Rockwell Automation 150-E User Manual

User Manual

Elevator Panel Solution

Bulletin 150-E

Important User Information

IMPORTANT

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/ important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software 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.

available from

) describes some

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

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.

Identifies information that is critical for successful application and understanding of the product.

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.

Introduction

Chapter 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Base Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fault Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Function Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Starter Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

For 6 or 12 Lead Wye-Delta Wound Motors . . . . . . . . . . . . . . . . . . . . . 8

For 3- or 9-Lead Closed Delta-Type Motors . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 2

Installation & Wiring

Programming

Troubleshooting

Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Terminal Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Delta Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Delta Connection (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Line Connection (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Delta-Connected Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Line-Connected Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 3

DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Motor FLA Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Motor Overload Trip Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Input & Output Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chapter 4

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Diagnostics Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Troubleshooting Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Repair Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Specifications

Chapter 5

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Dimensions & Shipping Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Rockwell Automation Publication 150-UM009D-EN-P - February 2011 3

Table of Contents

4 Rockwell Automation Publication 150-UM009D-EN-P - February 2011

Chapter

Base

Controller

Fault Contactor

Introduction

This manual provides and overview of the installation, set-up, and typical operation of the Allen-Bradley hydraulic elevator and escalator starter. This solidstate starter solution is designed to operate 3-phase standard squirrel cage induction motors and can be connected to a 6 or 12 lead Wye-Delta or standard 3 or 9 lead motors. Through the use of LINE or INSIDE-THE-DELTA control, the solid-state solution can provide ultimate control of the motor. The advantages of a solid-state solution include the following:

• Provides smooth motor starting.

• Reduces current surges on weak electrical systems.

• Reduces starting torque of the motor, wich helps to reduce mechanical

stress on system components.

• Helps meet both local and regional electrical codes when reduced voltage starting is a requirement.

• Eliminates voltage and current spikes associated with traditional WyeDelta starters.

• Maximizes the life of the motor with reduced electrical strain.

• Reduces general system maintenance requirements for improved uptime.

Component Overview

The starter is made up of two components, the base controller and a fault contactor.

Figure 1 - Bulletin 150-E Components

Rockwell Automation Publication 150-UM009D-EN-P - February 2011 5

Chapter 1 Introduction

Base Controller

The base controller is a standard product that uses a number of intelligent features to provide advanced motor control and simple diagnostics. The base controller consists of the elements necessary to control the motor. These elements include:

• a main micro-processor

• current sensing

• built-in adjustable overload

• solid-state power modules, and

• electro-mechanical bypass contacts.

Through the use of simple DIP switch configuration, the product can be configured for a variety of modes. The default configuration uses the built-in current sensing to limit current to the motor during starting. Once up to speed, the base controller transitions to the run mode by transitioning to internal bypass contactors and changing the state of the auxillary contact. The internal bypass contactor provides decreased heating during run and removes the SCRs from the circuit.

Fault Contactor

The fault contactor is controlled through the fault contact of the controller. When control power is applied to the controller, the normally open fault contact closes and applies control power to the coil of the contactor. The fault contact will open, removing power from the fault contactor, and thus disabling the motor during any one of the following events:

• The power is removed from the controller.

• The motor has developed a problem including overloading due to one of

the following:

– Mechanical or electrical reasons – Ground faults or – Motor short circuits.

• The starter has detected an internal problem such as a shorted SCR or

overtemperature condition.

6 Rockwell Automation Publication 150-UM009D-EN-P - February 2011

Introduction Chapter 1

Function Overview

The Bulletin 150-E elevator panel provides solution to both advanced motor control and simple diagnostics. The following information provides a brief overview of the basic product features.

Motor Control

Current Limit Through the use of internal current sensors, the SMC™ will regulate the current

Soft Start The voltage is ramped from an initial set point to full voltage over the programmed

Soft Stop The voltage is ramped down from full voltage and applied to the motor over a

level applied to the motor over the programmed period of time. This type of motor control produces a slow start and insures that the current does not exceed the programmed level. This is the standard configuration of the device and aligns well with traditional applications.

period of time. This type of motor control produces a smooth start in less time than the current limit setting. However, the current is not restricted.

programmed period of time. The result is a smooth stop.

Diagnostics

Overload Provides protection of the motor for over current conditions. This feature offers a

OverTemperature

Phase Reversal

Phase Loss/ Open Load

Phase Imbalance

Shorted SCR Each time the SMC initiates a start, it checks to see if the SCRs are operating

user-selectable setting called the trip class, which can be used to accommodate different applications and motor types. When the motor draws more than the nominal value of current for a period of time, the device will fault on a motor overload fault.

A built-in self-monitoring method for detecting a SCR over-temperature condition. If the internal temperature exceeds a design threshold, the device will fault on a SCR Overtemp fault.

The user can select the phase relationship of the incoming power. If this phase relationship changes, the device will fault indicating a problem.

When any one of the incoming 3 phases are lost, the controller will fault indicating a phase loss condition has occurred.

When enabled, will detect if a phase imbalance condition exists and fault the unit. A phase imbalance is defined as a 65% differential between the highest and lowest phase for more than 3 seconds.

correctly. If the controller is unable to properly turn on and off any one of the SCRs, the device will fault on a Shorted SCR fault.

Rockwell Automation Publication 150-UM009D-EN-P - February 2011 7

Chapter 1 Introduction

Starter Selection

For 6 or 12 Lead Wye-Delta Wound Motors

The following table lists the catalog numbers that can be used with 6 or 12 lead Wye-Delta motors. For proper operation, the connection should be verified during installation. Sample connection diagrams for INSIDE-THE-DELTA connected motors are included in the Installation and Wiring section found later in this manual.

Table 1 - Cat. Nos. For Use with 6- or 12-Lead Wye-Delta Motors

Hp at Nominal Ratings

200V 240V 480V 575V 120V 230V

10 10 20 30 10.9…32.9 15 15 30 40 17…51 150-E51NCE-FC 150-E51NCA-FC 20 20 40 60 21.3…64 150-E64NCE-FC 150-E64NCA-FC 20 25 50 60 24.7…74 30 40 75 100 34.7…104 150-E104NCE-FC 150-E104NCA-FC 40 50 100 150 49…147 150-E147NCE-FC 150-E147NCA-FC 75 75 150 200 59…234

Motor FLA must fall within the specified range to operate correctly.

➊

Overload Range ➊

Control Voltage Cat. Nos.

150-E32NCE-FC 150-E32NCA-FC

150-E74NCE-FC 150-E74NCA-FC

150-E234NCE-FC 150-E234NCA-FC

For 3- or 9-Lead Closed Delta-Type Motors

The following table lists the catalog numbers that can be used with 3- or 9-lead closed delta type motors. For proper operation, the connection should be verified during installation. Sample connection diagrams for LINE connected motors are included in the Installation and Wiring section found later in this manual.

Table 2 - Cat. Nos. For Use with 6 or 12 Lead Closed Delta-Type Motors

Hp at Nominal Ratings

200V 240V 480V 575V 120V 230V

5 5 10156.3…19 150-E32NCE-FC 150-E32NCA-FC

7.510202510…30 10 10 25 30 12.3…37 10 15 30 40 14.3…43 150-E74NCE-FC 150-E74NCA-FC 15 20 40 50 20…60 25 30 60 75 28.3…85 40 50 100 125 34…135

Motor FLA must fall within the specified range to operate correctly.

➊

Overload Range

➊

Control Voltage Cat. Nos.

150-E51NCE-FC 150-E51NCA-FC 150-E64NCE-FC 150-E64NCA-FC

150-E104NCE-FC 150-E104NCA-FC 150-E147NCE-FC 150-E147NCA-FC 150-E234NCE-FC 150-E234NCA-FC

8 Rockwell Automation Publication 150-UM009D-EN-P - February 2011

Installation & Wiring

4.56

(115.7)

5.67

(144.0)

7.01

(178.0)

6.50

(165.1)

5.00

(127.0)

4X Ø 0.220 thru

(5.6)

CAT. XXXXXXXX SER. B

T6 T4 T5

Chapter

Unpacking

Mounting

Dimensions

Prior to installation, unpack the starter panel from its packaging and perform a complete visual inspection of the panel. Inspect all components including the controller, wiring, and fault contactor for damage related to shipping and handling. Claims for damage must be made to the carrier as soon as possible after receipt of the shipment.

The small footprint of the starter panel makes it ideal for mounting in the same space previously occupied by legacy solid state starters and traditional Full Voltage starters. The starter panel does not require mounting requirements beyond the basic footprint of the panel.

The product may incorporate a small cooling fan. There are no additional cooling requirements for the product. However, it is good practice to leave at least 6 inches (15.24 cm) of free space above and below the unit for ideal air flow.

Figure 2 - Panel Dimensions for 32, 51, & 64 A Elevator Panels

This screw is intended to secure a prepared bonding conductor (e.g., a bonding conductor with a crimped-

➊

Rockwell Automation Publication 150-UM009D-EN-P - February 2011 9

on lug) or a suitable terminal for connection of an unprepared bonding conductor (e.g., a bonding conductor with a stripped wire end). This screw is not intended for a direct field wiring connection of an unprepared bonding conductor or equipment grounding conductor.

Chapter 2 Installation & Wiring

8.86

(225.0)

5.82

(147.9)

9.45

(240.0)

8.46

(215.0)

8.07

(205.0)

4X Ø 0.260 Thru

(6.6)

CAT. XXXXXXXX SER. B

T6 T4 T5

20.28

(515.0)

8.52

(216.4)

4X Ø 0.343 thru

(8.7)

CAT. XXXXXXXX SER. B

14.25

(362.0)

13.00

(330.2)

19.27

(489.5)

T6 T4 T5

Figure 3 - Panel Dimensions for 74, 104, & 147 A Elevator Panels

➊

This screw is intended to secure a prepared bonding conductor (e.g., a bonding conductor with a crimped-

Figure 4 - Panel Dimensions for 234 A Elevator Panels

➊

This screw is intended to secure a prepared bonding conductor (e.g., a bonding conductor with a crimped-

10 Rockwell Automation Publication 150-UM009D-EN-P- February 2011

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