Rockwell Automation 1560E SMC User Manual

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Medium Voltage SMC Flex™ Motor Controller

Bulletins 1503E, 1560E and 1562E

User Manual

Important User Information

IMPORTANT

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 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.

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.

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.

ARC FLASH 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 Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belong ing to Rockwell Automation are property of their respective companies.

Page

Preface Service Procedure............................................................................ P-1

Product Overview Chapter 1

Manual Objectives............................................................................ 1-1

Documentation.................................................................................. 1-1

Description........................................................................................ 1-1

1503E – OEM Controller ........................................................... 1-1

1560E – Retrofit Controller ....................................................... 1-2

1562E – Combination Controller ............................................... 1-2

SMC-Flex Control Module ......................................................... 1-2

Starting Modes.................................................................................. 1-3

Soft Start .................................................................................... 1-3

Selectable Kickstart.................................................................... 1-4

Current Limit Start ..................................................................... 1-4

Dual Ramp Start ......................................................................... 1-5

Full Voltage Start ....................................................................... 1-5

Preset Slow Speed ....................................................................... 1-6

Linear Speed Acceleration and Deceleration .............................. 1-7

Soft Stop...................................................................................... 1-8

Protection and Diagnostics ............................................................... 1-9

Overload..................................................................................... 1-9

Underload.................................................................................. 1-11

Undervoltage ............................................................................. 1-11

Overvoltage ............................................................................... 1-11

Unbalance.................................................................................. 1-12

Stall Protection and Jam Detection ........................................... 1-12

Ground Fault ............................................................................. 1-13

Thermistor/PTC Protection ....................................................... 1-14

Open Gate ................................................................................ 1-16

Line Faults................................................................................ 1-16

Excessive Starts/Hour .............................................................. 1-17

Overtemperature....................................................................... 1-17

Metering.......................................................................................... 1-17

Communication............................................................................... 1-18

Programming .................................................................................. 1-18

Status Indication ............................................................................. 1-19

Control Options .............................................................................. 1-19

Pump Control Option ............................................................... 1-19

Application Considerations.................................................. 1-20

Braking Control Option............................................................. 1-21

Hardware Description..................................................................... 1-22

Power Module .......................................................................... 1-22

Self-Powered Silicon-Controlled Rectifier Gate Driver Board .... 1-22

Interface Board......................................................................... 1-23

1560E-UM050B-EN-P - June 2013

ii Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual

Product Overview (cont.) Chapter 1 Page

Typical MV SMC-Flex Power System Diagrams

Bulletin 1562E (Without Stop Control).................................... 1-24

Bulletin 1562E (With Stop Control).......................................... 1-25

Bulletin 1562E (Without Stop Control)..................................... 1-26

Bulletin 1562E (With Stop Control).......................................... 1-27

Functional Descriptions .................................................................. 1-28

Bulletin 1562E • Basic Control – Controlled Start Only ......... 1-28

Bulletin 1562E • Basic Control – With Controlled Stop........... 1-29

Bulletin 1562E • DPI Control – Controlled Start Only............. 1-29

Bulletin 1560E • Basic Control – Controlled Start Only ......... 1-30

Bulletin 1560E • Basic Control – With Controlled Stop........... 1-30

Bulletin 1560E • DPI Control – Controlled Start Only............. 1-30

Schematics:

Bul. 1562E IntelliVAC Control Circuit (Without Stop Control) ... 1-31

Bul. 1562E IntelliVAC Control Circuit (With Stop Control) ........ 1-32

Bul. 1562E IntelliVAC Control Circuit (With DeviceNet)........... 1-33

Bul. 1560E IntelliVAC Control Circuit (Without Stop Control) ... 1-34

Bul. 1560E IntelliVAC Control Circuit (With Stop Control) ........ 1-35

Bul. 1560E IntelliVAC Control Circuit (With DeviceNet) .......... 1-36

Installation Chapter 2

Receiving .......................................................................................... 2-1

Safety and Codes .............................................................................. 2-1

Unpacking and Inspection ................................................................ 2-1

General Precautions .......................................................................... 2-2

Transportation and Handling ............................................................ 2-2

Installation Site ................................................................................. 2-3

Mounting ..................................................................................... 2-3

Grounding Practices .................................................................... 2-4

Recommended Torque Values........................................................... 2-4

Power Connections ........................................................................... 2-5

Bulletin 1562E ............................................................................ 2-5

Bulletin 1560E ............................................................................ 2-8

Bulletin 1503E .......................................................................... 2-11

Power Wiring.................................................................................. 2-12

Interlocking..................................................................................... 2-12

Installation ...................................................................................... 2-13

Physical Location ...................................................................... 2-13

Fan............................................................................................. 2-13

Ground Bus Bar......................................................................... 2-13

Power and Control Wiring ........................................................ 2-13

Control Cables........................................................................... 2-13

Fibre-Optic Cables .................................................................... 2-13

Power Factor Correction Capacitors ......................................... 2-14

1560E-UM050B-EN-P - June 2013

Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual iii

Installation (cont.) Chapter 2 Page

Surge Arrestor Protection Devices ................................................. 2-16

Motor Overload Protection ............................................................. 2-17

EMC Compliance ............................................................................ 2-18

Control Power.................................................................................. 2-19

Control Terminal Designations ...................................................... 2-20

Commissioning Procedure Chapter 3

Preliminary Set-Up ........................................................................... 3-1

System Characteristics...................................................................... 3-2

Preliminary Check ............................................................................ 3-3

Programming .................................................................................... 3-3

Hi-Pot and Megger Test.................................................................... 3-4

Typical MV SMC-Flex Power System Diagram ............................... 3-5

Connection and Test Information for Interface Board ...................... 3-6

Power Supply Tests .......................................................................... 3-7

Control Function Tests ................................................................... 3-10

Resistance Checks .......................................................................... 3-11

Voltage Sensing Module ................................................................. 3-11

Start-Up .......................................................................................... 3-12

Programming Chapter 4

Overview........................................................................................... 4-1

Keypad Description .......................................................................... 4-1

Programming Menu .......................................................................... 4-1

Menu Structure Hierarchy ................................................................. 4-2

Parameter Linear List ........................................................................ 4-4

Password ........................................................................................... 4-5

Parameter Management ................................................................... 4-6

Parameter Modification .................................................................... 4-8

Soft Start ........................................................................................... 4-9

Current Limit Start............................................................................ 4-9

Dual Ramp Start ............................................................................. 4-10

Full Voltage Start ........................................................................... 4-11

Linear Speed .................................................................................... 4-11

Basic Setup ..................................................................................... 4-11

Motor Protection.............................................................................. 4-13

Example Settings ............................................................................ 4-13

Motor Information ........................................................................... 4-15

1560E-UM050B-EN-P - June 2013

iv Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual

Metering Chapter 5 Page

Overview........................................................................................... 5-1

Motor Data Entry.............................................................................. 5-1

Options Chapter 6

Overview........................................................................................... 6-1

Human Interface Module .................................................................. 6-1

Programming Parameters................................................................... 6-3

Control Wiring................................................................................... 6-5

Diagnostics Chapter 7

Overview........................................................................................... 7-1

Fault Display...................................................................................... 7-1

Clear Fault ......................................................................................... 7-2

Fault Buffer........................................................................................ 7-2

Fault Contact...................................................................................... 7-3

Fault Definitions ................................................................................ 7-4

Communications Chapter 8

Overview............................................................................................ 8-1

Communication Ports ........................................................................ 8-1

Human Interface Module ................................................................... 8-1

Keypad Description..................................................................... 8-2

Connecting the Human Interface Module to the Controller........ 8-4

Control Enable ............................................................................ 8-4

Control Enable ................................................................................... 8-6

Loss of Communication and Network Faults .................................... 8-6

SMC-Flex Specific Information ........................................................ 8-6

Default Input/Output Configuration .................................................. 8-7

Variable Input/Output Configuration ................................................ 8-7

SMC-Flex Bit Identification .............................................................. 8-8

Reference/Feedback........................................................................... 8-9

Parameter Information ....................................................................... 8-9

Scale Factors for PLC Communication ............................................. 8-9

Display Text Unit Equivalents .......................................................... 8-9

Configuring DataLinks .................................................................... 8-10

Updating Firmware .......................................................................... 8-10

1560E-UM050B-EN-P - June 2013

Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual v

Troubleshooting Chapter 9 Page

General Notes and Warnings ............................................................ 9-1

Fault Display Explanation ................................................................ 9-3

Control Module Removal .................................................................. 9-6

Voltage Feedback Circuit Tests......................................................... 9-7

Voltage-Sensing Board Replacement ................................................ 9-8

IGDPS Boards ................................................................................... 9-9

IGDPS Board LEDs......................................................................... 9-10

Circuit Board Replacement.............................................................. 9-11

Power Circuit Troubleshooting ....................................................... 9-12

Thyristor (SCR) Testing............................................................ 9-12

SCR Replacement Procedure .................................................... 9-13

Snubber and Resistor Circuit Testing.............................................. 9-27

Snubber Resistor Replacement ........................................................ 9-30

Wiring Diagrams ............................................................................. 9-31

Maintenance Chapter 10

Safety and Preventative ................................................................... 10-1

Periodic Inspection .......................................................................... 10-1

Contamination ........................................................................... 10-1

Vacuum Bottles......................................................................... 10-2

Terminals .................................................................................. 10-2

Coils .......................................................................................... 10-2

Solid-State Devices ................................................................... 10-3

Static-Sensitive Items ................................................................ 10-3

Overload Maintenance After a Fault Condition........................ 10-3

Final Check Out ........................................................................ 10-3

"Keep Good Maintenance Records" ......................................... 10-4

Power Components ................................................................... 10-4

Control Components – Electronic ............................................. 10-4

Fans ........................................................................................... 10-4

Interlocks................................................................................... 10-4

Barriers...................................................................................... 10-4

Environmental Considerations......................................................... 10-5

Hazardous Materials ................................................................. 10-5

Disposal..................................................................................... 10-6

1560E-UM050A-EN-P – August 2004

vi Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual

Appendix A 1560E/1562E SMC-Flex Specifications Page

Specifications – Table A.1 ............................................................... A-1

Altitude Derating –Table A.2 ........................................................... A-3

Area Available for Cable Entry/Exit – Table A.3 ............................ A-3

Cable Quantity and Size – Table A.4 ............................................... A-4

Shipping Weights and Dimensions – Table A.5............................... A-5

Power Bus and Ground Bus – Table A.6.......................................... A-6

Power Fuses and Losses – Table A.7 ............................................... A-7

Control Wire and Power Wire – Table A.8 ...................................... A-8

Appendix B Parameter Information

Parameter List................................................................................... B-1

Appendix C 1560E and 1562E Relay Control

Functional Description ..................................................................... C-1

Bulletin 1562E • Basic Control – Controlled Start Only .......... C-1

Bulletin 1562E • Basic Control – With Controlled Stop............ C-2

Bulletin 1562E • DPI Control – Controlled Start Only.............. C-2

Bulletin 1560E • Basic Control – Controlled Start Only .......... C-3

Bulletin 1560E • Basic Control – With Controlled Stop............ C-3

Bulletin 1560E • DPI Control – Controlled Start Only.............. C-4

Schematics:

Bul. 1562E Relay Control Circuit (Without Stop Control) ............ C-5

Bul. 1562E Relay Control Circuit (With Stop Control)................. C-6

Bul. 1562E Relay Control Circuit (With DeviceNet) ................... C-7

Bul. 1560E Relay Control Circuit (Without Stop Control) ............ C-8

Bul. 1560E Relay Control Circuit (With Stop Control)................. C-9

Bul. 1560E Relay Control Circuit (With DeviceNet) ................. C-10

Appendix D Spare Parts

Bul. 1503E • 1000-1500V, 180/360A (6-device) ............................. D-1

Bul. 1503E, 1560E, 1562E • 2300V, 180/360A (6-device).............. D-2

Bul. 1503E, 1560E, 1562E • 2300V, 600A (6-device)..................... D-3

Bul. 1503E, 1560E, 1562E • 3300/4160V, 180/360A (12-device)... D-4

Bul. 1503E, 1560E, 1562E • 3300/4160V, 600A (12-device).......... D-5

Bul. 1503E, 1560E, 1562E • 5500/6900V, 180/360A (18-device)... D-6

Bul. 1503E, 1560E, 1562E • 5500/6900V, 600A (18-device).......... D-7

Accessories ....................................................................................... D-8

Appendix E Accessories

Accessories ........................................................................................E-1

1560E-UM050A-EN-P – August 2004

Preface

Service Procedure For your convenience, the Rockwell Automation Global Manufacturing

Solutions (GMS), provides an efficient and convenient method of servicing medium voltage products.

Contact your local area support office to make arrangements to have a qualified service representative come to your facility.

A complete listing of Area Support Offices may be obtained by calling your local Rockwell Automation Distributor or Sales Office.

For MV SMC-Flex technical support on start-up or existing installations, contact your Rockwell Automation representative. You can also call

1-519-740-4790 for assistance Monday through Friday from 9:00 a.m.

to 5:00 p.m. (Eastern time zone).

1560E-UM050B-EN-P - June 2013

Preface

1560E-UM050B-EN-P - June 2013

Chapter 1

Product Overview

Manual Objectives This manual is intended for use by personnel 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 controllers. The family consists of the following Bulletin numbers: 1503E, 1560E and 1562E.

Documentation The following Rockwell Automation publications provide pertinent

information for the MV SMC-Flex and components:

• MVB-5.0 General Handling Procedures for MV Controllers

• 1500-UM055B-EN-P Medium Voltage Controller Two-High Cabinet (200A/400A) – User Manual

• 1502-UM050C-EN-P 400A Vacuum Contactor, Series D – User Manual

• 1502-UM052B-EN-P 400A Vacuum Contactor, Series E – User Manual

• 1502-UM051C-EN-P 800A Vacuum Contactor, Series D and E – User Manual

• 1560E-SR022A-EN-P Medium Voltage SMC-Flex Controllers – General Specifications

family of

Description The MV SMC-Flex is a solid-state, three-phase, AC line controller. It is

designed to provide microprocessor-controlled starting and stopping of standard three-phase, squirrel-cage induction motors, using the same control module as the Allen-Bradley Bulletin 150 SMC-Flex.

1503E – OEM Controller

A chassis-mount medium voltage solid-state controller designed to mount in an OEM or customer supplied structure, and designed to work in conjunction with an existing or OEM/customer supplied starter. It is comprised of 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

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1-2 Product Overview%5-"%.0*UNE%5-"%.0*UNE

Description (cont.) 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 (3) current transformers

• A low voltage control panel complete with microprocessor-based control module

• Top and bottom plates to accommodate power cables.

Note: See Interlocking, page 2-8.

1562E – Combination Controller

A medium voltage solid-state controller that provides isolation and protection for new installations. It includes:

• Tin-plated, copper, horizontal power bus (optional)

• A continuous, bare copper ground bus

• Power electronics

• A main non-load-break isolating switch and operating handle

• An isolation vacuum contactor

• A bypass vacuum contactor

• Three (3) current limiting power fuses for NEMA Class E2 operation

• Three (3) current transformers

• A control power transformer (optional)

• A low voltage control panel complete with microprocessor-based control

module

• Space for necessary auxiliary control and metering devices

• Top and bottom plates to accommodate power cables

• Motor overload protection (included in SMC-Flex control module)

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SMC-Flex™ Control Module

The MV SMC-Flex controller offers a full range of starting and stopping modes as standard:

• Soft Start with Selectable Kickstart

• Soft Stop

• Current Limit Start with Selectable Kickstart

• Linear Acceleration with Selectable Kickstart

• Linear Deceleration

• Dual Ramp Start

• Preset Slow Speed

• Full Voltage Start

: This option utilizes gating patterns which result in motor and line currents that produce noise

and vibration in the motor and/or distribution transformer. This must be considered before applying this option.

SMC-Flex™ Control Module (cont.)

Other features that offer further user benefit include:

• Extensive protection features

• Metering

• Communication capability

Innovative control option provides enhanced performance:

• Pump Control (Start and Stop Control modes) These modes, features and options are further described in this chapter.

: This option utilizes gating patterns which result in motor and line currents that produce noise and vibration

in the motor and/or distribution transformer. The factory should be consulted before applying this option.

Starting Modes Soft Start

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This mode has the most general application. The motor is given an initial torque setting, which is user-adjustable from 0 to 90% of locked-rotor torque. From the initial torque level, the output voltage to the motor is steplessly increased during the acceleration ramp time. The acceleration ramp time is user-adjustable from 0 to 30 seconds. Once the MV SMC-Flex controller senses that the motor has reached the up-to-speed condition during the voltage ramp operation, the output voltage automatically switches to full voltage, and the bypass contactor is closed.

Figure 1.1– Soft Start

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1-4 Product Overview

Starting Modes (cont.) Selectable Kickstart :

Selectable kickstart provides a power boost at start-up that is user-adjustable from 0 to 90% of locked rotor torque. The additional power helps motors generate higher torque to overcome the resistive mechanical forces of some applications when they are started. The selectable kickstart time is useradjustable from 0.0 to 2.0 seconds.

Kickstart

100%

Initial

Torque

Start

Figure 1.2 – Selectable Kickstart

Run

Run e (seconds)

e (seconds)

Tim

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% to 600% of the motor's full-load ampere rating, and the current limit time is user-adjustable from 0 to 30 seconds. Once the MV SMC-Flex™ controller senses that the motor has reached the up-tospeed condition during the current limit starting mode, the output voltage automatically switches to full voltage and the bypass contactor is closed.

600%

Percent Full

Load Current

50%

Start

e (seconds)

Tim

Figure 1.3 – Current Limit Start

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: Kickstart is also available with Current Limit Start, Dual Ramp Start and Linear Acceleration. ; The Current Limit Start mode design is based on a motor with a locked-rotor current rating that is 600% of

the full-load current rating.

Product Overview 1-5

Dual Ramp Start :

This starting mode is useful for applications that have varying loads (and therefore varying starting torque requirements). Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings.

Percent

Percent Voltage

Voltage

100%

InitialTorque#2

Initial Torque #1

Start#1

mp #

Ramp #

Ramp #1

Time (seconds)

Run #1

Run #2Start#2

Figure 1.4 – Dual Ramp Start

: Dual Ramp Start is available only with the standard controller.

Full Voltage Start

This starting mode is used for applications requiring across-the-line starting. The output voltage to the motor will reach full voltage within ¼ second.

100%

Percent

Percent Voltage

Voltage

e (seconds)

Tim

Figure 1.5 – Full Voltage Start

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1-6 Product Overview

Starting Modes (cont.) 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 7% of base speed (low) or 15% of base speed (high) settings in the forward direction. Reverse can also be programmed and offers 10% of base speed (low) and 20% of base speed (high) settings.

Forward

15% – High

7% – Low

Time (seconds)

Start

Run

RunRun

10% – Low

20% – High

Reverse

Figure 1.6 – Preset Slow Speed Option

Important: Slow speed running is not intended for continuous operation due to reduced motor cooling. The two starts per hour limitation also applies to slow speed operation. This option employs a cycle-skipping scheme which produces limited torque. Applications should be checked with the factory.

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Product Overview 1-7

Linear Speed Acceleration and Deceleration

The SMC-Flex has the ability to control the motor speed during starting and stopping maneuvers. A tachometer signal (0 to 5V DC) is required to perform this start mode. The start time is selectable from 0 to 30 seconds and determines the time the motor will ramp from 0 speed to full speed. Kickstart is available with this option.

100%

Motor

Speed

Run Stop

Start

Run Stop

Time (seconds)

Figure 1.7 – Linear Speed Acceleration

Linear deceleration does not need to be used, even if linear acceleration is used. The stop time can be programmed for 0 to 60 seconds. Linear deceleration cannot brake the motor/load and reduce the stop time.

Note: Consult factory if settings over 30 seconds are required. The base rating of the MV SMC-Flex is two starts (or one start/stop combination) per hour, thirty seconds maximum for each operation. A stopping operation counts as a start for purposes of thermal capacity calculations.

A T T E N T I O NA T T E N T I O N

Linear Deceleration is not intended to be used as an emergency stop. Such usage may result in severe injury or death. Refer to the applicable standards for emergency stop requirements.

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Starting Modes (cont.) Soft Stop

This feature can be used in applications that require an extended coast-torest time. The voltage ramp-down time is user-adjustable from 0 to 60 seconds and is adjusted independently from the starting time. The load will stop when the output voltage drops to a point where the load torque is greater than the developed motor torque.

Percent

Percent Voltage

Voltage

100%

Initia

Torque

Kickstart

Coast-to-rest

Soft Stop

Start

Time

Run

(seconds)

SoftStop

Figure 1.8 – Soft Stop Option

A T T E N T I O NA T T E N T I O N

Soft Stop is not intended to be used as an emergency stop. Such usage may result in severe injury or death. Refer to the applicable standards for emergency stop requirements.

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Product Overview 1-9

Protection and Diagnostics 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 (see Chapter 4, Programming). An Overload Fault will occur when this value reaches 100%. The parameters below provide application flexibility and easy setup.

Parameter Range

Overload Class Off, 10, 15, 20, 30 Overload Reset Manual – Auto

Motor FLC 1.0 – 1000.0 amps

ServiceFactor 0.01–1.99

Important: During slow speed operations, current waveforms exhibit non-sinusoidal characteristics. These non-sinusoidal characteristics inhibit the controller's current-measurement capability. To compensate for additional motor heating that may result, the controller uses motor thermal modeling, which increments motor thermal usage. This compensation takes place when the Preset Slow Speed option is used.

Notes:

1. The factory default setting for Overload Class, which is "OFF", disables

overload protection. An overload trip class and the motor's full-load current rating must be programmed to enable overload protection.

2. If the 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.

3. Automatic reset of an overload fault requires the start input to be

cycled in a 2-wire control scheme.

4. The trip rating is 117% of the programmed FLC.

Figures 1.9 and 1.10 provide the overload trip curves for the available trip classes.

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1-10 Product Overview

Protection and Diagnostics (cont.)

Class 10

1000.0

100.0

10.0

1.0

Approximate Trip Time (seconds)

0.1

Class 10

11023 987654

Multiples of FLC

10000.0

1000.0

100.0

10.0

Approximate Trip Time (seconds)

1.0

1.0 11023 987654

11023 987654

Class 15

Multiplesof FLC

10000.0

1000.0

100.0

10.0

ApproximateTripTime (seconds)

1.0

1.0 11023 987654

11023 987654

Multiples of FLC

Class 20

10000.0

1000.0

100.0

10.0

Approximate Trip Time (seconds)

1.0

1.0 11023 987654

11023 987654

Class 30

Multiples of FLC

Approximate trip time for 3-phase balanced

Approximate trip time for 3-phase balanced condition from cold start.

condition from cold start.

100000

1000

100

Seconda

Approximate trip time for 3-phase balanced

Approximate trip time for 3-phase balanced condition from hot start.

condition from hot start.

Figure 1.9 – Overload Trip Curves

Auto Reset Times:

Class 10 = 90 s

Class 10 = 90 s Class 15 = 135 s

Class 15 = 135 s Class 20 = 180 s

Class 20 = 180 s Class 30 = 270 s

Class 30 = 270 s

Class 10

Class 10 Class 15

Class 15

Class 15 Class 20

Class 20

Class 20 Class 30

Class 30

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100% 1000%

Percent Full Load Current Setting

Figure 1.10 – Restart Trip Curves after Auto Reset

Product Overview 1-11

Underload :

Utilizing the underload protection of the MV SMC-Flex controller, motor operation can be halted if a sudden drop in current is sensed.

The MV SMC-Flex controller provides an adjustable underload trip setting from 0 to 99% of the programmed motor full load current rating. Trip delay time can be adjusted from 0 to 99 seconds.

: Underload protection is disabled during slow speed and braking operations.

Undervoltage ;

Utilizing the undervoltage protection of the MV SMC-Flex, motor operation can be halted if a sudden drop in voltage is detected.

The MV SMC-Flex controller provides an adjustable undervoltage trip setting from 0 to 99% of the programmed motor voltage. Trip delay time can be adjusted from 0 to 99 seconds.

Note: For medium voltage applications, undervoltage protection should be set from 80 to 99%.

An alarm (pre-fault) indication level can be programmed to indicate the unit is getting close to faulting. The alarm modification information is displayed through the LCD, HIM, Communication (if applicable) and alarm contact closing.

Overvoltage ;

Utilizing the overvoltage protection of the MV SMC-Flex, motor operation can be halted if a sudden increase in voltage is detected.

The MV SMC-Flex controller provides an adjustable overvoltage trip setting from 0 to 199% of the programmed motor voltage. Trip delay time can be adjusted from 0 to 99 seconds.

Note: For medium voltage applications, overvoltage protection should be set from 100 to 115%.

;Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.

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1-12 Product Overview

Protection and Diagnostics (cont.)

Unbalance :

The MV SMC-Flex is able to detect an unbalance in line voltages. Motor operation can be halted if the unbalance is greater than the desired range.

The MV SMC-Flex controller provides an adjustable unbalance setting from 0 to 25% of the line voltages. Trip delay time can be adjusted from 0 to 99 seconds.

:Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.

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 to 10.0 seconds (enabled only after the programmed start time expires).

• An alarm (pre-fault) indication level can be programmed to indicate the unit is getting close to faulting. The alarm modification information is displayed through the LCD, HIM, Communication (if applicable) and alarm contact closing.

• Jam detection allows the user to determine the jam level (up to 1000% of the motor's full-load current rating) and the delay time (up to 99.0 seconds) for application flexibility.

600%

Percent

FullLoad

Current

Programmed StartTime Stall

Time (seconds)

Figure 1.11 – Stall Protection

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Percent

FullLoad

Current

600%

Running

Time (seconds)

Figure 1.12 – Jam Detection :

Jam

Product Overview 1-1

User Programmed

User Programmed Trip Level

Trip Level

Jam Detection is disabled during slow speed and braking operation.

Ground Fault

In isolated or high impedance-grounded systems, core-balanced current sensors are typically used to detect low level ground faults caused by insulation breakdowns or entry of foreign objects. Detection of such ground faults can be used to interrupt the system to prevent further damage, or to alert the appropriate personnel to perform timely maintenance.

The MV SMC-Flex’s ground fault detection capabilities consist of using a core balance current transformer for 1 to 5A core-balanced ground fault protection with the option of enabling Ground Fault Trip, Ground Fault Alarm, or both (a core balance CT is provided with 1562E units).

Ground Fault Trip

The MV SMC-Flex will trip with a ground fault indication if:

• No trip currently exists

• Ground fault protection is enabled

• GF Inhibit Time has expired

• GF Current is equal to or greater than the GF Trip Level for a time

period greater than the GF Trip Delay

Parameter 75, Gnd Flt Inh Time, allows the installer to inhibit a ground fault trip from occurring during the motor starting sequence and is adjustable from 0 to 250 seconds.

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1-14 Product Overview

Protection and Diagnostics (cont.)

Ground Fault Trip (cont.)

Parameter 74, Gnd Flt Delay, allows the installer to define the time period a ground fault condition must be present before a trip occurs. It is adjustable from 0.1 to 25 seconds.

Parameter 73, Gnd Flt Level, allows the installer to define the ground fault current at which the MV SMC-Flex will trip. It is adjustable from

1.0 to 5.0 A.

Important: The ground fault inhibit timer starts after the maximum phase of load current transitions from 0 A to 30% of the device’s minimum FLA Setting or the GF Current is greater than or equal to 0.5 A. The MV SMC-Flex does not begin monitoring for a ground fault condition until the Gnd Flt 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 Gnd Flt A Lvl

Parameter 77, Gnd Flt A Lvl, allows the installer to define the ground fault current at which an alarm will be indicated. It is adjustable from 1.0 to 5.0 A.

Parameter 78, Gnd Flt A Dly, allows the installer to define the time period a ground fault alarm condition must be present before a trip occurs. It is adjustable from 0.1 to 25 seconds.

Thermistor/PTC Protection

The MV SMC-Flex provides terminals 23 and 24 for the connection of positive temperature coefficient (PTC) thermistor sensors. PTC sensors are commonly embedded in motor stator windings to monitor the motor winding temperature. When the motor winding temperature reaches the PTC sensor’s temperature rating, the PTC sensor’s resistance transitions from a low to high value. Since PTC sensors react to actual temperature, enhanced motor protection can be provided to address such conditions as obstructed cooling and high ambient temperatures.

The following table defines the MV SMC-Flex PTC thermistor input and response ratings:

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Product Overview 1-15

Table 1.A – PTC Input R atings

Response Resistance 3400Ω ± 150 Ω Reset Resistance 1600 Ω ± 100 Ω Short-circuit Trip Resistance 25 Ω ±10Ω Maximum Voltage at PTCTerminals (R Maximum Voltage at PTCTerminals (R Maximum Number of Sensors 6 Maximum Cold Resistance of PTC Sensor Chain 1500 Ω Response Time 800 ms

=4kΩ)<7.5V

PTC

= open) 30V

PTC

The following figure illustrates the required PTC sensor characteristics, per IEC-34-11-2.

4000

1330

550

550 250

250

250 100

100

-20°C

-20°C 0°C

0°C

TNF-20K

TNF- 5K

TNF

TNF+15K

TNF+ 5K

Figure 1.13 – PTC Sensor Characteristics per IEC-34-11-2

PTC Trip

The MV SMC-Flex will trip with a PTC indication if:

• No other fault currently exists

• PTC protection is enabled

• The resistance across terminals 23 and 24 is either greater than the relay’s response resistance or less than the short-circuit trip resistance.

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1-16 Product Overview

Protection and Diagnostics (cont.)

Open Gate

An open-gate fault indicates that improper SCR firing, typically caused by an open SCR gate or driver system, has been detected on one of the power poles. Before the controller shuts down, it will attempt to start the motor a total of three times (or as programmed in Parameter 82).

An open gate is detected when the module sends a gate signal to the SCRs but does not detect that they turned on. SCR turn-on is detected when the voltage across the leg (L-T) collapses.

Line Faults

The MV SMC-Flex™ controller continually monitors line conditions for abnormal factors. Pre-start protection includes:

• 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

: Phase reversal protection is functional only at pre-start.

: can be toggled either ON or OFF.

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Product Overview 1-17

Excessive Starts/Hour

The MV SMC-Flex™ module allows the user to program the desired number of starts per hour (up to 99). This helps eliminate motor stress caused by repeated starting over a short time period.

Note: The base rating of the MV SMC-Flex is two starts (thirty seconds each max.) per hour. Applications requiring more frequent starts, or longer duration starts, should be reviewed with the factory to avoid equipment damage.

Overtemperature

The power module temperature is monitored during starting and stopping maneuvers by thermistors. The thermistor is connected to the gate driver board where it is processed, and the status is transmitted by fibre-optic cable through the interface board to the control module. When an overtemperature condition exists (>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 (see page 9-1 for instructions).

Metering Power monitoring parameters include:

• Three-phase current

• Three-phase voltage

• Power in MW

• Power usage in MWh

• Power factor

• Motor thermal capacity usage

• Elapsed time

• Motor speed (100%, 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%.

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1-18 Product Overview

Communication A serial interface port (DPI) is provided as standard, which allows

connection to the Bulletin 20-HIM LCD human interface modules.

DPIDPI

Figure 1.14 – DPI Location

A T T E N T I O NA T T E N T I O N

Two peripheral devices can be connected to the DPI. The maximum output current through the DPI is 280 mA.

Programming Setup is easy with the built-in keypad and three-line, sixteen-character

backlit LCD. Parameters are organized in a three-level menu structure, using a text format for straightforward programming.

Port 5 –DPI Communications

Port 2

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Ports 2 and 3 when two HIMs

Ports 2 and 3 when two HIMs are connected with a splitter

are connected with a splitter

Figure 1.15 – Built-in Keypad and LCD

Product Overview 1-19

Status Indication Four programmable hard contact outputs are provided as standard:

• The Auxiliary #1 Contact is N.O. It is always programmed for

Up-to-speed to control the bypass contactor in MV applications.

• The fault Contact is for fault indication and is programmable for N.O./N.C.

• The alarm Contact is for alarm indication and is programmable for N.O./N.C.

• The Auxiliary #2 Contact is for normal indication and is programmable

for N.O./N.C. For MV applications, it is configured as N.O. to control the line contactor.

11 12 13 14 15 16 17 18 19 20 21 22

SMC-Flex

Control Terminals

23 24 25 26 27 28 29 30 31 32 33 34

PTC

PTC Input

Input

TACH

Input

Ground

Fault

Contact

Aux#1

Up-to-Speed

Alarm

Contact

Aux #2

Aux #2 Normal

Normal

Figure 1.16 – Control Terminals

Control Options The MV SMC-Flex™ controller offers the control options described below.

Important: The options listed in this section are mutually exclusive and must be specified when ordering. An existing controller may be upgraded to another control option by replacing the control module and possibly other components. Consult your nearest Rockwell Automation sales office.

Pump Control Option

This option reduces surges during the starting and stopping of a centrifugal pump by smoothly accelerating and decelerating the motor. The 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.

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1-20 Product Overview

Control Options (cont.) 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 st o pping 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 for a centrifugal pump running at greater than approximately 2/3 of the motor rated horsepower.

4. Pump applications with input and/or output valves that are closed during starting and/or stopping may not benefit from the Pump Control option. Consult the factory for applications with valves.

5. For starting or stopping times longer than 15 seconds, power fuse selection should be reviewed to ensure no element damage occurs. The fuse minimum melting time-current characteristic curve should be consulted to ensure that, at 1.1 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.

100%

Motor

Speed

Pump Start Run Pump Stop

me (seconds)

Figure 1.17 – Pump Control Option

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A T T E N T I O NA T T E N T I O N

Product Overview 1-21

Pump stopping is not intended to be used as an emergency stop. Refer to the applicable standard for emergency stop requirements.

A T T E N T I O NA T T E N T I O N

Pump stopping may cause motor heating depending on the mechanical dynamics of the pumping system. Therefore, select the lowest stopping time setting that will satisfactorily stop the pump.

Braking Control Option

The Braking Control option (Smart Motor Braking, Accu-Stop and Slow Speed with Braking) are not offered for standard use in MV applications. Please consult factory for further assistance.

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1-22 Product Overview

Hardware Description The following sections contain descriptions of system components and

system operation. Each section will be described to give the user an understanding of the MV SMC-Flex to facilitate operation and maintenance of the system. Refer to Figures 1.18 through 1.21, 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 gate driver circuits which derive their power from the snubber circuit.

Voltage sharing resistors are connected across each SCR pair to provide static voltage balance for series-connected SCRs. These resistors are tapped to provide a reference for overvoltage protection circuitry on the gate driver board.

A voltage sensing board is used to reduce the line-side and load-side voltages to lower levels that can be measured by the SMC-Flex control module.

Self-Powered Silicon-Controlled Rectifier Gate Driver Board

This board provides the turn-on capability for SCR devices. The board also provides optical fibre isolation between itself and the gating source logic. It is powered by recovering energy from the snubber circuit, so it is fully isolated from the control and logic circuits; it is self-economizing when the unit is not running, or is in bypass mode.

Note: If pump control or stop control are used, the gate driver boards are powered continuously using separate power supply boards. (Refer to Chapter 8 for additional details.)

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 fibre-optic cable if the temperature is below the setpoint (85°C). If the temperature rises above the setpoint, the driver is turned off, and the MV SMC-Flex is signalled to stop gating and initiate a temperature fault.

Due to the self-powered nature of the circuits, this function is active only while the SMC is active. While the starter is off, or in bypass, no power is dissipated in the SCRs and the temperature of the SCRs can only decrease.

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Product Overview 1-23

Interface Board

This circuit board takes current transformer signals plus line-side and loadside voltage feedback signals from the voltage sensing board and passes them to the SMC-Flex for processing. The control module produces gating signals for the SCRs, which are received on the interface board, and used to drive fibre-optic transmitters. The gating signals are sent to the gate-driver circuit board via fibre-optic cables. The interface board also receives temperature feedback from the gate-driver board via fibre-optic cable(s). If the heatsink temperature rises above a set value, a signal is sent to the SMC-Flex to stop gating the SCRs and initiate a temperature fault.

For a detailed layout of this circuit board, refer to Figure 3.2 on page 3-6.

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1-24 Product Overview

Figure 1.18 – Typical MV SMC-Flex Power System • Bulletin 1562E (Without Stop Control)

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Product Overview 1-25

Figure 1.19 – Typical MV SMC-Flex Power System • Bulletin 1562E (With Stop Control)

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1-26 Product Overview

Figure 1.20 – Typical MV SMC-Flex Power System • Bulletin 1560E (Without Stop Control)

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Product Overview 1-27

Figure 1.21– Typical MV SMC-Flex Power System • Bulletin 1560E (With Stop Control)

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1-28 Product Overview

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 C.

Bulletin 1562E • Basic Control – Controlled Start only

When wired as shown in Figure 1.22, the controller operates as follows:

Pressing the "Start" button initiates the start sequence. Relay "CR" closes and applies control power to terminal 17 of the SMC-Flex module. The auxiliary contact #2 ("Normal") closes, energizing "M-IV" and "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" (up-to-speed) auxiliary contacts, energizing "B-IV", which closes the bypass contactor. The motor then runs at full line voltage.

When the "Stop" button is pressed, the "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 "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.

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Product Overview 1-29

Bulletin 1562E • Basic Control – With Controlled Stop

When wired as shown in Figure 1.23, the controller operates in much the same manner as in Figure 1.22.

Terminal 16 on the SMC-Flex module now controls the start and stop maneuvers. Terminal 16 must remain energized for the module to run. When the “Stop” button is pressed, and “CR” opens, the

SMC-Flex module

will initiate the option stop. An uncontrolled, or coast stop, is achieved by opening the connection to terminal 17. This contact should remain open to ensure all hold-in contacts clear, to prevent a re-start.

If the motor has started, the unit is in the bypass mode, and a trip occurs within the SMC-Flex module or from an external protection relay; "AUX2" will open the line contactor immediately, and "AUX1" will remain closed for 10 seconds. A trip due to an overload or fault condition will result in a “coast” stop.

Bulletin 1562E • DPI Control – Controlled Start only

The control scheme shown in Figure 1.24 allows the MV SMC-Flex to be controlled using DPI (Drive Programming Interface). This special usage of DPI includes provisions for a "Hand" mode of control as well.

With the Hand-Auto selector switch in the "Auto" position, terminal 18 of the SMC-Flex module is energized, allowing a start command to be executed via DPI. The "AUX2" contact closes, energizing both "M-IV" and "MC".

When the motor approaches rated speed, the SMC-Flex module closes "AUX1", energizing "B-IV", which closes the bypass contactor.

To run in "Hand" mode, the "CR" contact is used to initiate a start sequence (similar to Figure 1.22).

A stop command can be generated via DPI or by opening "CR", depending on the control mode.

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1-30 Product Overview

Functional Description (cont.) 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

1.25, the controller operates as follows:

When a start is initiated in the existing motor controller and the contactor (or breaker) closes, a contact must be supplied to tell the 1560E to start also. A "CR" contact will apply control voltage to terminal 17 of the SMC-Flex module.

When stopping the motor, the contactor in the existing controller will open, removing power from the motor, and then the “CR” relay. The bypass hold-in rung will keep the bypass contactor closed for a short time.

The “Fault” contact on the SMC-Flex module should be wired into the existing controller to trip the main contactor (or breaker) in the event of a fault condition sensed by the SMC-Flex module.

If possible, it is better to have the SMC-Flex module control the main contactor directly. In this case, the control circuit would look like, and function like, the descriptions above for the Bulletin 1562E.

Bulletin 1560E • Basic control – With Controlled Stop

When wired as shown in Figure 1.26, 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 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.

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Product Overview 1-31

Bulletin 1560E • DPI Control – Controlled Start only

The control scheme shown in Figure 1.27 allows the MV SMC-Flex to be controlled using DPI. This special usage of DPI includes provisions for a "Hand" mode of control as well.

With the Hand-Auto selector switch in the "Auto" position, and closure of the existing starter main contactor, terminal 18 is energized, allowing a start command to be executed via DPI. "AUX2" 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 "AUX1", energizing "B-IV", as the motor approaches rated speed.

Hand control is enabled with the selector switch in the "Hand" position. Closure of the "Start" relay, from the existing starter, allows the unit to initiate motor soft starting.

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1-32 Product Overview

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Figure 1.22 – Bulletin 1562E IntelliVAC Control Circuit • Without Stop Control

Product Overview 1-33

Figure 1.23 – Bulletin 1562E IntelliVAC Control Circuit • With Stop Control

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1-34 Product Overview%5-"%.0*UNE

• With DeviceNet (or DPI) Communication and optional Hand/Auto

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Figure 1.24 – Bulletin 1562E IntelliVAC Control Circuit

Product Overview 1-35

Figure 1.25 – Bulletin 1560E IntelliVAC Control Circuit • Without Stop Control

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1-36 Product Overview

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Figure 1.26 – Bulletin 1560E IntelliVAC Control Circuit • With Stop Control

Product Overview 1-37

Figure 1.27 – Bulletin 1560E IntelliVAC Control Circuit

• DeviceNet (or DPI) Communication and optional Hand/Auto

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1-38 Product Overview

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Chapter 2

Installation

A T T E N T I O NA T T E N T I O N

Perform the installation duties correctly. Errors may

cause commissioning delays, equipment damage or personal injury.

Important: For the 1503E, refer to applicable documentation from OEM installation, grounding, interlocking and wiring. This manual should be utilized in conjunction with the OEM supplied documentation, and is suitable for commissioning, programming, calibration, metering, serial communications, diagnostics, troubleshooting, and maintenance of a standard solid-state controller.

Receiving 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.

Safety and Codes The Canadian Electrical Code (CEC), National Electrical

A T T E N T I O NA T T E N T I O N

Code (NEC), or other local codes outline provisions for safely installing electrical equipment. Installation MUST comply with specifications regarding wire type, conductor sizes, branch circuit protection, interlocking and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.

Unpacking and Inspection After unpacking the material, check the item(s) received against the bill of

lading to ensure that the nameplate description of each item agrees with the material ordered. Inspect the equipment for physical damage, as stated in the Rockwell Automation Conditions of Sale.

Remove all packing material, wedges, or braces 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°C and 75°C (-4°F and 167°F) with a maximum humidity of 95%, non-condensing, to guard against damage to temperature sensitive components in the controller.

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2-2 Installation

General Precautions In addition to the precautions listed throughout this manual, the following

statements, which are general to the system, must be read and understood.

A T T E N T I O NA T T E N T I O N

The controller contains ESD (electrostatic discharge) sensitive parts and assemblies. Static control precautions are required when installing testing, servicing, or repairing the assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to applicable ESD protection handbooks.

An incorrectly applied or installed controller can damage components or reduce product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures, may result in malfunction of the system.

Only personnel familiar with the controller and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage.

Transportation and Handling The controller must be transported on a pallet or via use of the lifting

angles supplied as part of all 90-inch (2.3 m) high cabinets or frame units.

A T T E N T I O NA T T E N T I O N

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 T T E N T I O NA T T E N T I O N

Ensure that the load rating of the lifting device is sufficient to safely raise the controller sections. Failure to do so may result in severe injury and/or equipment damage. Refer to the packing slip enclosed with shipment for shipping weights.

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.

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Installation 2-3

Installation Site Consider the following when selecting the installation site:

A. The operating ambient temperature should be between 0°C and 40°C

(32°F and 104°F) for NEMA Type 1 or 12 enclosures. For higher ambient conditions, please consult Rockwell Automation factory.

B. The relative humidity must not exceed 95%, non-condensing. Excessive

humidity can cause electrical problems from corrosion or excessive dirt build-up.

C. The equipment must be kept clean. Dust build-up inside the enclosure

inhibits proper cooling and decreases the system reliability. The equipment should not be located where liquid or solid contaminants can drop onto it. Controllers with ventilated enclosures (in particular those with fans) must be in a room free of airborne contaminants.

D. Only persons familiar with the function of the controller should have

access to it.

E. The losses in the controller produce a definite heat dissipation,

depending on the unit size, that tends to warm the air in the room. Attention must be given to the room ventilation and cooling requirements to ensure that the proper environmental conditions are met.

F. Operational altitude is 3,300 feet (1 km) maximum without derating.

Higher altitudes may require optional components. Please consult Rockwell Automation factory.

G. The area of the controller should be free of radio frequency interference

such as encountered with some welding units. This may cause erroneous fault conditions and shut down the system.

A T T E N T I O NA T T E N T I O N

An incorrectly applied or installed controller can result in component damage or a reduction in product life. Wiring or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or ambient temperatures above or below the specified temperature range may result in malfunction of the controller.

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 drawings for mounting requirements.

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2-4 Installation

Installation Site (cont.) Grounding Practices

The purpose of grounding is to:

A. Provide safety for Personnel. B. Limit dangerous voltages to ground on exposed parts. C. Facilitate proper overcurrent device operation under ground fault

conditions.

D. Provide for electrical interference suppression.

Important: Generally, grounding should be in accordance with the

Canadian Electrical Code (CEC) or National Electrical Code (NEC) and other local codes.

Each power feeder from the substation transformer to the controller must be equipped with properly sized ground cables. Simply utilizing the conduit or cable armour as a ground is not adequate. The conduit or cable armour and ground wires should be bonded to ground at both ends. Each enclosure and/or frame must be bonded to ground at a minimum of two locations.

Each AC motor frame must be bonded to grounded building steel within 20 feet (6.1 m) of its location and tied to the controller’s ground bus by ground wires within the power cables and/or conduit. The conduit or cable armour should be bonded to ground at both ends.

A T T E N T I O NA T T E N T I O N

Any instruments used for test or troubleshooting should have their case connected to ground for safety. Failure to do so may result in damage to equipment or personal injury.

Recommended Torque Values When reinstalling components or when reassembling the cabinet, tighten

the following bolt sizes to the specified torque values:

1/4-in. hardware 6 ft-lb. (8 N-m)

5/16-in. hardware 12 ft-lb. (15N-m)

3/8-in. hardware 20 ft-lb. (27 N-m) 1/2-in. hardware 48 ft-lb. (65 N-m)

NOTE: For 3/8 in. hardware in the 'T'-slots of aluminum heatsinks, the recommended torque is 16 ft-lb (22 N-m). Do not overtorque these connections as the slots will be damaged and the connection will be compromised.

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Installation 2-5

Power Connections The controller requires a three-phase supply and an equipment grounding

conductor to earth ground. A neutral conductor of the three-phase supply is not necessary and is usually not routed to the controller. Three-phase wiring will connect the controller to the motor.

Bulletin 1562E

The Bulletin 1562E unit is available in two main configurations:

1. A modified two-high cabinet (180/360A, 2400 to 4160 V)

2. A combination of a one-high full voltage non-reversing (FVNR) cabinet and a 1560E unit (600A, 2400 to 4160 V, and 180/360/600A, 5500 to 6900 V)

To make power connections for a two-high cabinet, refer to Figures 2.1 to

2.3, and Publication 1500-UM055B-EN-P (Chapter 2).

To make power connections for a one-high FVNR cabinet and a 1560E unit, proceed as follows:

• Make line connections within the one-high cabinet

• Make load connections at the 1560E CT terminals (refer to Figure 2.5 or

2.6)

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2-6 Installation

Power Connections (cont.)

PowerStack Assembly

Bypass VacuumContacto

Voltage Sensing Module

Load Cable Connection

t (top exit)

Poin

Current Transformers

Figure 2.1 – Cabinet Layout • 1562E – 180/360 A, 2400 V to 4160 V

(with LV panels not shown)

Non Load B

Non Load B Isolation Switch

Isolation Switch

Line Vacuum Contactor

reak

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Installation 2-7

Power Cable Lugs

Ground Bus Lug

Cable Duct Barrier

Cable Duct Boot

Motor Cable Terminals

Figure 2.2 – Incoming Line Cable Connections

(viewed from the rear with power bus access cover removed)

Figure 2.3 – Bottom Cable Exit Configuration

(with LV panel swung open)

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2-8 Installation

Power Connections (cont.) Bulletin 1560E

Refer to Figures 2.4 to 2.6 to make power connections for a 1560E unit. Note: The CT assembly can be oriented to allow either top or bottom load

cable exit.

Phase 1

Power Stack Assembly

Phase 2

Phase 2 PowerStack Assembly

PowerStack Assembly

Load Connec

(top exit shown)

Phase 1 (front)

through 3 (back)

Current Transformers

tions

Phase 3

Phase 3 PowerStack Assembly

PowerStack Assembly

Line Connections

Line Connections Phase 1 (top)

Phase 1 (top) through 3 (bottom)

through 3 (bottom)

Bypass VacuumContactor

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Figure 2.4 – Power Connections • 1560E – 180/360A, 2400 to 4160 V

Power

Phase 1

StackAssembly

Phase 1

Phase 1 Line Connection

Line Connection

Phase 2

Phase 2 Line Connection

Line Connection

Installation 2-9

Phase 2

Power Stack Assembly

Phase 3

Power Stack Assembly

Voltage Sensing Module

Load Connections

(top exit shown)

Phase 1 (front)

through 3 (back)

Current Transformers

Phase 3

Phase 3 Line Connection

Line Connection

Bypass VacuumContacto

Figure 2.5 – Power Connections • 1560E – 180/360A, 5500 to 6900 V

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2-10 Installation

Power Connections (cont.)

Phase 1

Power Stack Assembly

Phase 1

Phase 1 Line Connection

Line Connection

Phase 2

Phase 2 Line Connection

Line Connection

Phase 2

Power Stack Assembly

Phase

Power Stack Assembly

Voltage Sensing Module

Load Connections

Load Connections (top exit shown)

(top exit shown) Phase 1 (front)

Phase 1 (front) through 3 (back)

through 3 (back)

Current Transformers

Phase 3

Phase 3 Line Connection

Line Connection

Bypass Vacuum Contacto

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Figure 2.6 – Power Connections • 1560E – 600A, 2400 to 6900 V

Installation 2-11

Important: For retrofit units (Bul. 1560E), the CEC and NEC require that branch-circuit protection of the AC line input to the controller be provided by a circuit breaker or motor starter. This function is included with a Bulletin 1562E.

Important: The control and signal wires should be positioned at least six (6) inches (150 mm) from power cables. Additional noise suppression practices (including separate steel conduits for signal leads, etc.) are recommended.

Bulletin 1503E

For 1503E, refer to applicable documentation from OEM for installation, grounding, interlocking and wiring. This manual should be utilized in conjunction with the OEM supplied documentation, and is suitable for commissioning, programming, calibration, metering, serial communications, diagnostics, troubleshooting, and maintenance of a standard solidstate controller.

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2-12 Installation

Power Wiring 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.

Interlocking Hinged doors and panels, which provide access to medium voltage

components, must be mechanically interlocked to ensure circuit isolation. If a combination MV SMC-Flex (1562E) is purchased from Rockwell Automation, all medium voltage compartments will be mechanically interlocked such that they cannot be opened unless the isolating switch for the 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.

A T T E N T I O NA T T E N T I O N

For 1503E and 1560E, it is the responsibility of the installer/user to ensure the equipment interlocking scheme is in place and functional before energizing the equipment. Inadequate interlocking could expose personnel to energized parts which could result in severe burns, injury or death.

NOTE: Rockwell Automation can assist with the selection of an appropriate interlocking method, which may include mechanical modifications to the cabinet(s) or key-type lock systems.

NOTE: 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 it to be opened until the main power cell door is opened.

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Installation 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 (6 mm x 51 mm) [¼ in. x 2 inches], 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.

Installation 2-13

Important: Refer to 2-high, Series B drawings in Publication 1500-UM055B-EN-P 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.

Control Cables

Control cable entry/exit should be located near the terminal blocks; customer’s connections are to be routed along the empty side of the terminals. Nylon cable tie loops are provided at the left, front corner of the cabinet to route control cables safely behind the low voltage panel hinges. Cables should be routed so they do not interfere with the swing of the low-voltage panels.

Fibre-Optic Cables

The small, gray, fibre-optic cables are fragile and must be protected during installation from sharp bends and impact.

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2-14 Installation

Installation (cont.) Power Factor Correction Capacitors

The controller can be installed on a system with power factor correction capacitors. The capacitors must be located on the line side of the controller. This is required to prevent damage to the SCRs in the MV SMC-Flex controller. A separate switching contactor is recommended to apply the capacitors only after the bypass contactor has closed, and to remove them when the bypass contactor opens. See Figure 2.7 for two different acceptable connection methods.

NOTE: Consult the factory if there are any capacitors on the same branch circuit as the MV SMC-Flex.

When discharged, a capacitor has essentially zero impedance. For switching, sufficient impedance should be connected in series with the capacitor bank to limit the inrush current. A method of limiting the surge current is to add inductance in the capacitor conductors. This can be 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.

A T T E N T I O NA T T E N T I O N

Any covers or barriers removed during installation must be replaced and securely fastened before energizing equipment. Failure to do so may result in severe burns, injury or death.

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Power Bus

Isolation Switch Isolation Switch

Fuse

Contactor

di/dt Inductor

PFCC

Contactor

Bypass

Fuse

Isolation Contactor

di/dt Inductor

Capacitor

Capacitor Contactor

Contactor

PFCC

PFCC (Power Factor

(Power Factor CorrectionCapacitor)

CorrectionCapacitor)

Installation 2-15

Motor

Figure 2.7 – Typical One-Line Diagram

(Showing 2 Different Styles of Power Factor Capacitor Connections)

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2-16 Installation

Surge Arrestor Protection Devices

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 current can

change through the SMC. If capacitance is added at the motor, the inductance is negated. The surge capacitors downstream of the SMC represent a near zero impedance when presented with a step voltage from the turn on of the SCRs near the line voltage peak. This causes a high level of di/dt to occur, due to the fact that the motor cables are generally short in length. There is very little impedance between the capacitor and SCR to limit the di/dt of this capacitor charging current. This can result in damage to the power semiconductors (SCRs) in the SMC.

• It is essential to understand the clamping voltage of the arresters and

type of grounding used in the distribution system. The switching of the SCRs generates slightly higher than nominal peak line to ground voltages. The typical peaks are 1.5 times the nominal line to ground peak voltages. These may cause the arresters to conduct, which could affect the operation of the SMC and result in faults. Depending upon the instance at which the arresters conduct, this could also result in SCR damage.

• The capacitance in combination with the line and motor impedance could also be excited by the voltage steps from SCR switching to create resonant voltage swings which could exceed the device voltage withstanding ratings or surge arrester rating, or cause distorted voltage signals which may be misinterpreted by the MV SMC-Flex control system.

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Installation 2-17

Motor Overload Protection 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.

A T T E N T I O NA T T E N T I O N

Overload protection should be properly coordinated with the motor to avoid damage to equipment.

Two special applications require consideration: Two-speed Motors, and Multi-motor Protection.

Two-speed Motors

The MV SMC-Flex controller has overload protection available for single speed motors. When the MV SMC-Flex controller is applied to a two-speed motor, the Overload Class parameter must be programmed to OFF, and separate overload relays must be provided for each speed.

Multi-motor Protection

The MV SMC-Flex controller provides overload protection for only one motor. When the MV SMC-Flex is controlling more than one motor, the Overload Class Parameter must be programmed to OFF, and individual overload protection is required for each motor.

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2-18 Installation

EMC Compliance

A T T E N T I O NA T T E N T I O N

This product has been designed for Class A equipment. Use of the product in domestic environments may cause radio interference, in which case, the installer may need to employ additional mitigation methods.

The following guidelines are provided for EMC installation compliance.

Enclosure

Install the product in a grounded metal enclosure.

Wiring

Wire in an industrial control application can be divided into three groups: power, control, and signal. The following recommendations for physical separation between these groups is provided to reduce the coupling effect.

• Different wire groups should cross at 90° inside an enclosure.

• Minimum spacing between different wire groups in the same tray should

be 16 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-IN001A-EN-P.

• Wire earth ground to control terminal 14.

• Use shielded wire for: PTC Input

Tach Input Ground Fault Input

• Terminate shielded wires to terminal 14.

• Ground fault CT must be inside or within 3 m of metal enclosure.

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• 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 cable near the SMC-Flex control module. The recommended core is Fair-Rite no. 0431167281 or equivalent.

– When using DeviceNet, two cores need to be added to the DeviceNet

cable near the SMC-Flex control module. The recommended cores are TDK ZCAT2033 0930H and TDK ZCAT2035 0930 or equivalent.

Control Power Control Voltage

The SMC-Flex controller will accept a control power input of 100 to 240V AC, (-15 / +10%), 1 phase, 50/60 Hz. Refer to the product nameplate to verify the control power input voltage.

Installation 2-19

Connect control power to the controller at terminals 11 and 12. The control power requirement for the control module is 75 VA. Depending on the specific application, additional control circuit transformer VA capacity may be required.

Control Wiring

Table 2.C provides the control terminal wire capacity and the tightening torque requirements. Each control terminal will accept a maximum of two wires.

Table 2.C – C ontrol Wiringand Tightening Torque

Wire Size Torque

0.75 to 2.5mm2(#18 to #14AWG) 0.6Nm (5lb-in.)

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2-20 Installation

Control Terminal Designations As shown in Figure 2.10, the SMC-Flex controller contains 24 control

terminals on the front of the controller.

Figure 2.10 – SMC-Flex Controller Control Terminals

Terminal

Number

11 Control Power Input 23 PTC Input : 12 Control Power Common 24 PTC Input : 13 Control Enable Input : 25 Tach Input (- ) 14 Control Module Ground 26 Tach Input (+ ) 15 Option Input #2 : 27 GroundFault Transformer Input : 16 Option Input #1 : 28 GroundFault Transformer Input : 17 Start Input : 29 Fault Contact (N.O./N.C.) ➍ 18 Stop Input : 30 Fault Contact(N.O./N.C.) ➍ 19 N.O. Aux. Contact #1 (Up-to-Speed) ; ➍ 31 Alarm Contact (N.O./N.C.) ➍ 20 N.O. Aux. Contact #1 (Up-to-Speed) ; ➍ 32 Alarm Contact (N.O./N.C.) ➍ 21 Not Used 33 Aux. Contact #2 (Normal) (N.O./N.C.) ➌➍ 22 Not Used 34 Aux. Contact #2 (Normal) (N.O./N.C.) ➌➍

: Do not connect any additional loads to these terminals. These “parasitic” loads may cause problems with operation,

which may result infalse starting and stopping.

; Aux. Contact #1 is always programmed forUp-to-Speed to control the bypass contactor in MV applications.

➌ Aux. Contact #2 is always programmed for “Normal” indication in MV applications. ➍ RC snubbers are required on inductive loads connected to auxiliary.

Description

Terminal

Number

Description

Note: The OFF state leakage current fora solid-state device connected to an SMC-Flex input must be less than 6 mA.

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Chapter

Commissioning Procedure

Preliminary Set-Up A. Ensure the work area is clean and tidy. Pathways to main disconnect

and emergency stop push-button must be clear and unobstructed.

B. The following test equipment is to be prepared for use:

• Test power supply, 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.

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3-2 Commissioning Procedures1

System Characteristics

Job Name: _____________________________ Job Number: ________________________________

Rated Voltage: _________________________ Rated Current: _____________ S.F.: ________

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 S.F.: ________________________________________________

Motor L.R.A.: ______________________________________________

Frequency: ________________________________________________

Phases: ___________________________________________________

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Commissioning Procedures 3-3

Preliminary Check Ensure that all sources of power are isolated and locked

A T T E N T I O NA T T E N T I O N

out before working on installed equipment. Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device. Failure to do so may result in severe burns, injury or death.

A. Verify correct power cable phase sequencing, and that connections are

tight.

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 fibre-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 B. Settings may be different on engineered orders, or when option modules or

customer requirements dictate different settings. Important: The module should be programmed with an understanding of

how the SMC functions, and the characteristics of the motor and driven load. Inappropriate settings may elicit unexpected results such as lack of acceleration torque or full-voltage starting. For Pump Control applications, refer to Application Considerations on page 1-20.

If the factory settings are not suitable for the application, program the module to meet the application requirements. Contact your local Rockwell Automation representative or the factory if assistance is required.

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3-4 Commissioning Procedures

Hi-Pot and Megger Test 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.

A T T E N T I O NA T T E N T I O N

Solid-state devices can be destroyed by high voltage.

Use jumper wires between heatsinks to short out the SCRs before applying high test voltages to the power circuit. Disconnect the white wires (1L1, 1T1, 1L2,

1T2, 1L3, 1T3) from the voltage feedback board and remove the plug connector. If voltage transformers are present, remove one primary fuse from each device. On the 1503E, consult OEM documentation for location of voltage feedback board

A T T E N T I O NA T T E N T I O N

Use caution when performing the HI-POT or Megger Test. High voltage testing is potentially hazardous and may cause severe burns, injury or death. Where appropriate, the case of the test equipment should be connected to ground.

Insulation may be tested from phase to phase and phase to ground. The recommended level for AC HI-POT testing is (2 X VLL) Volts, where V

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.

1560E-UM050B-EN-P - June 2013

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 3.1) This will ensure the unit is isolated from the line and the motor. The line and the motor may be tested separately to locate problem areas. If a 1503E is being tested, consult OEM documentation.

After completing the test, remove all semiconductor jumpers and test the devices with a multimeter to ensure no damage has occurred from the insulation test. Reconnect the system as it existed prior to this section. Perform the power supply and resistance checks in the following sections.

A T T E N T I O NA T T E N T I O N

Failure to reconnect all wires and cables correctly may result in equipment damage, personal injury or death.

Commissioning Procedures 3-5

Points for disconnection, to allow Hi-Pot

or Megger tests (refer to Chapter 3)

Points for disconnection, to allow Hi-Pot

or Megger tests (refer to Chapter 3)

Points for disconnection, to allow Hi-Pot

or Megger tests (refer to Chapter 3)

Figure 3.1 – Typical MV SMC-Flex Power System Diagram

(Without Optional Stop Control)

* **

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3-6 Commissioning Procedures

SW2: When ON (up) provides

SW2: When ON (up) provides test pulses to gate driver circuits.

test pulses to gate driver circuits.

test pulses to gate driver circuits. NOTE: Must be OFF (down) for

NOTE: Must be OFF (down) for

NOTE: Must be OFF (down) for normal operation.

normal operation.

Phase A

Fibre Optic

Transmitters

send gate

signals to

driver boards

Phase B

Fibre Optic

Transmitters

LED (Red): ON when

LED (Red): ON when test pulses on.

test pulses on.

LED (Yellow) ON

LED (Yellow) ON when Phase A

when Phase A

when Phase A gate signal active

gate signal active

TP4: Phase A

TP4: Phase A gate signal

gate signal

TP8: Common for

TP8: Common for Gate/Pulse TPs

Gate/Pulse TPs

LED (Yellow) ON

LED (Yellow) ON when Phase B

when Phase B

when Phase B gate signal active

gate signal active

TP11: Phase B

TP11: Phase B gate signal

gate signal

SMC-Flex control module

Ribbon connectors to connect

Ribbon connectors to connect to SMC-Flex control module

to SMC-Flex control module

to SMC-Flex control module (underneath control module)

(underneath control module)

TP1,2,3,5,7,9:

TP1,2,3,5,7,9: Voltage feedback

Voltage feedback

Voltage feedback test points

test points

TB21: Ribbon

TB21: Ribbon connector to Voltage

connector to Voltage

connector to Voltage Sensing Board

Sensing Board

TB6: Gate driver

TB6: Gate driver power supply input

power supply input

Phase A

TB5:

TB5: Current

Current

Phase B

Current transformer

transformer

transformer connections

connections

Phase C

Fibre Optic

Transmitters

SW3: Used to

SW3: Used to defeat temperature

defeat temperature

defeat temperature feedback channels

feedback channels

Temperature

Feedback

Fibre Optic

Receivers

LED (Yellow): ON

LED (Yellow): ON when Phase C

when Phase C

when Phase C gate signal active

gate signal active

TP13: Phase C

TP13: Phase C gate signal

gate signal

TP15: Common for

TP15: Common for Gate/Pulse TPs

Gate/Pulse TPs

LEDs (Green): ON when signal

LEDs (Green): ON when signal present at temperature feedback

present at temperature feedback

present at temperature feedback fibre optic receivers

fibre optic receivers

L N G

Control Power

110-240 VAC or

110-250 VDC

Serial Number

Replacement

Replacement Part Number

Part Number

Phase C

LED (Green):

LED (Green): ON when power

ON when power

ON when power is present

is present

TP18,19,20:

TP18,19,20: Power supply

Power supply

Power supply test points

test points

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Figure 3.2 – Connection and Test Information for Interface Board

Commissioning Procedures 3-7

Power Supply Tests Servicing energized industrial control equipment can be

A T T E N T I O NA T T E N T I O N

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.

1. Isolate incoming power

2. Open the door(s) providing access to the SCR/heatsink assemblies.

You will be touching components which are connected to the high voltage power circuit, so be sure to isolate power as stated above.

3. 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.

4. Locate the SMC-Flex Interface board in the control section (See Figures 3.2 and 3.3). This circuit board has the control module mounted on it. Locate the switch labeled SW2 at the upper left corner of the board. Close the switch by sliding the toggle up. This starts a pulse generator to supply simulated gate-pulse signals via fibre optic cables to the gate driver boards. A red LED beside 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).

SW2 – Close (slide up)

to initiate test pulses

Red LED

Figure 3.3 – Interface PCB

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3-8 Commissioning Procedures

Power Supply Tests (cont.) NOTE: Systems with optional Pump Control or Soft Stop include

continuous gate drive power supplies (IGDPS); therefore, step 5 does not apply.

5. Since the gate driver circuits normally receive power from the snubber

circuits when the SMC is operating, an alternate source must be used for testing. Locate the Portable Test Power Supply that was included with the equipment, and verify that the rating corresponds to the available power system (i.e. 110/120 VAC or 220/240 VAC). Plug the unit into the power source, and plug the green connector into TB1 on each of the gate driver sections (See Figure 3.4).

Yellow LED

Plug in test

power supply

(TB1)

Plug in test

power supply

(TB1)

Figure 3.4 – Test Power Application on Gate Driver Board

TP7 (Gate)

TP1 (Com)

TP2 (+)

Yellow LED

TP7 (Gate)

TP7 (Gate) TP1 (Com)

TP1 (Com)

TP2 (+)

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6. The yellow LED on the upper right-hand side of the energized gate

driver circuit should be lit (it may appear dim, depending on ambient light conditions). This is normally sufficient to verify that the gate drive system is functioning, however, a more detailed check can be made utilizing steps 7 and 8.

Commissioning Procedures 3-9

7. The gate-driver board voltage may be checked by connecting a DC voltmeter to TP2 (+) and TP1 (-) (See Figure 3.4). With the specified power supply connected, the voltage should be 12 ± 2 VDC.

8. The actual gate pulse may be checked by connecting an oscilloscope between TP7 and TP1 (See Figure 3.4). The pulse should appear as shown in Figure 3.5.

14 12

12 10

Volts

6 4

4 2

2 0

-2

-2 0 2 4 6 8

Microseconds

Figure 3.5 – Gate Pulse Detail – Typical SCR (ABB)

-2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0 2.5 3.0

Milliseconds

Figure 3.6 – Gate Pulse Test Waveform

9. 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 7 (above), pinch the tab on the fibre-optic connector and carefully pull it straight out of the receiver. The end of the connector should glow red to indicate the presence of a gate signal.

If it does not, remove the other end of the cable from the interface board and check that the grey transmitter is emitting red light. If it is, the fibre-optic cable must be replaced. If it isn’t, the interface board should be replaced.

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3-10 Commissioning Procedures

10. When each gate driver circuit has been checked, disconnect the power

supply and remove it from the cabinet.

NOTE: Systems with optional Pump Control or Soft Stop include continuous gate drive power supplies (IGDPS); therefore, step 10 does not apply.

Control Function Tests

A T T E N T I O NA T T E N T I O N

The gate-drive circuits operate at high voltage when the SMC is energized. Failure to remove the portable test power supply will result in equipment damage and may cause severe injury or death.

11. Open the switch SW2 on the interface board (see Figure 3.3) before

returning the unit to service. Ensure the red LED is off.

A T T E N T I O NA T T E N T I O N

If the SW2 switch is not in the open position when the SMC is energized, the motor will start in an uncontrolled manner and may cause severe damage.

12. 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.

A T T E N T I O NA T T E N T I O N

Servicing energized industrial control equipment can be hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment. Recommended practice is to disconnect and lock out control equipment from power sources, and allow any stored energy in capacitors to dissipate. The safety related work practices of NFPA 70E, Electrical Safety Requirements for Employee Workplaces, must be followed if it is necessary to work in the vicinity of energized equipment.

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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.

Commissioning Procedures 3-11

Resistance Checks To ensure that resistors and connections have not been damaged during

shipment and installation, the following resistance tests should be performed before energizing the starter.

1. Remove all power from the equipment.

A T T E N T I O NA T T E N T I O N

Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device. Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment.

2. Measure DC resistance per the following chart:

Table 3.A – Power Circuit Resistance Measurements

Location of Probes 1000 V 1300 V 1500 V 2300 V 3300 V 4160 V 5500 V 6900 V

Cathode to Cathode (KOhms) Ê – – – – 22-30 23-31 21-29 24-32

Cathode to Cathode (KOhms) Ë 17-23 19-25 20-27 21-29 40-53 43-57 60-80 w 64-84 Ì

Cathode to Gate (Ohms)

Ê Measured between terminals “Cathode” on SPGD Boards, upper two or bottom two within a phase. Ë Measured between terminals “Cathode” on SPGD Boards, top to bottom within a phase. Ì Measured between line and load terminals within a phase.

10-40 10-40 10-40 10-40 10-40 10-40

10-40

3. If abnormal readings are obtained, refer to Power Circuit Trouble-

shooting on page 9-12.

10-40

Voltage Sensing Module The voltage-sensing module consists of a voltage sensing board and

mounting plate (refer to Figure 9.2). The voltage sensing board has six independent channels which convert voltages up to 10800 V (7.2 kV @

1.5 pu) down to low voltage levels which can be used by the SMC-Flex control logic.

Table 3.B shows the input voltage ranges for each of the input terminals on the voltage-sensing module. This module has been designed to operate at a nominal input voltage of up to 7200 V with a continuous 40% overvoltage. The output voltages are scaled to provide close to 10 V peak for a 140% input voltage at the high end of each of the voltage ranges.

Each of the channels has four taps to provide a range of input voltages, and software will be used to scale the output to show the correct value on the SMC-Flex front panel display. (See Parameter #106 – MV Ratio)

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3-12 Commissioning Procedures

Table 3.B – Input Voltage Ranges

Tap Voltage Range MV Ratio

D 800 – 1449 V 1020 C 1450 – 2499 V 390 B 2500 – 4799 V 165 A 4800 – 7200 V 105

The MV ratios shown above are nominal values and may be fine tuned to achieve better accuracy on the display of the SMC-Flex control module. While running the motor in bypass mode, compare the voltage displayed on the control module to a known accurate meter connected to the same source voltage as the motor the MV SMC-Flex is controlling. Parameter 106, MV Ratio, may be changed up or down to match the Flex display to the external meter. A small change in ratio can make a large change in the display, so 5 units at a time is recommended. Increasing the ratio will decrease the displayed voltage, and visa versa.

Start-Up 1. Remove any temporary jumpers or grounding devices used during

commissioning.

2. Check that all tools are removed from the equipment. Any tools or hardware used or dropped during installation and commissioning must be retrieved and accounted for.

3. Check that all barriers or covers removed during installation or commissioning have been securely mounted.

4. Close and secure all doors, and verify function of all interlocks that prevent access to medium voltage compartments when the unit is energized.

5. The controller is ready to power the motor.

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Chapter

Programming

Overview 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.

Keypad Description The keys found on the front of the SMC-Flex controller are described below.

EscEsc

SelSel

Escape

Select Up/Down

Arrows Enter

Exit a menu, cancel a change to a parameter value, or acknowledge a fault/alarm.

Select a digit, select a bit, or enter edit mode in a parameter screen.

Scroll through options increase/decrease a value, or toggle a bit.

Enter a menu, enter edit mode in a parameter screen, or save a change to a parameter value.

Note: For ease of programming values, after using the Enter key to edit,

use the Sel key to jump to the digit that needs to be modified, then use the arrow keys to scroll through the digits.

Programming Menu Parameters are organized in a three-level menu structure for

straightforward programming. Figure 4.1 details the programming menu structure and the three-level hierarchy.

In order to change parameters, the controller must be in the STOP mode, and the control voltage must be present.

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4-2 Programming

Programming Menu (cont.)

Esc

EscEsc

Sel

SelSel

Power-up and

Power-up and Status Display

Status Display

Choose Mode

or oror or

OPERATION LEVEL

MAIN MENU

Memory

Device

Parameter

Esc

EscEsc

Monitoring

Monitoring Set Up

Set Up Motor Protection

Motor Protection Communications

Communications Utility

Utility

Linear List

Esc

EscEsc

u The SMC-Flex controller does not support EEPROM, Link, Process or Start-up modes.

v Steps back one level.

w Shown if password protection is configured.

Linear List

Parameter menu

Parameter menu continued in Figure 4.2

continued in Figure 4.2

Device

Select

SMC-Flex Reset to Defaults

Memory Storage

Storage

Save to EEPROM

Save to EEPROM Recall EEPROM

Recall EEPROM

Figure 4.1 – Menu Structure Hierarchy

Preferences

Change Password

Change Password User Dspl Line

User Dspl Line User Dspl Time

User Dspl Time User Dspl Video

User Dspl Video Reset User Display

Reset User Display

Log

Diagnostics

Alarms

Alarms Faults

Faults Device Version

Device Version

GROUP MENU

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Esc

EscEsc

Monitoring

Parameter

Motor

Set Up Utility

Motor

Protection

Communications

Programming 4-3

Linear List

Metering

Volts Phase A-B SMC Option Overload Class Jam F Lvl Logic Mask Language All parameters Volts Phase B-C Motor Connection Service Factor Jam F Dly Parameter Mgt x Parameter Mgt x Parameter Mgt. x Volts Phase C-A Line Voltage Motor FLC Jam A Lvl Current Phase A MV Ratio Overload Reset Jam A Dly Current Phase B Starting Mode Overload A Lvl Parameter Mgt x Current Phase C Ramp Time Parameter Mgt x Data In A1 Motor Flc Watt Meter Initial Torque Data In A2 Motor ID Megawatt Hours Cur Limit Lvl Elapsed Time Kickstart Time Meter Reset Kickstart Lvl Underload F Lvl Parameter Mgt x Data In C1 Parameter Mgt x Power Factor Option 2 Input Underload F Dly Data In C2 Mtr Therm Usage Stop Mode Underload A Lvl Data In D1 Stop Time Underload A Dly Braking Current Parameter Mgt x Gnd Flt Enable Data Out A1 Overload Class Gnd Flt Lvl Data Out A2 Service Factor Gnd Flt Dly Data Out B1 Motor FLC CT Ratio Undervolt F Lvl Gnd Flt A Enable Data Out C1 Overload Reset Undervolt F Dly Gnd Flt A Lvl Data Out C2 Aux1 Config Undervolt A Lvl Gnd Flt A Dly Data Out D1 Fault Contact Undervolt A Dly Parameter Mgt x Data Out D2 Alarm Contact Parameter Mgt x Parameter Mgt x Aux2 Config

Starting Mode 2 Overvolt A Lvl Ramp Time 2 Overvolt A Dly Initial Torque 2 Parameter Mgt x Phase Reversal Cur Limit Lvl 2 Parameter Mgt x Kickstart Time 2 Kickstart Lvl 2 Parameter Mgt x Unbalance F Lvl Starts Per Hour Preset SS (Option 2 Unbalance F Dly Restart Attempts Input = Preset SS) Unbalance A Lvl Restart Dly Slow Speed Sel Unbalance A Dly Parameter Mgt x Slow Speed Dir Parameter Mgt x Slow Speed Acc Slow Running Cur Parameter Mgt x

(Option 2 Input =

Braking Current Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cu Stopping Current

Basic

Backspin Timer Parameter Mgt x Overvolt F Lvl Parameter Mgt x Dual Ramp (Option 2 Input = Dual Ramp)

Accu-Stop)

Overload

Underload

Undervoltage

Overvoltage

Overvolt F Dly

Unbalance

Jam

Stall

Stall Dly Data In B2 MV Ratio

Ground Fault

Gnd Flt Inh Time Data Out B2

PTC

PTC Enable

Phase Reversal

Restart

Comm Masks

Data Links

Data In B1 CT Ratio

Data In D2

Language

Motor Data

u Depending upon SMC option selected, some parameters may not appear in product display. v Steps back one level. w For further information on parameters, see Appendix B. x For further information on parameter management, see page 4-7.

Parameter Mgt x

Linear List

Figure 4.2 – Menu Structure Hierarchy

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4-4 Programming

Programming Menu (cont.) Table 4.A

Parameter Linear List

Parameter No. Description Parameter No. Description Parameter No. Description

1 Volts Phase A-B 40 Slow Speed Dir 79 PTC Enable 2 Volts Phase B-C 41 Slow Speed Cur 80 Phase Reversal 3 Volts Phase C-A 42 Slow Running Cur 81 Starts per Hour 4 Current Phase A 43 Stopping Current 82 Restart Attempts 5 Current Phase B 44 Overload Class 83 Restart Delay 6 Current Phase C 45 Service Factor 84 Factory Use 7 Watt Meter 46 Motor FLC 85 Factory Use 8 Kilowatt Hours 47 Overload Reset 86 Factory Use

9 Elapsed Time 48 Factory Use 87 Logic Mask 10 Meter Reset 49 Factory Use 88 Data In A1 11 Power Factor 50 Overload A Lvl 89 Data In A2 12 Mtr Therm Usage 51 Underload F Lvl 90 Data In B1 13 Motor Speed 52 Underload F Dly 91 Data In B2 14 SMC Option 53 Underload A Lvl 92 Data In C1 15 Motor Connection 54 Underload A Dly 93 Data In C2 16 Line Voltage 55 Undervolt F Lvl 91 Data In D1 17 Starting Mode 56 Undervolt F Dly 95 Data In D2 18 Ramp Time 57 Undervolt A Lvl 96 Data Out A1 19 Initial Torque 58 Undervolt A Dly 97 Data Out A2 20 Cur Limit Level 59 Overvolt F Lvl 98 Data Out B1 21 Torque Limit 60 Overvolt F Dly 99 Data Out B2 22 Kickstart Time 61 Overvolt A Lvl 100 Data Out C1 23 Kickstart Level 62 Overvolt A Dly 101 Data Out C2 24 Option 2 Input 63 Unbalance F Lvl 102 Data Out D1 25 Starting Mode 2 64 Unbalance F Dly 103 Data Out D1 26 Ramp Time 2 65 Unbalance A Lvl 104 Motor ID 27 Initial Torque 2 66 Unbalance A Dly 105 CT Ratio 28 Cur Limit Level 2 67 Jam F Lvl 106 MV Ratio 29 Torque Limit 2 68 Jam F Dly 107 Aux1 Config 30 Kickstart Time 2 69 Jam A Lvl 108 Fault Contact 31 Kickstart Level 2 70 Jam A Dly 109 Alarm Contact 32 Stop Mode 71 Stall Delay 110 Aux2 Config 33 Stop Time 72 Gnd Flt Enable 111 Language 34 Factory Use 73 Gnd Flt Level 112 Factory Use 35 Braking Current 74 Gnd Flt Delay 113 Factory Use 36 Factory Use 75 Gnd Flt Inh Time 114 Factory Use 37 Factory Use 76 Gnd Flt A Enable 115 Parameter Mgmt 38 Factory Use 77 Gnd Flt A Lvl 116 Backspin Timer 39 Slow Speed Sel 78 Gnd Flt A Dly 117 Factory Use

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Programming 4-5

Password The SMC-Flex Controller allows the user to limit access to the

programming system through password protection. This feature is disabled with a factory-set default of 0. To modify the password or login after a password is programmed, complete the procedure below.

Description Action Display

– –

1. Press the ESC key to go from the status display to the Main menu.

2. Scroll with the Up/Down keys until the Preferences option is highlighted.

3. Press the Enter key to access the Preferences menu.

4. Scroll with the Up/Down keys until the Change Password option is highlighted.

5. Press the Enter key.

6. Press the Up/Down keys to enter the desired number. If you are modifying the password, make a note of it as displayed.

7. Verification of the new password is required. Press the Enter key.

8. Press the Enter key after you have completed modifying the password. u v

EscEsc

u After you have changed your password, go to Parameter Management and Save to User Store.

v To complete the programming process, re-enter the Main Menu mode to log out.

This will eliminate unauthorized process to the programming system.

Note: If you lose or forget the password, contact your nearest Rockwell

Automation sales office. You can also call Rockwell Automation Medium Voltage Product Support at 1-519-740-4790 for assistance.

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4-6 Programmi

Parameter Management Before you begin programming, it is important to understand how the

controller memory is:

• structured within the SMC-Flex controller

• used on power-up and during normal operation

Refer to Figure 4.3 and explanations below.

EEPROM RAM ROM

EscEsc SelSel

Figure 4.3 – Memory Block Diagram

Random Access Memory (RAM)

This is the work area of the controller after it is powered up. When you modify parameters in the Set Up mode, the new values are stored in RAM. When power is applied to the 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.

Electrically Erasable Programmable Read-only Memory (EEPROM)

The SMC-Flex controller provides a nonvolatile area for storing usermodified parameter values in the EEPROM.

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Using Parameter Management

Description Action Display

Saving to EEPROM

To ensure that the newly modified

parameters are not lost if control power is removed from the controller, store the values into EEPROM.

Recalling from EEPROM

Parameters stored in EEPROM can

be manually brought to RAM by directing the controller to recall the values in its EEPROM.

Recalling Defaults

After parameter values have been

modified and saved to EEPROM, factory default settings can still be re-initialized.

Programming 4-7

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4-8 Programming

Parameter Modification All parameters are modified using the same method. The basic steps to

performing parameter modification are described below.

Note: Parameter values modified while the motor is operating are not

valid until the next start sequence begins.

Description Action Display v

– –

1. Press the ESC key to go from the status display to the Main menu.

2. Scroll with the Up/Down keys until the Preferences option is highlighted.

3. Press the Enter key to access the Parameter menu.

4. Scroll with the Up/Down keys until the option you want to use (Monitoring, Motor Protection, etc.) is highlighted. For 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. u

7. Scroll to the Starting Mode parameter by using the Up/Down keys, and press Enter.

EscEsc

—

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8. Press Enter to select the option. Scroll to the option of your choice by using the Up/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 Down key. Continue the process until all desired settings are entered.

11. To save modifications to memory, scroll to Parameter Mgmt, press Enter twice and scroll to User Store. Press the Enter key again to save the new settings to EEPROM.

u The SMC Option advises the user if any control option (i.e., Pump Control) is resident. This parameter is

factory set and cannot be modified by the user.

v 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.

—

Programming 4-9

Soft Start The following parameters are specifically used to adjust the voltage ramp

supplied to the motor.

Parameter Option

Starting Mode

This must be programmed for Soft Start.

Ramp Time u

This programs the time period that the controller will ramp the output voltage up to full voltage from the initial Torque level programmed.

Initial Torque

The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter.

Kickstart Time

A boost of current is provided to the motor for the programmed time period.

Kickstart Level

Adjusts the amount of current applied to the motor during the kickstart time.

u If the 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.

Soft Start

0 to 30 s

0 to 90% locked rotor torque

0.0 to 2.0 s

0 to 90/% locked rotor torque

Current Limit Start To apply a fixed, reduced-output voltage to the motor, the following

parameters are provided for user adjustment:

Parameter Option

Starting Mode

This must be programmed for Current Limit.

Ramp Time u

This 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.

Kickstart Time

A boost of current is provided to the motor for the programmed time period.

Kickstart Level

Adjusts the amount of current applied to the motor during the kickstart time.

u If the controller senses that the motor has reached full speed before completing the Current

Limit Start, it will automatically switch to providing full voltage to the motor.

Current Limit

0 to 30 s

50 to 600% full load current

0.0 to 2.0 s

0 to 90/% locked rotor torque

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4-10 Programming

Dual Ramp Start The SMC-Flex controller provides the user with the ability to select

between two Start settings. The parameters below are available in the Set Up programming mode. To obtain Dual Ramp control, Ramp #1 is located in the Basic Set Up and Ramp #2 is located in the Option 2 Input (Dual Ramp).

Parameter Option

Set Up

The user must select the Set Up programming mode to obtain access to the Dual Ramp parameters.

Basic Set Up/Starting Mode

Set up as stated in previous pages.

Option 1 Input (Dual Ramp) u

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 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 v

This selects the start mode for option #1.

Basic Set Up/Ramp Time

This programs the time period during which the controller will ramp the output voltage up to full voltage for the first Start setup.

Basic Set Up/Initial Torque

This parameter establishes and adjusts the initial reduced output voltage level for the first Soft Start setup.

Dual Ramp/Start Mode 2 v

This selects the start mode for option #2.

Dual Ramp/Ramp Time 2

This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Start setup.

Dual Ramp/Initial Torque 2

The initial reduced output voltage level for the second Start setup is established and adjusted with this parameter.

u The Dual Ramp feature is available on the standard controller.

v Kickstart can be programmed for both start modes.

—

0 to 30 s

0 to 90/% locked rotor torque

—

0 to 30 s

0 to 90/% locked rotor torque

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Programming 4-11

Full Voltage Start The SMC-Flex controller may be programmed to provide a full voltage

start (output voltage to the motor reaches full voltage within 1/4 second) with the following programming:

Parameter Option

Starting Mode

This must be programmed for Full Voltage.

Full Voltage

Linear Speed 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 on page 1-7.

Parameter Option

Starting Mode

This must be programmed for Linear Speed.

Ramp Time

This programs the time period that the controller will ramp from 0 speed to full voltage.

Kickstart Time

A boost of current is provided to the motor for the programmed time period.

Kickstart Level

Adjusts the amount of current applied to the motor during the kickstart time.

Linear Speed

0 to 30 s

0.0 to 2.2 s

0 to 90/% locked rotor torque

Basic Setup The Basic Setup programming group provides a limited parameter set,

allowing quick start-up with minimal adjustments. If the user is planning to implement some of the advanced features (i.e., Dual Ramp, Unbalance Level, etc.), then the Linear List programming group should be selected. It provides all the Basic Setup parameter set plus the advanced set.

Parameter Option

SMC Option

Displays the type of controller. This is factory set and not adjustable.

Motor Connection

Displays the motor type the device is being connected to.

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.

Starting Mode

Allows the user to program the SMC-Flex controller for the type of starting that best fits the application.

Ramp Time

This sets the time period during which the controller will ramp the output voltage.

Initial Torque u

The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter.

u Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter.

Standard

Line or Delta

—

1 to 10000 (See Table 3.B – Input

Voltage Ranges) Soft Start, Current Limit,

Full Voltage, Linear Speed

0 to 30 s

0 to 90/% locked rotor torque

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4-12 Programming

Basic Setup (cont.)

Parameter Option

Current Limit Level v

50 to 600% FLC The current limit level that is applied for the Ramp time selected.

Kickstart Time

0.0 to 2.0 s A boost current is provided to the motor for the programmed time period.

Kickstart Level

Adjusts the amount of current applied to the motor

0 to 90% of locked rotor torque

during kickstart.

Option 2 Input

Allows the user to select a Dual Ramp or Preset Slow Speed (SS).

Stop Mode

Allows the user to program the SMC-Flex controller

Disable, Preset SS, Dual Ramp Emergency Run x

Disable, Soft Stop, Linear Speed

for the type of stopping that best fits the application.

Stop Time

0.0 to 120 s This sets the time period which the controller will ramp the voltage during a stopping maneuver.

CT Ratio

1 to 1500 Scales the CT input to actual motor current (5 amp secondary assumed)

Aux1 Config

Normal, Up-to-speed/Bypass N.O. contact is provided as standard with the SMC-Flex controller. This contact is located at terminals 19 and 20. Aux Contacts 1 allows the user to configure the operation of the contacts.

Fault Contact

N.O., N.C. A fault auxiliary contact is provided between terminals 29 and 30. Fault Contact allows the user to program the operation of the contact for a fault condition.

Alarm Contact

N.O., N.C. An alarm contact is provided between terminals 31 and 32. Alarm contact allows the user to program the operation of the contact for an Alarm condition.

Aux2 Config

N.O., N.C. This parameter provides the user with the ability to program the “Normal” state of the second auxiliary contact. This contact is located at terminals 33 and 34.

Parameter Mgmt w

The newly programmed parameters’ values can be

Ready, User Store, User

Recall, Load Default saved to memory, or the factory default parameter values can be recalled.

v Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level

parameter.

w The new programmed parameter values will not be stored to the EEPROM without the user’s

direction in Parameter Management: User Store.

x When programmed for ‘Emergency Run’ and the Option 2 input is energized, a ‘Start’ command

will first close the bypass contactor, then the line contactor for an across-the-line start of the motor. A ‘Stop’ command will open the line contactor first and allow the motor to coast, regardless of the programmed ‘Stop Mode’. For Pump Option modules, the Option 2 input defaults to ‘Emergency Run’ for MV applications.

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Programming 4-13

Motor Protection While the Basic Set Up group allows the user to get started with a

minimum number of parameters to modify, the Motor Protection group allows full access to the SMC-Flex controller's powerful parameter set. Following is a listing of the additional setup parameters provided.

Note: The majority of parameters have a Fault and an Alarm setting.

Parameter Option

Overload

Allows the user to select the operation of the overload.

Underload v

Determines the trip level as a percentage of the motor’s FLA, and the delay period.

Undervoltage u

Determines the trip level as a percentage of line voltage and delay period.

Overvoltage u

Determines the trip level as a percentage of line voltage and delay period.

Unbalance u

Allows the user to set the current unbalance trip level and delay period.

Jam v

Determines the trip level as a percentage of motor full load current and delay period.

Stall

Allows the user to set the stall delay time.

Ground Fault w

Allows the user to enable the ground fault level in amps, delay time and inhibit time. A separate 825-CBCT is required.

PTC x

Allows the user to connect a PTC to the SMC and enable a fault when it becomes active.

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

Allows the user to determine the maximum number of restarts per hour the unit can experience, and delay time between consecutive starts.

u The delay time must be set to a value greater than zero when Undervoltage, Overvoltage and

Unbalance are enabled.

v For Jam and Underload detection to function, the Motor FLC must be programmed in the Motor

Protection group. See Chapter 5 for instructions.

w See details in Ground Fault on page 1-12. x See details in Termistor/PTC Protection on page 1-13.

Trip Class, Service Factor, Motor FLC, Overload Reset, Overload Alarm Level

Underload Fault Level, Underload Fault Delay, Underload Alarm Level, Underload Alarm Delay

Undervoltage Fault Level, Undervoltage Fault Delay, Undervoltage Alarm Level, Undervoltage Alarm Delay

Overvoltage Fault Level, Overvoltage Fault Delay, Overvoltage Alarm Level, Overvoltage Alarm Delay

Unbalance Fault Level, Unbalance Fault Delay, Unbalance Alarm Level, Unbalance Alarm Delay

Jam Fault Level, Jam Fault Delay, Jam Alarm Level, Jam Alarm Delay

Stall Delay

Ground Fault Enable, Ground Fault Level, Ground Fault Delay, Ground Fault Inhibit Time, Ground Fault Alarm Enable, Ground Fault Alarm Level, Ground Fault Alarm Delay

PTC Enable

Phase Reversal

Restarts Per Hour, Restart Attempts, Restart Delay

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4-14 Programming

Example Settings Undervoltage u

With Line Voltage programmed for 4160 V and the Undervoltage level programmed for 80%, the trip value is 3328 V.

Overvoltage u

With Line Voltage programmed for 3300 V and the Overvoltage level programmed for 115%, the trip value is 3795 V.

Jam v

With Motor FLC programmed for 150 Amps and the Jam level programmed for 400%, the trip value is 600 Amps.

Underload v

With Motor FLC programmed for 90 Amps and the Underload level programmed for 60%, the trip value is 54 Amps.

u The average value of the three phase-to-phase voltages is utilized. v The largest value of the three phase currents is utilized.

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Programming 4-15

Motor Information The Basic Set Up and Overload programming group allows the user to set

parameters indicating to the controller which motor is connected. It is important to correctly input the data to achieve the best performance from your controller.

A T T E N T I O NA T T E N T I O N

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 vw The factor default setting disables

overload protection. To enable it, enter the desired trip class in this parameter.

Service Factor vw Enter the value from the motor’s

nameplate.

Motor FLC uvw Enter the value from the motor’s

nameplate.

Overload Reset vw Allows the user to select either a manual

or auto reset after an overload.

Motor Connection w Enter the type of motor being connected

to the SMC-Flex: Line or Delta

Line Voltage uw Enter the system voltage in this

parameter. This must be done to ensure

optimum motor performance and correct operation of undervoltage and overvoltage protection.

Disable, 10, 15, 20, 30

0.01 to 1.99

1.0 to 1000A

Manual, Auto

Line, Delta

1 to 10,000 V

u Refer to the SMC -Flex controller nameplate for maximum ratings. Exceeding these could result in

damage to the controller.

v Found in Overload programming group. Only one location needs to be programmed. w Found in Basic Set Up programming group.

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4-16 Programming

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Chapter

Metering

Overview While the SMC-Flex controller operates your motor, it also monitors

several different parameters, providing a full function metering package.

Viewing Metering Data To access the metering information, follow the procedure below:

Description Action Display

– –

EscEsc

1. Press any key to access the Main menu.

2. Scroll with the Up/Down keys until the Parameter option is shown.

3. Press the Enter key to access the Parameter option.

4. Scroll with the Up/Down keys until the Monitoring option is displayed.

5. Press the Enter key to access the Monitoring group.

6. Press the Enter key to access the Metering group.

u Refer to Metering on page 1-16 or Figure 4.2 on page 4-3 for details on the metering functions .

—

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5-2 Metering

Viewing Metering Data (cont.)

Description Action Display

7. Scroll through the Metering parameters with the Up/Down keys to access the desired information. Press the Enter key to view that parameter.

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Chapter

Options

Overview The SMC-Flex controller offers a variety of unique control programming

and communication options that provide enhanced capabilities. (See Chapter 1 for brief descriptions of each option.)

Note: Only one option can reside in a controller.

Human Interface Module The control buttons available with the Bulletin 20-HIM Human interface

modules are compatible with the SMC-Flex controller’s control options. The following table details the functionality of each button with regards to each option.

Notes: (1) The logic mask port must be enabled prior to initiating control

commands to the SMC-Flex controller. Refer to Control Enable on page 2-16 for instructions.

(2) The control terminals must be wired according to

Figure 3.10 on page 3-10 and Figure 3.16 on page 3-16.

Option Action Operation

Standard

The green start button, when pressed, will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop, and/or reset a fault.

The jog button, when pressed, will initiate the programmed maneuver.

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.

Soft Stop

Current Limit

Full Voltage

Linear Speed

Preset

Slow Speed

JogJog

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6-2 Optio

Human Interface Module (cont.)

Option Action Operation

Pump Control

Braking Control Ê

Smart Motor Braking

Accu-Stop

Slow Speed

with Braking

Ê Braking Control is not offered for standard use in MV applications. Please consult factory for further

assistance.

JogJog

The green start button, when pressed, will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop, and/or reset a fault.

The jog button, when pressed, will initiate a pump stop maneuver.

The green start button, when pressed, will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop, and/or reset a fault.

The jog button, when pressed, will initiate a brake stop.

The green start button, when pressed, will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop, and/or reset a fault.

With a “stopped” status, the jog button, when pressed, will initiate slow speed motor operation. From an “at speed” condition, the jog button, when pressed, will initiate braking to slow speed operation. The controller will maintain slow speed operation as long as the jog button is pressed.

The green start button, when pressed, will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop, and/or reset a fault.

The jog button will initiate a brake stop. * Slow Speed cannot be operated via the HIM.

A T T E N T I O NA T T E N T I O N

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.

1560E-UM050B-EN-P - June 2013

Rockwell Automation 1560E SMC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Table of Contents

Preface

Manual Objectives This manual is intended for use by personnel familiar with Medium Voltage and

Documentation The following Rockwell Automation publications provide pertinent

Description The MV SMC-Flex is a solid-state, three-phase, AC line controller. It is

Starting Modes Soft Start

Current Limit Start ;

Full Voltage Start

Starting Modes (cont.) Preset Slow Speed

Linear Speed Acceleration and Deceleration

Soft Stop

Protection and Diagnostics The MV SMC-Flex™ controller is capable of providing the following

Overload

Stall Protection and Jam Detection

Ground Fault

Thermistor/PTC Protection

Open Gate

Line Faults

Excessive Starts/Hour

Overtemperature

Metering Power monitoring parameters include:

Communication A serial interface port (DPI) is provided as standard, which allows

Programming Setup is easy with the built-in keypad and three-line, sixteen-character

Status Indication Four programmable hard contact outputs are provided as standard:

Control Options The MV SMC-Flex™ controller offers the control options described below.

Pump Control Option

Braking Control Option

Hardware Description The following sections contain descriptions of system components and

Power Module

Self-Powered Silicon-Controlled Rectifier Gate Driver Board

Interface Board

Functional Description The following functional descriptions and associated control circuits are

Bulletin 1562E • Basic Control – Controlled Start only

Bulletin 1562E • Basic Control – With Controlled Stop

Bulletin 1562E • DPI Control – Controlled Start only

Functional Description (cont.) Bulletin 1560E • Basic Control – Controlled Start Only

Bulletin 1560E • Basic control – With Controlled Stop

Bulletin 1560E • DPI Control – Controlled Start only

Receiving It is the responsibility of the user to thoroughly inspect the equipment

Safety and Codes The Canadian Electrical Code (CEC), National Electrical

Unpacking and Inspection After unpacking the material, check the item(s) received against the bill of

General Precautions In addition to the precautions listed throughout this manual, the following

Transportation and Handling The controller must be transported on a pallet or via use of the lifting

Installation Site Consider the following when selecting the installation site:

Mounting

Installation Site (cont.) Grounding Practices

Recommended Torque Values When reinstalling components or when reassembling the cabinet, tighten

Power Connections The controller requires a three-phase supply and an equipment grounding

Bulletin 1562E

Power Connections (cont.) Bulletin 1560E

Bulletin 1503E

Power Wiring The wire sizes must be selected individually, observing all applicable

Interlocking Hinged doors and panels, which provide access to medium voltage

Installation Physical Location

Ground Bus Bar

Power and Control Wiring

Control Cables

Fibre-Optic Cables

Installation (cont.) Power Factor Correction Capacitors

Surge Arrestor Protection Devices

Motor Overload Protection Thermal motor overload protection is provided as standard (though it must

Two-speed Motors

Multi-motor Protection

EMC Compliance

Enclosure

Wiring

Control Power Control Voltage

Control Wiring

Control Terminal Designations As shown in Figure 2.10, the SMC-Flex controller contains 24 control

Preliminary Set-Up A. Ensure the work area is clean and tidy. Pathways to main disconnect

System Characteristics

Preliminary Check Ensure that all sources of power are isolated and locked

Programming MV SMC-Flex™ Module

Hi-Pot and Megger Test It is recommended that insulation levels be checked before energizing

Power Supply Tests Servicing energized industrial control equipment can be