Aux 3 and Aux 4 All auxiliary contacts are programmable to the function found on page 95 If programmed to Network or Network NC they can be controlled over a Network Please see Table 16 on page 121 which defines the Logic Command Word Control TIP For MV applications some of the 1 0 are assigned to specific functions Please refer to Status Indication on page 30 for additional details A serial interface port DPI is provided as standard which allows connection to the Bulletin 20 HIM LCD human interface modules Figure 14 DPI Location pussSFPEES z Wa A ATTENTION Two peripheral devices can be connected to the DPI The DPI maximum output current through the DPI is 280 mA Rockwell Automation Publication 1560E UM051G EN P March 2015 29 Chapter1 Product Overview Programming Status Indication 30 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 Figure 15 Built in Keypad and LCD Port 5 DPI Communications Port 2 Ports 2 and 3 when two HIMs are connected with a splitter
121. eration ramp time is user adjustable from 0 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 1 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 15 Chapter 1 16 Product Overview Figure 1 Soft Start Percent Voltage 100 Initial Torque amp Start Time seconds Selectable Kickstart Selectable kickstart provides a power boost at start up that is user adjustable from 0 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 2 0 seconds Figure 2 Selectable Kickstart Kickstart 100 Initial Torque amp Start Run gt Time seconds Current Limit Start 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 50 600 of the motor s full load ampe
122. ernal DPI comm card connection Rockwell Automation Publication 1560E UM051G EN P March 2015 113 Chapter8 Communication Human Interface Module 14 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 TIP 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 10 Keypad Descriptions 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 ES Up Down Arrows Scroll through options increase decrease a value or toggle a bit Enter Enter a menu enter edit mode in a parameter screen or save a change to a parameter value TIP If a human interface module is disconnected from the SMC Flex controller while the Logic Mask is set to 1 a Coms Loss will occur TIP 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 progra
123. ess 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 Check voltage on each gate driver board by connecting DC voltmeter at TP4 and TP3 See Figure 39 The voltage should be 18 22V DC Locate the SMC Flex Interface board in the control section See Figure 37 and Figure 38 This circuit board has the control module mounted on it Locate the switch labeled 55 2 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 fiber optic cables to the gate driver boards A red LED beside 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 Figure 38 Interface PCB SW2 Close slide up to initiate test pulses Red LED ON when test pulses active Y LE Y F D1 m SW2 EI E E O 1 Rockwell Automation Publication 1560E UM051G EN P March 2015 Current loop CT Snubber terminal Cathode termina
124. eter 34 to between 20 and 30 not recommended to go above 40 Although the default settings accommodate the vast majority of applications these tuning parameters may require more than one adjustment to achieve optimal results Some parameters are affected by motor loading and power system conditions so one setting may not be optimal for all conditions 129 Chapter9 Troubleshooting Table 23 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 Lower kickstart time or turn off Accelerates too slow Starting time Decrease starting time 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 with Soft Stop option Time setting Verify the programmed stopping time and correct if necessary Motor stops
125. ette San kero Fault Odes Mr e EI Me c Fault and Alarm Auxiliary Indication Fault Definitions Chapter 8 OVERVIEW e ov E RISO TENES SUCHT DETTA Communication Human Interface Module Keypad Description s a ana ege Connecting the Human Interface Module to the Controller HIM Control Enable Control En ble 22 60 vsu basa ia u d aga Loss of Communication and Network SMG Flex Specific Inforimati ness Default Input Output Variable Input Output Configuration SMG Flex Bit Identification Reference Feedback Parameter Information Scale Factors for PLC Communication Read turus petri eH E Write Example ecce ce RH e ee Display Text Unit Equivalents Configuring DataLinks e mesas oes parame Rules for Using DataLinks 2425 ace ebore e Updating es tarda ney et
126. evel as a percentage of line voltage and delay period Overvoltage Fault Level Overvoltage Fault Delay Overvoltage Alarm Level Overvoltage Alarm Delay Unbalance Allows the user to set the current unbalance trip level and delay period Unbalance Fault Level Unbalance Fault Delay Unbalance Alarm Level Unbalance Alarm Delay Jam Q Determines the trip level as a percentage of motor full load current and delay period Jam Fault Level Jam Fault Delay Jam Alarm Level Jam Alarm Delay Stall Allows the user to set the stall delay time Stall Delay Ground Fault 3 Allows the user to enable the ground fault level in amps delay time and inhibit time 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 prc PTC Enable Allows the user to connect a PTC to the SMC and enable a fault when it becomes active Phase Reversal 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 Restarts Restarts Per Hour Allows the user to determine the maximum number of Restart Attempts restarts per hour the unit can experience and delay time Restart Delay between consecutive starts 1 The delay time must be set to a value gre
127. eys to access the desired information vy Volts Phase Press the Enter key to view that parameter Volt nma F P 2 Volts Phase B C Volt F P 3 Volts Phase C A Hitt Volt F Gig Pit 4 Current Phase A Amps F P 5 Current Phase B Amps F P 6 Current Phase C Amps F Gig P 7 Watt Meter KW F Gig P 8 Kilowatt Hours KWH F P 9 Elapsed Time Hour F 10 Meter Heset No F 11 Power Factor F P 12 Mtr Therm Usage MTU The metering values that are displayed on the SMC Flex can be modified to show you desired values by accessing Main Menu Preferences 100 Rockwell Automation Publication 1560E UM051G EN P March 2015 Overview Human Interface Module Chapter 6 Options The SMC Flex controller offers a variety of unique control programming and communication options that provide enhanced capabilities refer to Chapter 1 for brief descriptions of each option TIP Only one option can reside in a controller 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 118 of C
128. ff 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 When a Start is executed the Aux 4 contact closes which 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 A stop command can be generated via DPI or by opening CR depending on the control mode 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 Bulletin 1560E DPI Control With Controlled Stop The control scheme shown in Figure 27 allows the MV SMC Flex to be controlled using DPI Drive Programming Interface Refer to Table 16 page 121 for Logic Command Word bits assignment for DPI control 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
129. g Appendix E Recommended Torque Values General Plenum Layout for ArcShield Line up Cabinet Preparation Chimney Placement on Structure Appendix F Power Stacks su ayl y Re eccl ui TR YAN Yuma E us Appendix G PSCCESSOLIES ix er devoret a aa eed Rockwell Automation Publication 1560E UM051G EN P March 2015 Service Procedure Preface For your convenience the Rockwell Automation Global Manufacturing Solutions CSM provides an efficient and convenient method of servicing medium voltage products Contact your local area support office to make arrangements to have a qualified service representative come to your facility A complete listing of Area Support Offices may be obtained by calling your local Rockwell Automation Distributor or Sales Office TIP 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 11 Preface Notes 12 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 Manual Objectives Documentation Description Chapter 1 Product Overview This manual is intended for use by personnel
130. g the Front of the Plenum Sections on Extension Elbow to Plenum page 195 the last Plenum at the exhaust side of the line up has the front duct section removed This allows access to fastener holes in order to mount the Li Ine up Extension Elbow components see Figure 99 Figure 99 Optional Extension Elbow with Vertical Extension Right side exit Z CA Last Plenum in Line up f remains open for installation of Extension Assembly After the Extension Elbow assembly is attached through the fastener holes on the inside flange of the Plenum the front duct section can be replaced and fastened through the holes on the outside flanges Rockwell Automation Publication 1560E UM051G EN P March 2015 197 AppendixD ArcShield Plenum Installation Instructions STEP 7 Additional The Extension Elbow Assembly must have additional mounting support Mounting Support 90 Elbow Section Approximate weight 64 kg 142 Ib 36 in Extension Assembly Approximate weight 51 kg 112 Ib Figure 100 shows an example of how the Extension Elbow Sections can be supported by suspension from a high ceiling Points A B and C show where chains or high tension cables may be connected Figure 100 Completed Assembly for optional vertical exit Plenum Right hand exit A B C A A A
131. g the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system A ATTENTION 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 result in personal injury and or equipment damage The controller must be transported on a pallet or via use of the lifting angles supplied as part of all 2 3 m 90 in high cabinets or frame units ATTENTION Ensure that the load rating of the lifting device is sufficient to A 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 installation site Once at the final site the pipe rolling technique can be used to place the cabinet in the desired position A ATTENTION 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 Consider the following when selecting the installation site A The operating ambient temperature should be between 0 40 C 32 104 F for NEMA Ty
132. h all LCD applicable DPI interfaces Regardless of the type of interface being used the information below can be used to configure the rest of the system Rockwell Automation Publication 1560E UM051G EN P March 2015 Default Input Output Configuration Variable Input Output Configuration Communication Chapter8 The default configuration for I O is 4 bytes in and 4 bytes out TX 4 bytes RX 4 bytes and is arranged according to the following table Table 13 Default Input Output Configuration Produced Data Status Consumed Data Control Word 0 Logic Status Logic Command Word 1 Feedback Reference 1 The feedback word is always Current in Phase A 2 Thereference word is not used with the SMC Flex however the space must be reserved The SMC Flex supports 16 bit DataLinks Therefore the device can be 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 14 Variable Input Output Configuration Rx Size Tx Size Logic Status Reference Data Links Byte Byte Command Feedback 16 bit 16 bit A B C D 4 4 X X 8 8 X X X 12 12 X X X X 16 16 X X X X X 20 20 X X X X X X To configure DataLinks refer to Configuring DataLinks on page 122 Rockwell Automation Publication 1560E UM051G EN P March 2015 119 Chapter 8 Communication SMC Flex Bit Identif
133. h may be misinterpreted by the MV SMC Flex control system 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 ATTENTION 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 Hlex 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 65 Chapter2 Installation EMC Compliance product in domestic environments may cause radio interference in which case ATTENTION This product has been designed for Class A equipment Use of the the installer may need to employ additional mitigation methods The following guidelines are provided for EMC installation compliance End
134. hapter 8 for instructions 2 The control terminals must be wired according to Figure 36 on page 74 and Figure 37 on page 75 Option Action Operation Standard Soft Stop The green start button when pressed will commence Current Limit motor acceleration to full speed Voltage The red stop button when pressed will provide a coast Linear Speed stop and or reset a fault The jog button when pressed will initiate the programmed maneuver Preset Slow Speed The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop The jog button is not active for Preset Slow Speed Slow Speed cannot be operated via the HIM Rockwell Automation Publication 1560E UM051G EN P March 2015 101 Chapter6 Options Option Action Operation Pump Control The green start button when pressed will commence motor acceleration to full speed Pump Control 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 Braking Control The green start button when pressed will commence motor acceleration to full speed Smart Motor Braking The red stop button when pressed will provide a coast Stop and or reset a fault The jog button when pressed will initiate a brake stop The green start but
135. harge level of power during periods when the SCR power modules are inactive this allows SCR gating while the snubber circuit is being charged Figure 49 Current Loop Power Supply x H4 H3 H2 HI X2 gt lt 3 L TE 5 H eie eie ele SIISISISIISIS I 5d To Interface Board Phase A Phase B Phase C NEN 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 133 Chapter9 Troubleshooting 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 destroyed by static charges generated by friction of materials made with synthetic fibres Use of damaged circuit boards may also damage related components A grounding wrist strap is recommended for handling sensitive circuit boards ATTENTION Some circuit boards may contain CMOS components which can be 1 Remo
136. he 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 to protect the power electronics from any voltage transients due to opening the motor circuits 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 73 allows the MV SMC Flex to be controlled using DPI Drive Programming Interface Refer to Table 16 on page 121 for Logic Command Word bits assignment for DPI control 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 ofthe SMC Flex module is energized allowing a start command to be executed via DPI The Aux 4 contact closes energizing which closes the main contactor When the motor approaches rated speed the SM
137. he Soft Start it will automatically switch to providing full voltage to the motor 2 For ramp times greater than 30 s set Ramp Time to zero and program Ramp Time E parameter 129 to the new time Do not exceed the thermal capacity ofthe controller 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 0 3052 Programs the time period that the controller will hold the fixed reduced output voltage before switching to full voltage Current Limit Level This parameter provides adjustability for the reduced output voltage level provided to the motor 50 60096 full load current Kickstart Time 0 0 2 05 A boost of current is provided to the motor for the programmed time period Kickstart Level 0 90 locked rotor torque Adjusts the amount of current applied to the motor during the kickstart time 1 Ifthe controller senses that the motor has reached full speed before completing the Soft Start it will automatically switch to providing full voltage to the motor 2 For ramp times greater than 30 s set Ramp Time to zero and program Ramp Time E parameter 129 to the new time Do not exceed the thermal capacity ofthe controller Rockwell Automation Publication 1560E UM051G EN P March 2015 91 Chapter4 Programming Dual Ra
138. he assembly Place the heatsink on a cart to aid in its transport Place the module on a flat surface see Figure 53 Figure 56 and Figure 62 When tilting the module ensure that wires are not damaged Rockwell Automation Publication 1560E UM051G EN P March 2015 Troubleshooting Chapter 9 B Replace SCRs TIP For 600A units it is mandatory that the entire stack be replaced The high damping force requires the factory to tighten the clamp hardware See Appendix F Spare Parts for part numbers Proceed to step C TIP Refer to Figure 50 to Figure 62 positions are numbered in succession from the top down The SCR cathode is at the end with the wide flange up or down depending on the specific assembly Note the orientation before removing the SCRs and refer to the detail in the appropriate figure in this chapter ATTENTION The SCRs must be oriented correctly with the cathode end either 1 Remove the shorting bar Measure the resistance between adjacent heatsinks to determine which SCR s is are shorted Assemblies with four or six SCRs must use matched sets See Figure 54 and Figure 60 for the position of the matched sets Ifan SCR from each set is shorted all of the SCRs in the module must be replaced A properly functioning SCR will measure in excess of 100 kohms from anode to cathode and 10 40 from gate to cathode IMPORTANT DONOTloosen any of the nuts on the fiber rods on either side of the
139. ial 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 ofthe SMC Flex module is energized allowing start and stop maneuvers to be executed via DPI When a Start is executed the Aux 4 contact closes energizing both M IV and MCX The line contactor closes and the unit initiates a start sequence When the motor approaches rated speed the SMC Flex module closes Aux 1 energizing which closes the bypass contactor When Stop is executed the unit opens Aux 1 The bypass contactor opens and the unit initiates a controlled stop sequence followed by opening of Aux 4 which opens the line contactor Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 An uncontrolled or coast stop can be achieved via DPI or by opening the connection on terminal 18 i e by pressing Coast Stop button When using the optional HIM pressing the Jog button will initiate the optional stop maneuver and pressing the O button will initiate a coast stop To run in Local mode the CR contact is used to initiate a start and stop sequence similar to Figure 21 An uncontrolled or coast stop is achieved by opening the connection on terminal 17 This contact should remain open to ensure all hold in contacts clear to prevent a re
140. ication Table 15 Logic Status Word Bit Status Description 15 14 13 12 11 10 6151413 2 1 0 X Enabled 1 Control Power Applied 0 No Control Power X Running 1 Power Applied to Motor 0 Power not Applied to Motor X Phasing 1 ABC Phasing 0 CBA Phasing X Phasing Active 1 3 phase is valid 0 No valid 3 phase is detected X Starting Accel 1 Performing a Start Maneuver 0 Not performing a Start Maneuver X Stopping Decel 1 Performing Stop Maneuver 0 Not performing a Stop Maneuver X Alarm 1 Alarm Present 0 No Alarm Present Fault 1 Fault Condition Exists 0 No Fault Condition At Speed 1 Full Voltage Applied 0 Not Full Voltage Applied Start Isolation 1 Start Isolation Contactor Enabled 0 Start Isolation Contactor Disabled X Bypass 1 Bypass Contactor Enabled 0 Bypass Contactor Disabled X Ready 1 Ready 0 Not Ready X X Option 1 Input 1 Input Active 0 Input Inactive X X Option 2 Input 1 Input Active 0 Input Inactive Bits 12 15 Not Used 120 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 Table 16 Logic Command Word Control Communication Chapter8 Bit Status Description 15 14 13 12 11 10 9
141. ications only Motor PTC A motor PTC can be connected to terminals 23 and 24 If the PTC parameter is enabled and the PTC trips the SMC Flex will trip and indicate a Motor PTC fault Open Bypass Power Pole bypass contacts are monitored for proper operation In the event of a contact failure the SMC Flex will 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 Voltage unbalance is detected by monitoring the three phase supply voltages The formula used to calculate the percentage voltage unbalance is as follows Vy 100 Va V V Percent voltage unbalance Vq Maximum voltage deviation from the average voltage V4 Average voltage The controller will shut down when the calculated voltage unbalance reaches the user programmed trip percentages Overvoltage and Undervoltage Protection 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 motors full load current rating can be programmed Overload Protection
142. ics 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 compensation takes place when the Preset Slow Speed option is used Notes 1 Ifthe MV SMC Flex is used to control a multi speed motor or 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 11796 of the programmed FLC Figure 9 and Figure 10 provide the overload trip curves for the available trip classes Rockwell Automation Publication 1560E UM051G EN P March 2015 21 Chapter1 Product Overview Figure 9 Overload Trip Curves Class 10 1000 0 10000 0 100 0 1000 0 10 0 100 0 10 0 Approximate Trip Time Seconds Approximate Trip Time Seconds 1 2 3 4 52678910 Approximate trip time for 3 phase balanced condition from cold start Class 15 Class 20 Class 30 40000 0 10000 0 000 0 100 0 100 0 10 0 10 0 Approximate Trip Time Seconds Approximate Trip Time Seconds 1 3 4 5 6 78910 T UR 3 4 5678910 2 2 Multiples of FLC Multiples of FLC Multiples of RC 5 6 78910 Approximate trip time for 3 phase balanced condition from hot start
143. iliary contacts energizing which closes the bypass contactor The motor then runs at full line voltage When the Stop button is pressed the CR 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 Bulletin 1562E Basic Control With Controlled Stop When wired as shown in Figure 21 the controller operates in much the same manner as in Figure 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 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 37 Chapter 1 38 Product Overview 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
144. in this chapter Option Parameter Range Pump Control Pump Control SMC Option Pump Control This parameter identifies the type of control present and is not user programmable Pump Stop Time 0101205 Allows the user to set the time period for the pump stopping function Starting Mode Pump Start Soft Start Current Limit Allows the user to program the SMC Start Full Voltage Flex controller for the type of starting that best fits the application Braking Control SMB Smart Motor Braking SMC Option Braking Control This parameter identifies the 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 40096 of full load current 1 Braking Control is not offered for standard use in MV applications Please consult factory for further assistance 2 All braking stopping current settings in the range of 1 100 will provide 100 braking current to the motor Rockwell Automation Publication 1560E UM051G EN P March 2015 103 Chapter 6 104 Options Option Braking Control cont Parameter Range 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
145. ing Control Options The Braking Control options 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 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 Figure 18 and Figure 19 Typical MV SMC Flex Power System Power Module The controller consists of 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 33 Chapter 1 34 Product Overview 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 lin
146. int compound to surfaces of SCR Install SCR so that it is 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 SCR 2 SCR 1 Shoring Bar Hardware Heatsink 3 Heatsink 1 Locating Pin Rockwell Automation Publication 1560E UM051G EN P March 2015 Chapter 9 11 Chapter9 Troubleshooting Figure 54 Power Module Assembly one phase 3300 4160V 180 360A E m Heatsink 1 SCR 1 Heatsink 2 R2 Heatsink3 SCR3 e Heatsink4 1 SCR 4 Heatsink5 Note SCR 1 and SCR 3 are a matched set SCR 2 and SCR 4 are a matched set Figure 55 Heatsink Clamp Do not loosen Center Nut c WI Locking Nut o not adjust I Indicating Washer To remove clamp pressure loosen lower center nut so that the gap between the damp surface and the heatsink is approximately 6 mm 0 25 in 142 Rockwell Automation Publication 1560E UM051G EN P March 2015 Troubleshooting Chapter 9 Figure 56 Removal of SCR 2 and SCR 4 3300 4160V 180 360A
147. intenance of Solid State Control state controls may result in damage to the control or test equipment or ATTENTION Use of other than factory recommended test equipment for solid unintended actuation of the controlled equipment Static Sensitive Items While performing maintenance 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 ofa control malfunction Rockwell Automation Publication 1560E UM051G EN P March 2015 159 Chapter 10 160 Maintenance 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
148. ion 1560E UM051G EN P March 2015 Recommended Torque Values Plenum Bracing Appendix D ArcShield Plenum Installation Instructions The following instructions are provided to ensure the proper installation and function of plenum components supplied with ArcShield enclosures Refer to Appendix C for additional information related to ArcShield plenums before attempting to follow these instructions 1 4 20 Thread Fasteners 7 5 Nem 6 lbeft 5 16 18 Thread Fasteners 14 Nem 11 Ibeft Bracing of the plenum must be able to withstand the dynamic forces of the arc fault as well as any other vibration or seismic effects associated with the installation Most of this force will be in the direction opposite to where the relief vent exits The amount of bracing will depend on how the plenum is supported at its exit as well as the distance from the end of the cabinets to the exit vent A flange is available for installing hangers for supporting the weight of the plenum The plenum extension has holes for mechanical support Weight per unit length of Rockwell supplied plenum 28 kg m 19 lb ft Installer is responsible for ensuring that the plenum extension has sufficient support to resist the effect of vibrations and seismic effects IMPORTANT Planthe location where the plenum will exhaust refer to Appendix C Be aware that equipment in the area ofthe plenum exhaust may be damaged or destroyed The plenum exhaust area is
149. ion 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 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 19996 of the programmed motor voltage Trip delay time can be adjusted from 0 99 seconds TIP For medium voltage applications overvoltage protection should be set from 100 115 An alarm pre fault indication level programmed 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 6 The 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 2596 of the line voltages Trip delay time can be adjusted from 0 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 5 Undervoltage overvoltage and v
150. ioning Checks 71 Preliminary Check siiri Sa hun ap 72 Programming y s a yaa hum qaa ua ih ca asas 72 MV SMC Flex Module 72 Hi Pot and Megger TOS in vec ve veh pir http V 73 PowetSupply Tua S be dal 76 Control Function Tests 79 Resistance pasasqa MM ES n pusupa 80 Voltage Sensing Module 80 Sart Prd PER 81 Chapter 4 Ov rvleWononcrlixde d 4 ee 83 Keypad DescrpHol icu Pk AS 83 Programming Menu d duae ee eens REPAS ss ss 83 Password inattention shat aan te aqa 87 Parameter Management uk maa dade id ee neus bend 88 Random Access Memory 88 Read Only Memory ROM 88 Electrically Erasable Programmable Read Only Memory EEPROM 89 Using Parameter Management with DPI 89 Parameter Modification 90 SOLUS tabs s pa oleh uqa late heel h kaya eu 91 Current Limit Start Sais Ae 91 Dual Ramp SOY n 92 Full Voltage Starti o vo trepidi 93 Lincar speed c
151. 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 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 1560E and 1562E Relay Control Appendix B Bulletin 1560E DPI Control With Controlled Stop The control scheme shown in Figure 78 allows the MV SMC Flex to be controlled using DPI Drive Programming Interface Refer to Table 16 page 121 for Logic Command Word bits assignment for DPI control 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 ofthe SMC Flex module is energized allowing start and stop maneuvers to be executed via DPI When a Start is executed the Aux 4 contact closes which 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 as the motor approaches rated speed When a Stop is executed the unit opens Aux 1 which drops the BC relay and opens the bypass contactor The unit initiates a controlled sto
152. it to be opened until the main power cell door is opened 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 specifications 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 10 x 51 mm 0 375 x 2 in which runs the entire length of the equipment in the center back side be reconnected A mechanical lug for 8 10 AWG or 6 250 MCM 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 0 055 for power ground bus connection Power and Control Wiring Controllers consisting of two or more sections will require that the power and control wiring be connected per the schematic drawings provided
153. ivalents Configuring DataLinks 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 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 17 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 A Table 17 Display Text Unit Equivalents Text Descriptor Numerical Equivalent Disabled 0 Class10 1 Class 15 2 Class 20 3 Class 30 4 DataLinks are supported in the SMC Flex A DataLink is a 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 DataL ink Parameter settings in the SMC determine the data passed thr
154. justs the initial reduced output voltage level for the first Soft Start set up 0 90 locked rotor torque Dual Ramp Start Mode 20 This selects the start motor 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 set up 0 305 9 Dual Ramp Initial Torque 2 The initial reduced output voltage level for the second Start set up is established and adjusted with this parameter 1 TheDual Ramp feature is available on the standard controller 2 Kickstart can be programmed for both start modes 0 90 locked rotor torque 3 For ramp times greater than 30 s set Ramp Time 2 to zero and program Start Time 2E parameter 130 for the new time Do not exceed the thermal capacity of the controller Rockwell Automation Publication 1560E UM051G EN P March 2015 Full Voltage Start Linear Speed Stop Control Programming Chapter 4 The SMC Flex controller may be programmed to provide a full voltage start output voltage to the motor reaches full voltage within 1 4 second with the following programming Parameter Option Starting Mode Full Voltage This must be programmed for Full Voltage The SMC Flex provides the user the ability to control the motor speed during starting and stopping maneuvers A tach input is required as specified in Linear Speed Acceleration and Deceleration on page 19
155. king Current Overload Class Service Factor Motor FLC CT Ratio Overload Reset Aux Config Aux2 Config Aux3 Config Aux4 Config Backspin Timer Parameter Mgt Dual Ramp Option 2 Input Dual Ramp Starting Mode 2 Ramp Time 2 Initial Torque 2 Cur Limit Lvl 2 Kickstart Time 2 Kickstart Lvl 2 Parameter Mgt 4 Preset SS Option 2 Input Preset SS Slow Speed Sel Slow Speed Dir Slow Speed Acc Slow Running Cur Parameter Mgt 4 Option 2 Input Accu Stop Braking Current Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cur Stopping Current Parameter Mgt 4 Parameter 7 3 Motor Protection Overload Overload Class Jam F Lvl Service Factor Jam F Dly Motor FLC Jam A Lvl Overload Reset Jam A Dly Overload A Lvl Parameter Mgt 4 arameter Mgt 4 Stall Dly Parameter Mgt 4 Ground Fault Gnd Fit Enable Gnd Fit Lvl Gnd Fit Dly Gnd Fit Inh Time Gnd Fit A Enable Gnd Fit A Lvl Gnd Fit A Dly Parameter Mgt 4 Underload Underload F Lvl Underload F Dly Underload A Lvl Underload A Dly arameter Mgt 4 Undervoltage Undervolt F Lvl Undervolt F Dly Undervolt A Lvl Undervolt A Dly arameter Mgt 4 PTC Overvoltage PTC Enable Overvolt F Lvl Parameter Mgt 4 Overvolt F Dly Overvolt A Lvl Overvolt A Dly Parameter Mgt 4 Phase Reversal Phase Reversal Parameter Mgt 4 Unbalance Unbalance F Lvl Restart Unbalance F
156. l 6 Commissioning Procedure Chapter3 With the gate pulses on check the voltage again on each gate driver board as described in Step 4 above The voltage should be 4 5V DC 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 120V AC or 220 240V AC Plug the unit into the power source and plug the green connector into J1 on each of the gate driver boards see Figure 39 Figure 39 Test Power Application on Gate Driver Board Gate signal Temperature signal fiber optic receiver fiber optic transmitter Plug in test power supply Yellow LED Thermistor connector 5V test point 3 MS KUU UL tH H JI T3 TP4 d RXT RQ TP2 1 A JI Gate signal 1 test point Lop 3 200 1 I T n Common test point 20V test point Overvoltage sense terminal Theyellow 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 While the gate pulses are still on check the voltage
157. le 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 39 Chapter 1 40 Product Overview Bulletin 1560E Basic Control With Controlled Stop When wired as shown in Figure 25 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 It is 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 ofthe 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 is initiated and remain closed until it has sensed the motor has stopped following an option stop maneuver Bulletin 1560E DPI Control Controlled Start only The control scheme shown in Figure 26 allows the MV SMC Flex to be controlled using DPI Refer to Table 16 on page 121 for Logic Command Word bits assignment for DPI control This special usage of DPI includes provisions for a Local mode of control as well With the Local O
158. le Plenum over an MV enclosure the front duct section Plenum must first be removed This is shown in Figure 87 Figure 87 Removing Front Duct Section Front Duct Section Components 192 Rockwell Automation Publication 1560E UM051G EN P March 2015 ArcShield Plenum Installation Instructions Appendix D Cabinet Preparation In preparation for mounting Plenum remove 1 4 20 fasteners from the Relief vent on the top of the MV enclosure Leave the 4 corner fasteners in place see Figure 89 Figure 88 Typical Relief Vent Fasteners top view Figure 89 Relief Vent Relief Vent PU F 5 i o Do not remove olo 4 corner o fasteners Remove Fasteners The Plenums are designed to fit over the fastener heads at the corners of the Relief vent The corner fasteners are required to secure the Relief vent during installation Plenum Placement on Structure Once the Plenum has been lifted in place directly over the relief vent shown in Figure 90 all 1 4 20 fasteners removed in Cabinet Preparation above are replaced to attach the Plenum to the top of the enclosure Use hand tools only Rockwell Automation Publication 1560E UM051G EN P March 2015 193 AppendixD ArcShield Plenum Installation Instructions Figure 90 Plenum Placement Use recommended torque value for 1 4 20 fasteners
159. le 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 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 provides the control terminal wire capacity and the tightening torque requirements Each control terminal will accept a maximum of two wires Table 2 Control Wiring and Tightening Torque Wire Size 0 70 2 5 mm 18 to 14 AWG Torque 0 6 Nem 5 Ib in Rockwell Automation Publication 1560E UM051G EN P March 2015 67 Chapter2 Installation Control Terminal As shown in Figure 35 the SMC Flex controller contains 24 control terminals on the front of the controller Designations Figure 35 SMC Flex Controller Control Terminals LG Sagan K K Terminal Description Terminal Description Number Number 11 Control Power Input 23
160. ler ATTENTION For overload protection it is critical that the data be entered as it appears on the motor nameplate Motor Data Entry In the Program mode enter the correct values into the Overload group Description Option Display Overload Class 2 Disable 10 15 20 30 Fab PH 44 The factor default setting disables overload Overload Class protection To enable it enter the desired trip class Class in this parameter Service Factor 2 0 01 1 99 F Gia P 45 Enter the value from the motor s nameplate Service Factor Motor 3 1 0 2200A PH 46 Enter the value from the motor s nameplate Motor FLC zi Amps Overload Reset 1 2 Manual Auto P 47 Allows the user to select either a manual or auto Overload Reset reset after an overload Motor Connection 2 4 Line Delta Fo P 15 Enter the type of motor being connected to the SMC Motor Connection Flex Line or Delta Line Voltage 3 1 10 000V Enter the system voltage in this parameter This Line Voltage must be done to ensure optimum motor Volt performance and correct operation of undervoltage and overvoltage protection 1 NJ Found in Basic Set Up programming group 3 4 Found in Overload programming group Only one location needs to be programmed Rockwell Automation Publication 1560E UM051G EN P March 2015 Refer to the SMC Flex controller nameplate
161. ller 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 180 360 A 2400 4160V 2 A combination ofa one high full voltage non reversing FVNR cabinet and a 1560E unit 600 A 2400 4160V and 180 360 600 A 5500 6900V Rockwell Automation Publication 1560E UM051G EN P March 2015 Installation Chapter2 To make power connections for a two high cabinet refer to Figure 28 to Figure 30 and Publication 1500 UM055 EN P Chapter 2 be installed in accordance with instructions in Publication 1500 UM055 EN P ATTENTION Bulletin 1562E units provided with an arc resistant enclosure must Failure to do so may result in damage to equipment or personal injury 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 e Make load connections at the 1512 CT terminals Bulletin 1560E Refer to Figure 31 to Figure 33 to make power connection for a 1560E unit depending on the rating of the unit e Make line connections to the line connection terminals e Make load connections to the current transformer terminals TIP The CT assembly can be oriented to allow either top or bottom load cable exit Rockwell Automation Publication 1560E UM051G EN P March 2015 55 Chapter2 Installation Bulletin 1562E Figure
162. m 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 D for a listing of human interface module catalog numbers that are compatible with the controller TIP Bulletin 20 HIM Rev3 002 or later must be utilized with the SMC Flex TIP Extension cables are available up to a maximum of 10 m in total length TIP A maximum of two HIM modules can be installed Rockwell Automation Publication 1560E UM051G EN P March 2015 Communication Chapter8 The control panel provides the operator interface to the controller 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 intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements ATTENTION The external HIM has a similar programming operation to the built in programmer but note that differences do exist ATTENTION The Bulletin 20 HIM interface module s stop p
163. ment 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 Please 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
164. mitted by fiber optic cable through the interface board to the control module When an overtemperature condition exists gt 85 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 Refer to Troubleshooting on page 125 for instructions Power monitoring parameters include Three phase current Three phase voltage e Power in MW e Power usage in MWh Power factor e Motor thermal capacity usage e Elapsed time Motor speed full speed 96 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 1 0 Communication Product Overview Chapter 1 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 ref
165. mmended torque value for 1 4 20fasteners TIP Use silicone caulking generously to fill any air gaps once the chimney has been securely mounted in place Rockwell Automation Publication 1560E UM051G EN P March 2015 201 AppendixE ArcShield Chimney Installation Instructions Notes 202 Rockwell Automation Publication 1560E UM051G EN P March 2015 Power Stacks Spare Parts Table 26 Replacement scs Appendix F SMCRated Description Part Number Voltage max 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 1 Due to stringent torquing specifications for 600A power stacks individual SCRs are not replaceable It is mandatory that the entire power stack be replaced Table 27 Complete Power Stacks 3 per controller SMCRated Part Number Voltage 1 180 360 600 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 1 Due to stringent torquing specifications for 600A power stacks individual SCRs are
166. mmunications 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 9 Communication Interfaces Protocol Type Cat No User Manual DeviceNet 20 COMM D 20 002 ControlNet 20 COMM C 20COMM UMO003 EN P Remote 1 0 20 COMM R 20COMM UM004 EN P Profibus 20 COMM P 20 0MM UM006 EN P 5 485 20 5 20COMM UMO005 EN P InterBus 20 COMM I 20COMM UMO007 EN P EtherNet IP 20 COMM E 20COMM UM010 EN P RS485 HVAC 20 COMM H 20COMM UMO009 EN P LonWorks 20 COMM L 20COMM UM008 EN P ControlNet Fiber 20 COMM Q 20COMM UM003 EN P 1 The final letter in a publication number prior to the language indicator e g here EN for English denotes revision level of user manual Example Publication 2000MM UMOO2C 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 side 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 int
167. motor shaft Repair or replace motor Broken belts tool bits etc Check machine Pump cavitation Check pump system Jam 24 Motor current has exceeded the user e Correct source of jam programmed jam level Check programmed time value Stall 25 Motor has not reached full speed by the end of Correct source of stall the programmed ramp time Phase Reversal 26 Incoming supply voltage is not in the expected Check power wiring ABC sequence Disable protection if not needed Comm Loss 27 28 29 Communication disconnection at the serial port Check fora communication cable disconnection to the SMC Flex controller Network 30 31 32 DPI network loss Reconnect for each DPI connected device Ground Fault 33 Ground fault current level has exceeded Check power system and motor correct if programmed values necessary Check programmed ground fault levels to match application requirements Excess Starts Hr 34 Number of starts in a one hour period has Wait an appropriate amount of time to restart exceeded the value programmed Consult factory if more than 2 starts per hour are required Power Loss with phase indication 35 36 37 Missing supply phase as indicated Check for open line i e blown line fuse Loss of feedback Check CT connections replace Interface board HAL ID 38 Faulty interface Check ribbon cable connections between interface board and control module Check current loop system Replace interf
168. mp Start 92 The SMC Flex controller provides the user with the ability to select between two Start settings The parameters below are available in the Setup programming mode To obtain Dual Ramp control Ramp 1 is located in the Basic Setup and Ramp 2 is located in the Option 2 Input Dual Ramp Parameter Set Up The user must select the Set up programming mode to obtain access to the Dual Ramp parameters Option Basic Set up Starting Mode Set up as stated in previous pages Option Input 2 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 combination is determined by a hard contact input to terminal 15 When this input signal is low ramp time initial torque are selected When input signal is high ramp time 2 initial torque 2 are selected Once the Option 2 input has been set to 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 set up 0 30s Basic Set up Initial Torque This parameter establishes and ad
169. n 1560E UM051G EN P March 2015 Troubleshooting Chapter 9 Figure 59 Power Module Assembly one phase with Boards and Frame Removed 5500 6900V 180 360A Module retaining hardware locations 4 Figure 60 6900V Heatsink Assembly 180 360A Positioned on bench for SCR replacement SCR4 SCR3 SCR5 Note SCR 1 SCR 2 and SCR 5 are a matched set SCR 3 SCR 4 and SCR 6 are a matched set Heatsink 1 Heatsink 2 Heatsink 3 Heatsink 4 Heatsink 7 Heatsink 6 Heatsink 5 EW g Spacer block must be flat Minimum Height 30 mm 1 25 in Maximum Width 200 mm 8 0 in Minimum Length 400 mm 16 0 in Rockwell Automation Publication 1560E UM051G EN P March 2015 145 Chapter9 Troubleshooting Figure 61 6900V SCR Replacement 180 360A Do not loosen To remove clamp pressure H Center Nut Loosen lower center nut so that the gap between the clamp surface and the heatsink is approximately 6 mm 0 25 in Locking Nut Do not adjust A21 mm open en
170. n 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 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 158 Rockwell Automation Publication 1560E UM051G EN P March 2015 Maintenance Chapter 10 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 Ma
171. n engineered orders or when option modules or customer requirements dictate different settings IMPORTANT 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 Pump Application Considerations on page 32 of Chapter 1 72 Rockwell Automation Publication 1560E UM051G EN P March 2015 Hi Pot and Megger Test Commissioning Procedure Chapter 3 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 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 Megger a 5000 volt type is recommended 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
172. ndix F Notes 1 Reference only 2 1503 For OEM products refer to OEM supplied documentation for specific spare parts list 1560 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 Documentation on page 13 Rockwell Automation Publication 1560E UM051G EN P March 2015 205 AppendixF Parts Notes 206 Rockwell Automation Publication 1560E UM051G EN P March 2015 Appendix G Accessories Accessories Table 31 Accessories Description Description Used With Catalog Number HIM Remote Door Mounted 20 HIM C3 IP66 Type 4 12 Programmer Only Communication Modules Remote 1 0 20 COMM R RS 485 DF 1 20 COMM S DeviceNet 20 COMM D ControlNet 20 COMM C EtherNet IP 20 COMM E Profibus 20 COMM P InterBus 2 20 0 LonWorks 20 COMM L ControlNet Fiber 20 COMM Q RS485 HVAC 20 COMM H Rockwell Automation Publication 1560E UM051G EN P March 2015 207 AppendixG Accessories Notes 208 Rockwell Automation Publication 1560E UM051G EN P March 2015 Numerics 1503E OEM Controller 14 1560E Retrofit Controller 14 Relay Control 169 1562E Combination Controller 14 Relay Control 169 A Accessories 207 Alarm Auxiliary Indication 109 ArcShield Unit Chimney Installation Instructions 199 Design 183 Overview 183 Plenum Installation Instructions
173. njury IMPORTANT Forthe 1503E refer to applicable documentation from OEM 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 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 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 ATTENTION The Canadian Electrical Code CEC National Electrical Code NEC After unpacking the material check the item s received against the bill of lading to ensure that the nam
174. 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 73 Chapter3 Commissioning Procedure Figure 36 Typical MV SMC Flex Power System Wiring Diagram 5500 6900V shown TO SMC Flex Ters MODULE i a B lt elo b fo E 2 CTINPUTS 5 QUT 8 GATE TRANSMITTERS test PHASE A PHASE B PHASE C TEMP IN I2 z z zm FE S sic EB
175. not replaceable It is mandatory that the entire power stack be replaced Table 28 Snubber Capacitor Snubber Resistor Snubber Capacitor Part Number All voltages Snubber Resistor 180 360 Amp 80025 812 02 R 0 68 pF 600 Amp 80025 812 01 R 1 0 uF Part Number 1500 2500 4800V 180 360 Amp 80025 588 02 R 20 0 100W 600 Amp 80025 642 08 R 15 0 225W 7200V 80025 642 09 R 30 0 225W 1 All parts are ceramic wirewound non inductive winding 80025 642 08 R 15 Q 225W 2 Resistors are series connected for a total of 60 0 per snubber for 180 360A assemblies and 30 0 per snubber 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 203 AppendixF Spare Parts Table 29 Common Parts Quantity Description Part Number 1 per SCR pair Sharing resistor 32 5 225W two 2 5 taps 80025 753 01 R 1 per SCR Current loop self powered gate driver board CLGD 80190 519 01 R 1 per controller Voltage Sensing Board VSB 1500V 80187 708 51 R 2500V 80187 708 52 R 4800V 80187 708 54 R 7200V 80187 708 55 R 1 per controller Interface Board 80190 440 03 R 1 per SCR 3 Fiber Optic Cable 25m 80025 549 03 R 5 0m 80025 549 01 R 1 per controller Test Power Supply 120V AC for North America 80187 051 51
176. ns TIP 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 93 Chapter4 Programming Preset Slow Speed motor Parameter Slow Speed Select Allows the user to program the slow speed that best fits the application This control mode may be configured to allow slow speed operation ofthe Option Low 7 Forward 1096 Reverse Basic Setup 94 High 15 Forward 20 Reverse Slow Speed Direction This parameter programs the slow Forward Reverse speed motor rotational direction Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 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 45096 of full load current The Basic Setup programming group provides a limited parameter set allowing quick start up with minimal adjustments
177. nt has been disconnected before working on the sensing board Verify that all circuits are voltage free using a hot stick or appropriate high voltage measuring device Failure to do so may result in injury or death SHOCK HAZARD To prevent electrical shock ensure the main power 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 nuts and washers See Figure 48 Replace ring lugs on terminals Plug in ribbon cable making sure that it is positioned properly and fitting is secure locking mechanism is engaged For personnel and equipment safety ensure both grounding connections are reconnected to the sensing board Figure 48 Sensing Board with mounting hardware placement Mounting Hardware Mounting Hardware Mounting Hardware Rockwell Automation Publication 1560E UM051G EN P March 2015 Troubleshooting Chapter 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 c
178. ntrol circuit are part of the Rockwell Automation relay control panel 1503E CXXX This control panel ensures reliable operation of the contactor within its published specification 174 Rockwell Automation Publication 1560E UM051G EN P March 2015 1560E and 1562E Relay Control Appendix B Figure 72 Typical 400 Amp Bulletin 1562E Relay Control Circuit With Stop Control 120V KAAS AN TO SMCLEXIB W K TB6 J MOV 4 nw 2 MC MC ME ME C D 2 RECTIFIER 44 1 1 4 A bk HH MAIN CONTACTOR M REC MOV 1 lt N Le AO lt gt fib MOV 4 mon tt BC BC B B C D J JL J CC RECTIFIER f f Hf f f lt Y gt BYPASS CONTACTOR B REC MOV 2 4 MOV lt O ABB jedes CN OPTION STOP START ole s e 4 MASTER CONTROL CR a 2 COAST STOP s o lo 4 BYPASS CONTROL BC BC t N T FROM SMC 13 4 I T 12 13 14 15 16 17 18 19 2 2 SMC Flex CONTROL TERMINALS AUX 1 EXTERNAL BYPASS DPI AUX 2 AUX3 AUXA PIC TACH GROUND AULT ALARM NO
179. ntrol commands other than Stop through the serial communication port Rockwell Automation Publication 1560E UM051G EN P March 2015 Communication Chapter8 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 Go to Logic Mask found as follows Main Menu Parameter Communications Comm Mask Logic Mask gt j 4 Set bOX equal to 1 where X is the port number noted 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 117 Chapter8 Communication Control Enable Loss of Communication and Network Faults SMC Flex Specific Information 118 If enabling control from the built in SMC Flex programmer the Logic Mask must be set as follows Table 12 Logic Mask Requirements Mask Code Description 0 No external DPI devices are enabled 4 Only one HIM on port 2 is enabled 1 Two HIMs are enabled on ports 2 and 3 32 Only the DPI communication card on port 5 is enabled 36 One HIM on ports 2 and
180. ode and the control voltage must be present Rockwell Automation Publication 1560E UM051G EN P March 2015 83 Chapter4 Programming Figure 42 Menu Structure Hierarchy Power up and Status Display Lang Ban Select language Choose Mode OPERATION LEVEL being deployed MAIN MENU Lo Parameter Device Select Preferences Diagnostics Q orage In ES ES ER 621 Ex Monitoring SMC Flex Reset to Defaults Change Password Alarms Set Up Save to EEPROM User Dspl Line Faults Motor Protection Recall EEPROM User Dspl Time Device Revision Communications User Dspl Video Utility Reset User Display Q Linear List Parameter menu GROUP MENU continued in Figure 43 1 The SMC Flex controller does not support EEPROM Link Process or Start up modes 2 Steps back one level 3 Shown if password protection is configured 84 Rockwell Automation Publication 1560E UM051G EN P March 2015 Programming Chapter4 Figure 43 Menu Structure Hierarchy Volts Phase A B Volts Phase B C Volts Phase C A Current Phase A Current Phase B Current Phase C Watt Meter Megawatt Hours Elapsed Time Meter Reset Power Factor Mtr Therm Usage Motor Speed SMC Option Motor Connection Line Voltage MV Ratio Starting Mode Ramp Time Initial Torque Cur Limit Lvl Kickstart Time Kickstart Lvl Stop Input Option 1 Input Option 2 Input Stop Mode Stop Time Bra
181. odule 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 The Open Gate detection is active during starting or stopping only Line Faults The MV SMC Flex controller continually monitors line conditions for abnormal factors Pre start protection includes Line Fault with phase indication Line voltage loss Missing load connection Shorted SCR Running protection includes Line Fault no phase indication Line voltage loss Missing load connection Phase reversal protection can be toggled either ON or OFF 8 Phase reversal protection is functional only at pre start Rockwell Automation Publication 1560E UM051G EN P March 2015 27 Chapter1 Product Overview Metering 28 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 TIP 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 trans
182. of Chapter 1 Parameter Option Starting Mode Linear Speed This must be programmed for Linear Speed Ramp Time 0 305 Programs the time period that the controller will ramp from 0 speed to full voltage Kickstart Time 0 0 2 25 A boost of current is provided to the motor for the programmed time period Kickstart Level 0 90 locked rotor torque Adjusts the amount of current applied to the motor during the kickstart time 1 For ramp times greater than 30 5 set Ramp Time to zero and program Ramp Time E parameter 129 to the new time Do not exceed the thermal capacity ofthe controller 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 Soft Stop This may be set to of two Linear Speed Stopping Mode standard choices Stop Time Allows the user to set the time period 0 120 50 for the stopping function 1 Referto Chapter 6 for optional stop control modes 2 Amotortachometer is required refer to Linear Speed Acceleration and Deceleration on page 19 3 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 thermal capacity calculatio
183. 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 should be kept clean and free of dirt and obstructions This will avoid tracking and heat buildup 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 Environmental Considerations Maintenance Chapter 10 Hazardous Materials Environmental protection is a top priority for Rockwell Automation The facility that manufactured this medium voltage product operates an environmental manage
184. oltage unbalance protection are disabled during braking operation 6 Undervoltage overvoltage and voltage unbalance protection are disabled during braking operation Rockwell Automation Publication 1560E UM051G EN P March 2015 23 Chapter1 Product Overview Stall Protection and Jam Detection The MV SMC Flex controller provides both stall protection and jam detection for enhanced motor and system protection Stall protection is user adjustable from 0 0 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 Jam detection allows the user to determine the jam level up to 100096 of the motor s full load current rating and the delay time up to 99 0 s for application flexibility Figure 11 Stall Protection 600 Percent Full Load Current Programmed Start Time gt lt Time seconds Figure 12 Jam Detection Percent Full Load Current 10096 amp Ruming gt lt Jam gt Time seconds 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 objec
185. omation Publication 1560E UM051G EN P March 2015 81 Chapter3 Commissioning Procedure Notes 82 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 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 TIP 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 in Table 5 Table 5 Keypad Descriptions Escape Exit a menu cancel a change to a parameter value or acknowledge a fault alarm screen Up Down Arrows Scroll through options increase decrease a value or toggle a bit Select Select a digit select a bit or enter edit mode in a parameter Enter Enter a menu enter edit mode in a parameter screen or save a change to a parameter value TIP 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 Parameters are organized in a three level menu structure for straightforward programming Figure 42 details the programming menu structure and the three level hierarchy In order to change parameters the controller must be in the STOP m
186. or 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 times 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 32 Rockwell Automation Publication 1560E UM051G EN P March 2015 Hardware Description Product Overview Chapter 1 Figure 17 Pump Control Option 100 Motor Speed lt lt Pump Start gt lt X PumpStop Time seconds ATTENTION Pump stopping is not intended to be used as an emergency stop Refer to the applicable standard for emergency stop requirements mechanical dynamics of the pumping system Therefore select the lowest stopping time setting that will satisfactorily stop the pump ATTENTION Pump stopping may cause motor heating depending on the Brak
187. osure 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 cm 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 INO01_ EN P Wire earth ground to control terminal 14 Use shielded wire for PTC Input Tach Input Ground Fault Input e Terminate shielded wires to terminal 14 e Ground fault CT must be inside or within 3 m of metal enclosure 66 Rockwell Automation Publication 1560E UM051G EN P March 2015 Control Power Installation Chapter2 To meet produce susceptibility requirements ferrite cores need to be added to the communication lines All 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 added to the HIM cab
188. ough the DataLink mechanism e 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 122 Rockwell Automation Publication 1560E UM051G EN P March 2015 Updating Firmware Communication Chapter8 Parameters 88 103 are used to configure the DataLinks For additional information regarding DataLinks refer to the user manual for the communication interface being used TIP 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 The latest version of firmware and instructions for the SMC Flex can be obtained from www ab com TIP The MV SMC Flex must use firmware release 3 006 or later This User Manual pertains to units with firmware release 4 xxx or later Rockwell Automation Publication 1560E UM051G EN P March 2015 123 Chapter8 Communication Notes 124 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 Chapter 9 Troubleshooting General Notes and Wa rnings 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 NFPA 70E Part II in the United States Maintenance personnel must be trained in the safety practices procedures and
189. ould 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 6 1 m 20 ft 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 armor should be bonded to ground at both ends their case connected to ground for safety Failure to do so may result in damage ATTENTION Any instruments used for test or troubleshooting should have 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 1 4 in 6 8 Nem 6 lb ft 5 16 in M8 15 Nem 11 Ib ft 3 8 in M10 27 Nem 2016 9 1 2 in M12 65 Nem 48 Ib ft Control Wire Terminals 2 5 4 0 Nem 2 0 3 3 Ib in CLGD Power Assembly Terminals 5 6 Nem 50 Ib in SMC Flex Control Module Terminals 0 6 Nem 5 Ib in TIP For 3 8 in hardware the T slots of aluminum heatsinks the recommended torque is 22 Nem 16 Ib ft Do not overtorque these connections as the slots will be damaged and the connection will be compromised 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 contro
190. ould 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 gray transmitter is emitting red light If it is the fiber optic cable must be replaced If it isn t the interface board should be replaced When each gate driver circuit has been checked disconnect the power supply and remove it from the cabinet energized Failure to remove the portable test power supply will result in ATTENTION The gate drive circuits operate at high voltage when the SMC is equipment damage and may cause severe injury or death 78 Rockwell Automation Publication 1560E UM051G EN P March 2015 Commissioning Procedure Chapter3 12 Open the switch SW2 on the interface board see Figure 38 before returning the unit to service Ensure the red LED is off energized the motor will start in an uncontrolled manner and may cause severe ATTENTION If the SW2 switch is not in the open position when the SMC is 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 Control Function Tests 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
191. ower to the SMC Flex controller IMPORTANT An overload fault cannot be reset until the Motor Thermal Usage parameter 12 value is below 75 Refer to Protection and Diagnostics on page 21 of Chapter 1 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 Fault and Alarm Auxiliary Indication Fault Codes Diagnostics Table 7 provides a complete cross reference of the available fault codes and corresponding fault descriptions Table 7 Fault Code Cross Reference Chapter 7 Fault Code Fault Code Line Loss A 1 Stall 25 Line Loss B 2 Phase Reversal 26 Line Loss C 3 Coms Loss P2 27 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 7 Network P3 31 Open Gate B 8 Network P5 32 Open Gate C 9 Ground Fault 33 PTC Pwr Pole 10 Excess Starts Hour 34 SCR Overtemp 7 11 Power Loss A 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 1 Line Loss A 41 No Load C 18 Line Loss B 42
192. p sequence followed by opening of Aux 4 which opens the main contactor or breaker in the existing starter When using the optional HIM pressing the Jog button will initiate the optional stop maneuver and pressing the O button will initiate a coast stop An uncontrolled or coast stop can be achieved via DPI or by opening the connection on terminal 18 i e by energizing Coast Stop relay in the existing starter To run in Local mode the CR contact is used to initiate a start and stop sequence similar to Figure 76 Closure of the Start relay from the existing starter allows the unit to initiate motor soft starting Likewise opening of Start relay from the existing starter will initiate a controlled stop An uncontrolled or coast stop is achieved by opening the connection on terminal 17 i e by energizing Coast Stop relay in the existing starter This contact should remain open to ensure all hold in contacts clear to prevent a re start It is 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 is initiated and remain closed until it has sen
193. pe 1 or 12 enclosures For higher ambient conditions please consult Rockwell Automation factory B The relative humidity must not exceed 95 non condensing Excessive humidity can cause electrical problems from corrosion or excessive dirt buildup 52 Rockwell Automation Publication 1560E UM051G EN P March 2015 Installation Chapter2 C The equipment must be kept clean Dust buildup 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 Thelosses 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 requirements to ensure that the proper environmental conditions are met F Operational altitude is 1 km 3300 ft maximum without derating Higher altitudes may require optional components Please consult Rockwell Automation factory 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 component damage or a reduction in product life Wiring or applica
194. perable bypass contactor Check control circuit operation Check control plug on contactor e IntelliVAC fault e Check status of IntelliVAC correct the condition reset the module No load 16 17 18 40 Loss of load side power wiring Check all load side power connections and Loss of feedback motor windings Check voltage sensing module Line Unbalance 19 Supply unbalance is greater than the user Check power system and correct if necessary programmed value Extend the delay time to match the application The delay time is too short for the application requirements Unbalanced feedback Check voltage sensing module Overvoltage 20 Supply voltage is greater than user Check power system and correct if necessary programmed value Correct the user programmed value Undervoltage 21 Supply voltage is less than user programmed Check power system and correct if necessary value Correct the user programmed value The delay time is too short for the application Extend the delay time to match the application requirements Overload 22 Motor overloaded Check motor overload condition Overload parameters are not matched to the motor Rockwell Automation Publication 1560E UM051G EN P March 2015 Check programmed values for overload class and motor FLC 127 Chapter9 Troubleshooting Display Fault Code Possible Causes Possible Solutions Underload 23 Broken
195. pter2 Figure 32 Power Connections 1560E 180 360A 5500 6900V Not available in an Arc resistant design Phase 1 Power Stack Assembly Phase 2 Power Stack Assembly Phase3 Power Stack Assembly m 5 Phase 1 Line Connections Voltage Sensing Module _ Phase2 Line Connections Load Connections top exit Shown Phase 1 front through 3 back Current Transformers Phase 3 I Line Connections Bypass Vacuum Contactor Rockwell Automation Publication 1560E UM051G EN P March 2015 59 Chapter2 Installation Figure 33 Power Connections 1560E 600A 2400 6900V Not available in an Arc resistant design
196. ptions 101 Product 13 Programming 30 83 Protection and Diagnostics 21 Receiving 51 Safety and Codes 51 SMC Flex Control Module 15 Status Indication 30 Transportation Handling 52 Unpacking 51 Overvoltages 23 Example Settings 97 P Parameters List 163 Programming 103 Management 88 Index Modification 90 Ports Communication 113 Power Connections 54 Power Factor Correction Capacitors Installation 63 Power Stacks Spare Parts 203 Power Supply Tests 76 Power Wiriing Installation 62 Power Wiring 61 Preset Slow Speed Programming 94 Preset Slow Speed Starting Mode 18 Product Overview 13 Programming 30 Basic Setup 94 Current Limit Start 91 Dual Ramp Start 92 Full Voltage Start 93 Keypad 83 Linear Speed Acceleration Mode 93 Menu 83 Motor Information 98 Motor Protection 96 Overview 83 Parameter Management 88 Parameter Modification 90 Parameters 103 Password 87 Preset Slow Speed 94 Soft Start 91 Stop Control 93 Protection and Diagnostics 21 Excessive Starts Hour 28 Ground Fault 24 Jam Detection 24 Line Faults 27 Open Gate 27 Overload 21 Overtemperature 28 Overview 21 Overvoltage 23 PTC Protection 26 Stalls 24 Thermistor 26 Unbalance 23 Underload 22 Undervoltage 23 PTC Protection 26 Receiving 51 Relay Control 169 Resistance Checks 80 Resistor Circuit Troubleshooting 149 Rockwell Automation Publication 1560E UM051G EN P March 2015 211 Index 5 V Safety and Codes 51 Voltage Feedback
197. r 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 AUX1 Ext Bypass auxiliary contacts closing relay BC which closes the bypass contactor The motor then 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 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 169 Appendix B 170 1560E and 1562E Relay Control Bulletin 1562E Basic Control With Controlled Stop When wired as shown in Figure 72 the controller operates in much the same manner as in Figure 71 Terminal 16 on t
198. re rating and the current limit time is user adjustable from 0 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 automatically switches to full voltage and the bypass contactor is closed 2 Kickstart is also available with Current Limit Start Dual Ramp Start and Linear Acceleration Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 Figure 3 Current Limit Start Percent Full Load 60096 Current 50 gt Time seconds 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 Figure 4 Dual Ramp Start Percent Voltage 10096 Initial Torque 2 Initial Torque 1 lt Start gt lt Run gt lt lt Start 2 gt lt 2 Time seconds 3 Dual Ramp Start is available only with the standard controller Rockwell Automation Publication 1560E UM051G EN P March 2015 7 Chapter 1 Product Overview 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 1 4 se
199. rk Network NC External Bypass Language Language 111 English English French Spanish German Portuguese Mandarin All Parameter Mgmt 115 Ready Ready Load Default Basic Set Up Backspin Timer 116 SEC 0 999 0 1 This parameter does not appear for MV applications for firmware versions 5 X or lower 2 Appears in Pump option modules only 166 Rockwell Automation Publication 1560E UM051G EN P March 2015 Parameter Information Appendix A Group Parameter Description Parameter Units Min Max Default User Number Settings Settings Linear List Fault 1 124 0 255 Fault 2 125 0 255 Fault 3 126 0 255 Fault 4 127 0 255 Fault 5 128 0 255 Basic Set Up Option 1 Input 132 Disable Stop Stop Option Option Fault Fault NC Network Stop Input 133 Coast Coast Stop Option Tung and Special Parameters Pump Pedestal 34 0 50 0 0 Visible with 6 001 and later firmware ET Visible and writable only with Password Braking Time 36 Sec 0 999 0 9 1196 on 5 00n and earlier firmware Load Type 37 Standard Standard 0 High Inertia High Friction Ramp 89 High Eff Brake 38 96 0 99 0 3 OL Shunt Time 48 Sec 0 999 0 OL Trip Enable 49 Disable Enable Enable Line Fault 84 Disable Enable Disable F1 Disable F41 Enable Emergency Run 85 Disable Disable Enable Current Loss 86 Disable Enable Enable Timed S
200. rmer connections and feedback module programming Check voltage sensing board connections and module programming Check ribbon cable connections between Interface Board and Control Module Check voltage feedback circuits Consult factory Shorted SCR 4 5 6 Shorted Power Module Check for shorted SCR replace if necessary refer to Power Circuit Troubleshooting on page 135 Open Gate with phase indication 7 8 9 Open gate circuitry Perform power supply tests Chapter 3 Loose gate lead Check gate lead connections to the 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 Ambient temperature limit exceeded Wait for controller to cool or provide external cooling Failed thermistor Check connection or replace thermistor Failed control module Replace control module e Failed gate driver board Test or replace gate driver board Failed fiber optic cable Test or replace cable Failed interface board Test or replace interface board check ribbon cables Motor PTC 12 Motor ventilation blocked Check for proper ventilation Motor duty cycle exceeded Check application duty cycle PTCopen Wait for 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 Ino
201. rrent transformers A control power transformer optional A low voltage control panel complete with microprocessor based control module 14 Rockwell Automation Publication 1560E UM051G EN P March 2015 Starting Modes Product Overview Chapter 1 Space for necessary auxiliary control and metering devices and bottom plates to accommodate power cables Motor overload protection included in SMC Flex control module available in Arc Resistant enclosures SMC Flex Control Module The MV SMC Flex controller offers a full range of starting and stopping modes as standard e Soft Start with Selectable Kickstart Soft Stop e Current Limit Start with Selectable Kickstart e Linear Acceleration with Selectable Kickstart e Linear Deceleration e Dual Ramp Start Preset Slow Speed e Full Voltage Start Other features that offer further user benefit include Extensive protection features e Metering Communication capability I O Innovative control option provides enhanced performance 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 9096 of locked rotor torque From the initial torque level the output voltage to the motor is steplessly increased during the acceleration ramp time The accel
202. rriers are recommended as a means of restricting access by personnel while the equipment is energized Chain link fencing is a suitable barrier material Equipment that consists of more than 4 vertical sections bolted together may require additional plenum exits Rockwell Automation will provide guidance on requirements for additional plenum exits when required Where adequate clean height space is available chimney can be provided for each unit in place ofthe plenum system It is to be field mounted on top of the unit structure The purpose of the chimney is to direct the hazardous flames and gases away from the top of the resistant enclosure for the chimney is secured to the top of each unit structure Refer to Appendix E for chimney installation instructions Each ArcSheild line up includes a chimney exhaust section that extends vertically directly above the enclosure 1 From the outlet of the chimney there needs to be a minimum clear distance of 1 7m from the top of the chimney to the ceiling and 1m 39 in on each side 2 No obstructions e g Piping can be in path of the exhaust within this 1 7m 67 in height requirement Plan the location where the chimney will exhaust Ensure that e There is no access to personnel while equipment is energized Area is free of flammable material or vapors Ensure that adequate space is provided around the chimney exhaust as outlined in Figure 83 Rockwell Automation Publicat
203. s 1 allows the user to configure the operation of the contacts Normal Normal NC Up to Speed Up to Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Aux2 Config Contact is provided as standard with the SMC Flex controller The contact is located at terminals 29 and 30 Aux Contacts 2 allows the user to configure the operation of the contacts Normal Normal NC Up to Speed Up to Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Aux3 Config Contact is provided as standard with the SMC Flex controller The contact is located at terminals 31 and 32 Aux Contacts 3 allows the user to configure the operation of the contacts Normal Normal NC Up to Speed Up to Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Aux4 Config Contact is provided as standard with the SMC Flex controller The contact is located at terminals 33 and 34 Aux Contacts 4 allows the user to configure the operation of the contacts Normal Normal NC Up to Speed Up to Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Parameter Mgmt Recall of factory default parameter values 1 Not accessible in MV applications for Firmware up to 5 001 Ready Load Default 2 Refer to 1 0 on page 29 of Chapter 1 and Note page 31 of Chapter 1 for MV specific functionality 3 When programmed for Emergenc
204. s obstructed cooling and high ambient temperatures Table 1 defines the MV SMC Flex PTC thermistor input and response ratings Table 1 PTC Input Ratings Response Resistance 34000 1500 Reset Resistance 16000 1000 Short circuit Trip Resistance 250 100 Maximum Voltage at PTC Terminals 400 lt 75V Maximum Voltage at PTC Terminals open 30V Maximum Number of Sensors 6 Maximum Cold Resistance of PTC Sensor Chain 15000 Response Time 800 ms Figure 13 illustrates the required PTC sensor characteristics per IEC 34 11 2 Figure 13 PTC Sensor Characteristics per 34 11 2 L TNF 20K TNF 5K I L TNF 5K i TNF 15K 26 Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 PIC 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 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 m
205. sable Disable Preset SS Dual Ramp Fault Fault NC Network Clear Fault Emergency Run Dual Ramp Starting Mode 2 25 Full Voltage Soft Start Current Limit Soft Start Linear Speed Ramp Time 2 26 SEC 0 30 10 Initial Torque 2 27 96 LRT 0 90 70 Cur Limit Level 2 28 96 FLC 50 600 350 Kickstart Time 2 30 SEC 0 0 2 0 0 0 Kickstart Level 2 31 96 LRT 0 90 0 1 Pump modules do not display this parameter Default setting for MV applications is typically Emergency Q Do not set to Delta Rockwell Automation Publication 1560E UM051G EN P March 2015 163 AppendixA V Parameter Information Group Parameter Description Parameter Units Min Max Default User Number Settings Settings BasicSetUp a soft Linear Speed smB Accu Stop Stop Time 33 SEC 0 120 0 Basic Set Up Accu Stop Braking Current 35 FLC 0 400 0 Preset SS Accu Stop Slow Speed Sel 39 55 Low SS High SS High Slow Speed Dir 40 SS FWD SS FWD SS REV Slow Speed Cur 4 FLC 0 450 0 Slow Running Cur 42 FLC 0 450 0 Accu Stop Stopping Current 43 FLC 0 400 0 Basic Set Up Overload Overload Class 44 Disable Class 10 Class 10 Class 15 Class 20 Class 30 Service Factor 45 0 01 1 99 1 15 Motor FLC 46 A 1 0 1000 0 10 Overload Reset 47 Manual Manual Overload Overload A Lvl 50 96 MTU 0 100 0 Underlo
206. se Reversal 80 Disable Disable Enable Restart Starts Per Hour 81 0 99 2 Restart Attempts 82 0 5 2 Restart Delay 83 SEC 0 60 0 Comm Masks Logic Mask 87 8 bit binary Data Links Data In A1 88 Data In A2 89 Data In B1 90 Data In B2 91 Data In C1 92 Data In Q 93 Data In D1 94 Data In D2 95 Data Out A1 96 Data Out A2 97 Data Out B1 98 Data Out B2 99 Data Out C1 100 Data Out C 101 Data Out D1 102 Data Out D2 103 Motor Data Motor ID 104 0 65535 0 CT Ratio 105 1 1500 MV Ratio 106 1 10000 1 Program the module for primary current rating 150 5 CT program 150 2 Referto Chapter 3 Commissioning Procedure to determine the appropriate setting Rockwell Automation Publication 1560E UM051G EN P March 2015 165 Parameter Information Group Parameter Description Parameter Units Min Max Default User Number Settings Settings Basic Set Up Aux Config 107 Normal External Normal NC Bypass Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Aux 3 Config 108 Normal Alarm Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Aux 4 Config 109 Normal Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Aux 2 Config 110 Normal Fault Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Netwo
207. sed the motor has stopped following an option stop maneuver Rockwell Automation Publication 1560E UM051G EN P March 2015 173 AppendixB 1560 1562E Relay Control Figure 71 Typical 400 Amp Bulletin 1562E Relay Control Circuit Without Stop Control 115V ar TO SMCLEXIB 186 M 5 MOV T 2 1 4 MC MC ME ME ME ME she D 2 RECTIFIER 4 HH PAL HH HHI Vn OANE MAIN CONTACTOR M REC MOV 1 lt HO CN ME MOV 7 B s BC BC BE B C mx D RECTIFIER 4 EL AF AFAR lt i n1 7 BYPASS CONTACTOR 8 REC MOV 2 L Ls f STAVA CN BE STOP START e 55 CR MASTER CONTROL CR a d MC e BC CR 55 N 4 BYPASS CONTROL BC FROM SMC 3 4 LI 11 12 13 14 15 16 17 18 19 20 21 22 SMC CONTROL TERMINALS AUX 1 EXTERNAL BYPASS DPI AUX 2 AUX3 AUX4 PICO GROUND FAULT ALARM NORMAL INPUT 11 T 23 24 25 26 27 28 29 30 31 32 33 34 aM FROM GFCT DE OPTIONAL MAIN CONTROL MC SMC FlexlB INPUT POWER u DIN 1 CCand HC and their wiring into the co
208. sent Failed control module Check control wiring and correct if necessary Replace control module Stopped 0 0 Amps Pilot devices Check wiring SMC Enable input is open at terminal 13 Check wiring e Terminal 16 is open Check wiring Start Stop control has not been enabled for the human Follow the instructions on page 116 to page 118 to interface module enable control capability Control voltage Check control voltage Failed control module Replace control module Starting Two or three power phases are missing Check power system Table 20 Motor Rotates but does not accelerate to full speed Check voltage sensing module and connections Display Possible Causes Possible Solutions Fault displayed See fault description See Table 18 addressing fault conditions Starting e Mechanical problems Check for binding or external loading and correct Table 21 Motor Stops While Running Display Fault displayed Inadequate Current Limit setting Failed control module Possible Causes See fault description Check motor Adjust the Current Limit Level to a higher setting Replace control module Possible Solutions See Table 18 addressing fault conditions Display is blank Control voltage is absent Failed control module Check control wiring and correct if necessary Replace control module Stopped 0 0 Amps Pilot devices Check control wiring and correct if n
209. sibility 183 Changed Voltage Sensing Board partnumbes Rockwell Automation Publication 1560E UM051G EN P March 2015 3 Summary of Changes Notes 4 Rockwell Automation Publication 1560E UM051G EN P March 2015 Preface Product Overview Table of Contents Service Procedure 11 Chapter1 Manil Objectives cos da E t EN c e eU VRAC 13 Documentation eet eed eres e Rente e e VEN 13 ESCH DION ee s eee ee ahold Uu t olet 13 1503E OEM Controller 14 1560E Retrofit Controller 14 1562E Combination Contrroller 14 SMC Flex Control Module 15 Starting Modes a seua aa 15 SERIES ames 15 Selectable Kickstart 16 Current Limit 16 Dual Ramp Start ua an 17 Full Voltage Start 18 Preset Slow Speed 18 Linear Speed Acceleration and Deceleration 19 SOR StOD qaya asian agente 20 Protection and Diagnostics c nos arte m ehe eb ines t te d 21 Overload zs sq vet Ia Saa un 21 ACEO man
210. t epp CERTE 37 Bulletin 1562E e Basic Control Controlled Start only 37 Bulletin 1562E e Basic Control With Controlled Stop 37 Bulletin 1562E e DPI Control Controlled Start only 38 Bulletin 1562E DPI Control With Controlled Stop 38 Bulletin 1560E e Basic Control Controlled Start only 29 Bulletin 1560E e Basic Control With Controlled Stop 40 Bulletin 1560E e DPI Control Controlled Start only 40 Bulletin 1560E e DPI Control With Controlled Stop 4 Chapter 2 Installation e n n a o vati eC D dd s utu D easels 51 Safety and Codes oce deberet bs oic Eres teu waya m s 51 Unpacktingsnddaspectlonc osse e s eel 51 General Precautions e Las aqa tus stss 52 Transportation and 52 Installation Site asss PH MATE 52 Mounting tarde adapt leat er 53 Grounding Practices sos ce eG I Rt entere E HER d 53 Recommended Torque Values 54 Power Connections 54 Bulletin 1502 EU A US 54 J GOE DR sh lap wie tui pieds 55 Bulletin 1503E 2 alii deine 61 Power WEBB r seerias vc Octa eoa Ste pup de n d de 61 Interlocking sp eR
211. t in severe injury or equipment damage ATTENTION Make sure ground wires from the Voltage Sensing Module 5 Repeat Thyristor SCR resistance checks page 135 and Power Supply Tests page 76 Snubber Resistor When replacing the ceramic wire wound type snubber resistors use caution R epl acement when 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 151 Troubleshooting Chapter 9 Figure 67 Typical 1500 2400V Module Wiring 180 360 A QV31300H1V 043139 YOLDVdV 939915 80151538 39915 80151534 DNIHVHS 013931 avol ESH o INN GH o YOLSIWYIHL O 40 19 Lo ISH Lad _ SY O 6 m AO Jm 709 o a amp AO 109 5 Is Miss 1 g YOLSIWYJHL 504 08 309 Rockwell Automation Publication 1560E UM051G EN P March 2015 152 Chapter 9 Troubleshooting Figure 68 Typical 1500 2400V Module Wiring 600 A 0 0V31300HV 7 GIHM 0111199 9 SH uOLDVdV 399005 5 80151538 H38 lNS su 80151534 DNIHVHS Yy 0N3511 6 0
212. t settings in the range of 1 100 will provide 100 braking current to the motor Rockwell Automation Publication 1560E UM051G EN P March 2015 Options Chapter 6 TIP 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 Control Wiring Refer to Chapter 1 Product Overview for typical control wiring examples used with various control schemes Rockwell Automation Publication 1560E UM051G EN P March 2015 105 Chapter6 Options Notes 106 Rockwell Automation Publication 1560E UM051G EN P March 2015 Overview Fault Display Chapter 7 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 Motor Protection on page 96 of Chapter 4 The SMC Flex controller comes equipp
213. t 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 37 on page 75 Rockwell Automation Publication 1560E UM051G EN P March 2015 Chapter 1 Product Overview Figure 18 Typical MV SMC Flex Power System Bulletin 1562E 3300 4160V shown aee EE 5 EZ wa xa WS 01 N 88 go a m 181 AONO OH omi 0212 500408 IBAMO3ID IHL 7 NO S L JHL HONOWHL SS d 58012001802 4001 IN3HHD sin H E 5 oun be 5 3SVHd NMOHS SNOLD3NNOD 5 e SNOLLIANNOD 8 3 SNOLLIANNOD g 5 7 FEE S
214. tart 112 Disable Disable See Param Enable 114 Shutoff Level 113 0 37 0 Do not change UTS Level 114 0 100 75 V Shutoff Level 117 0 100 25 OL Reset Level 118 0 99 75 Ambient Temp 119 0 60 50 Do not change Notch Position 120 96 40 0 100 0 87 5 Do not change Notch Maximum 121 50 70 70 Do not change Start Delay 122 Sec 0 30 0 Bypass Delay 123 Sec 0 15 0 Start Time E 129 Sec 0 999 0 Start Time E2 130 Sec 0 999 0 Stop Time E 131 Sec 0 999 0 Elapsed Time 2 134 Hours 0 3000 1 1 Read only parameter 2 Pump modules only 3 Brake modules only Rockwell Automation Publication 1560E UM051G EN P March 2015 167 Parameter Information Notes 168 Rockwell Automation Publication 1560E UMO05 1G EN P March 2015 Functional Description Appendix B 1560E and 1562E Relay Control The following functional descriptions and associated control circuits are for units using electromechanical relay control IMPORTANT Rockwell Automation relay control panel 1503E CXXX ensures reliable operation of the contactor within its published specifications The relays break the DC current drawn by the closing holding and trip coils The relays coordinate their pick up and drop out voltages with the pick up and drop out voltages of the contactor to operate in under voltage conditions Bulletin 1562E Basic Control Controlled Start only When wired as shown in Figure 71 the controlle
215. tion errors Such as undersizing the motor incorrect or inadequate AC supply or ambient temperatures above or below the specified temperature range may result in malfunction ofthe controller An incorrectly applied or installed controller can result in Mounting The 1503E 1560E and 1562E are designed to be mounted in the vertical 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 the drawings supplied with your order for mounting requirements 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 Rockwell Automation Publication 1560E UM051G EN P March 2015 53 Chapter2 Installation Recommended Torque Values Power Connections 54 Each power feeder from the substation transformer to the controller must be equipped with properly sized ground cables Simply utilizing the conduit or cable armor as a ground is not adequate The conduit or cable armor and ground wires sh
216. to be marked as a Hazardous Zone and labeled per Figure 84 Rockwell Automation Publication 1560E UM051G EN P March 2015 189 0 ArcShield Plenum Installation Instructions Figure 84 Plenum Exhaust Label NDANGER ADANGER ARC FLASH HAZARD HAZARD D ARC LECTRIQUE PRESSURE RELIEF EXIT SORTIE DE L EVENT R GION TRE INACCESSIBLE AUX PERSONNEL INACCESSIBLE TO PERSONNEL PENDANT QUE L QUIPEMENT WHILE EQUIPMENT ENERGIZED EST SOUS TENSION FREE OF OBSTRUCTIONS D MUNI D OBSTRUCTIONS REFER TO USER MANUAL R F RER AU MANUEL AREAS TO BE SEVERE INJURY OR RISQUE DE BLESSURES DEATH MAY RESULT CORPORELLES GRAVES OU M ME LA MORT 190 Rockwell Automation Publication 1560E UM051G EN P March 2015 ArcShield Plenum Installation Instructions Appendix D Figure 85 Various Plenum Components Available 18 in wide Plenum 26 wide Plenum 36 wide Plenum Fastened directly over the 0 5 m 18inch Fastened directly over the 0 7 m 26 inch Fastened directly over the 0 9 m 36 inch wide cabinet wide cabinet wide cabinet 18 in long Extension 26 in long Extension 36 in long Extension Connected to the last Plenum on the Connected to the last Plenum on the Connected to the last Plenum on the exhaust end of the line up exhaust end of the line up exhaust end of the line up A Sa Screen Cover Plate End Cover Plate 90 Elbow Section
217. to program the required current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the required current to operate the motor at slow speed operation 0 400 of full load current Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 400 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 40096 of full load current Slow Speed with Braking SMCOption 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 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 45096 of full load current Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 40096 of full load current 1 Braking Control is not offered for standard use in MV applications Please consult factory for further assistance 2 All braking stopping curren
218. ton when pressed will commence motor acceleration to full speed Accu Stop 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 The green start button when pressed will commence motor acceleration to full speed Slow Speed with Braking 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 1 Braking Control is not offered for standard use in MV applications Please consult factory for further assistance ATTENTION 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 102 Rockwell Automation Publication 1560E UM051G EN P March 2015 Programming Parameters Options Chapter 6 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 Setup and Metering groups Diagrams supporting the options described below are shown later
219. too slowly with Soft Stop option Stopping time setting Misapplication Verify the programmed stopping time and correct if necessary 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 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 Identify fault and correct Check for shorted SCR replace if necessary Ensure power terminals are secure Motor coasts when option stop is programmed 1 Various faults may occur if Parameter 15 is set to Delta It must be set to Line for all MV applications 130 Option not programmed Current loop power supply not active Incorrect control logic Verify the option parameter settings and correct if necessary Verify c
220. ts 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 7 Jam Detection is disabled during slow speed and braking operation 24 Rockwell Automation Publication 1560E UM051G EN P March 2015 Product Overview Chapter 1 MV SMC Flex ground fault detection capabilities consist of using a core balance current transformer for 1 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 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 Fit Inh Time allows the installer to inhibit a ground fault trip from occurring during the motor starting sequence and is adjustable from 0 250 seconds Parameter 74 Fit 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 25 seconds Parameter 73 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 5 0 A IMPORTANT ground fault inhibit
221. u 159 Keep Good Maintenance 48 160 Power Components cceevexee edere KE Y DON RU e PARU 160 Control Components Electronic 160 Saa Cogit 160 ia mtem dus tue 160 DARIUS sis pith ch aati 160 Environmental Considerations 161 Hazardous Materials 161 Capacitor Dielectric Fluid 161 Printed Circuit Boards 161 Chromate Plating sais uode rau ISO e Ce Que TERRAS 161 Ir Gase Edo P NM 162 Disposal oen Ride eet 162 Appendix A Parameter ton pul qaq epit adt anette oe ha cde 163 Appendix B Functional Descriptlom d ee S I vp eere 169 Bulletin 1562E e Basic Control Controlled Start only 169 Bulletin 1562E e Basic Control With Controlled Stop 170 Bulletin 1562E DPI Control Controlled Start only 170 Bulletin 1562E e DPI Control With Controlled Stop 171 Bulletin 1560E e Basic Control Controlled Start only 171 Bulletin 1560E Basic Control With Controlled Stop 172 Bulletin 1560E e DPI Control Controlled Start only 172 Bulletin 1560E DPI Control With Controlled Stop
222. ure 50 Upper Low Voltage Panel and Power Cell Detail 1562E 2400 4160V 180 360A Rockwell Automation Publication 1560E UM051G EN P March 2015 139 Chapter9 Troubleshooting Figure 51 Power Module Assembly one phase 1000 1300 1500 2400V 180 360A Heatsink 1 Heatsink 2 Heatsink 3 Figure 52 Heatsink Clamp SCR 1 140 Do not loosen Do not loosen Center Nut ocking Nut L not adjust Indicating Washer 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 in Rockwell Automation Publication 1560E UM051G EN P March 2015 Troubleshooting Figure 53 Removal of SCR 1000 240V 180 3604 To Remove SCR Remove shorting bar hardware Pry opposing heatsinks apart Extract SCR To Insert New SCR Apply thin film of electrical jo
223. urrent loop power supply refer to Power Supply Tests on page 76 of Chapter 3 Verify connections to module terminals 16 and 17 refer to Functional Description on page 37 of Chapter 1 TIP For Pump Stop issues refer to Pump Application Considerations on page 32 of Chapter 1 Rockwell Automation Publication 1560E UM051G EN P March 2015 Control Module Removal Voltage Feedback Circuit Tests Troubleshooting Chapter 9 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 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 SHOCK HAZARD To avoid shock hazard ensure the main power has 2 Make sure that the wires are properly marked and that the program parameters are recorded 3 Disconnect all control wires to control module Loosen the four control module screws 5 Carefully rotate the module to the left and unplug the five ribbon cables from the interface board the module in place as the screws are removed to avoid strain on the ATTENTION When removing the control module make sure to hold ribbon cables To install control module follow th
224. ush button is not All other controls available with the various human interface modules are non functional with the SMC Flex controller Rockwell Automation Publication 1560E UM051G EN P March 2015 115 Chapter 8 116 Communication Connecting the Human Interface Module to the Controller Figure 46 shows the connection of the SMC Flex controller to a human interface module Table 11 provides a description of each port TIP 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 21 on page 43 or Figure 24 on page 6 for the control wiring diagram that enables start stop control from a human interface module Figure 46 SMC Flex Controller with Human Interface Module Port 5 DPI Communications Port 2 Ports 2 and 3 when two HIMs are connected with a splitter Table 11 SMC Flex Controller with Human Interface Module 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 DPI 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 modules programming keys The Bulletin 20 HIM LCD human interface modules with control panels can start and stop the SMC Flex controller However the factory default settings disable co
225. ve all power from the equipment 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 ATTENTION To avoid shock hazard ensure the main power has been 2 Carefully detach all wires cables and connectors noting their location and orientation For the interface board remove the control module see page 131 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 ATTENTION The fiber optic cables can be damaged if struck or bent 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 the 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 F 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 134 Rockwell Automation Publication 1560E UM051G
226. vel parameter 3 This is not to indicate how the motor windings are configured Do not select Delta for MV applications Rockwell Automation Publication 1560E UM051G EN P March 2015 Programming Chapter 4 Parameter Option Kickstart Time 0 0 2 05 A boost current is provided to the motor for the programmed time period Kickstart Level 0 9096 of locked rotor torque Adjust the amount of current applied to the motor during kickstart Stop Input Allows the user to select the operation of terminal 18 Stop Input Coast Stop Option Option 1 Input Allows the user to select the operation of terminal 16 Option Input 1 Disable Stop Option Fault Fault NC Network Option 2 Input Allows the user to select the operation of terminal 15 Option Input 2 Disable Preset Slow Speed Dual Ramp Fault Fault NC Network Clear Fault Emergency Run Stop Mode Allows the user to program the SMC Flex controller for the type of stopping that best fits the application Soft Stop Linear Speed Stop Time This sets the time period which the controller will ramp the voltage during a stopping maneuver 0 0 1205 CT Ratio Scales the CT input to actual motor current 5 amp secondary assumed Example CT Ratio 150 5 program 150 1 1500 Aux1 Config 2 Contact is provided as standard with the SMC Flex controller This contact is located at terminals 19 and 20 Aux Contact
227. ware 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 electronic and electrical equipment They are to be kept as dust free as possible A scheduled program of inspection will reduce the possibility of problems 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 ATTENTION Servicing energized industrial control equipment can be TIP 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 elimin
228. when itis unclamped 3 Ifa short circuit is suspected the SCR must be isolated from all surrounding circuitry i e 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 Ifa faulty device is found the entire heatsink assembly must be removed 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 ATTENTION For heatsink assemblies containing four or more SCRs the 5 Complete heatsink assemblies with matched SCRs are available as a renewal part see Appendix E In most cases the assembly can be dismantled to replace the SCRs Rockwell Automation Publication 1560E UM051G EN P March 2015 135 Chapter 9 136 Troubleshooting SCR Replacement Procedure TIP This procedure applies to 180 A and 360 A units 5000V only IMPORTANT _ Refer 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 disconnected before working on the controller motor or control devices Verify that all circuits are voltage free using a
229. y 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 For Pump Option modules the Option 2 input defaults to Emergency Run for MV applications Rockwell Automation Publication 1560E UM051G EN P March 2015 95 Chapter4 Programming Motor Protection 96 While the Basic Setup 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 ofthe additional setup parameters provided TIP The majority of parameters have a Fault and an Alarm setting Parameter Option Overload Trip Class Service Factor Motor FLC Overload Reset Allows the user to select the operation of the overload Overload Alarm Level Underload 1 2 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 Determines the trip l

1560E-UM051 - Rockwell Automation

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