Rockwell Automation MV SMC Flex Motor Controller User Manual

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User Manual Series K (or later)

Medium Voltage SMC™ Flex Motor Controller Bulletin 1503E, 1560E and 1562E

Publication 1560E-UM051F-EN-P

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 belonging to Rockwell Automation are property of their respective companies.

Table of Contents

Preface

Product Overview

Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

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

Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

1560E – Retrofit Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1562E – Combination Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SMC Flex™ Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Starting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Selectable Kickstart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Current Limit Start

Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Full Voltage Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preset Slow Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Linear Speed Acceleration and Deceleration . . . . . . . . . . . . . . . . . . . . . . 6

Soft Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Protection and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Overvoltage

(5)

Unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Stall Protection and Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Thermistor/PTC Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Open Gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Line Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Excessive Starts/Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Status Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pump Control Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Braking Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Hardware Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Current Loop Gate Driver (CLGD) Board . . . . . . . . . . . . . . . . . . . . . 21

Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 3

Table of Contents

Installation

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Bulletin 1562E • Basic Control – Controlled Start only. . . . . . . . . . 25

Bulletin 1562E • Basic Control – With Controlled Stop. . . . . . . . . 25

Bulletin 1562E • DPI Control – Controlled Start only . . . . . . . . . . 26

Bulletin 1562E • DPI Control – With Controlled Stop. . . . . . . . . . 26

Bulletin 1560E • Basic Control – Controlled Start only. . . . . . . . . . 27

Bulletin 1560E • Basic Control – With Controlled Stop. . . . . . . . . 28

Bulletin 1560E • DPI Control – Controlled Start only . . . . . . . . . . 28

Bulletin 1560E • DPI Control – With Controlled Stop. . . . . . . . . . 29

Chapter 2

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Safety and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Transportation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Grounding Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Bulletin 1562E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Bulletin 1560E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Bulletin 1503E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Physical Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Ground Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Power and Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Fiber-Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Power Factor Correction Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Surge Arrestor Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Two-speed Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Multi-motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

EMC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Control Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Control Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Chapter 3

Table of Contents

Commissioning Procedure

Programming

Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

System Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Important Commissioning Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

MV SMC Flex Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Hi-Pot and Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Power Supply Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Control Function Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Resistance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Voltage Sensing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Chapter 4

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Keypad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Programming Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Parameter Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Random Access Memory (RAM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Read-Only Memory (ROM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Electrically Erasable Programmable Read-Only Memory (EEPROM)

Using Parameter Management with DPI HIM. . . . . . . . . . . . . . . . . . 77

Parameter Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Linear Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Preset Slow Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Example Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Overvoltage

Jam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Underload

Motor Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Motor Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Metering

Chapter 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Viewing Metering Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 5

Table of Contents

Chapter 6

Options

Diagnostics

Communication

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Chapter 7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Protection Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Fault Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Clear Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Fault Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Fault and Alarm Auxiliary Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Fault Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Chapter 8

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Keypad Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Connecting the Human Interface Module to the Controller . . . . 104

HIM Control Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Control Enable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Loss of Communication and Network Faults . . . . . . . . . . . . . . . . . . . . . . 106

SMC Flex Specific Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Default Input/Output Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Variable Input/Output Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

SMC Flex Bit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Reference/Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Parameter Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Scale Factors for PLC Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Read Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Write Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Display Text Unit Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Configuring DataLinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Rules for Using DataLinks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Updating Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Chapter 9

Troubleshooting

6 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

General Notes and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Control Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Voltage Feedback Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Voltage Sensing Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Current Loop Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Maintenance

Table of Contents

Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Power Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Thyristor (SCR) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

SCR Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Snubber and Resistor Circuit Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Snubber Resistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Chapter 10

Safety and Preventative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Periodic Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Vacuum Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Solid-State Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Static-Sensitive Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Overload Maintenance After a Fault Condition. . . . . . . . . . . . . . . . 147

Final Check Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

“Keep Good Maintenance Records”. . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Power Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Control Components – Electronic. . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Interlocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Environmental Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Hazardous Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Specifications

Parameter Information

1560E and 1562E Relay Control

Appendix A

1560E/1562E SMC Flex Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Appendix B

Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Appendix C

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Bulletin 1562E • Basic Control – Controlled Start only . . . . . . . . 165

Bulletin 1562E • Basic Control – With Controlled Stop . . . . . . . 165

Bulletin 1562E • DPI Control – Controlled Start only . . . . . . . . . 166

Bulletin 1562E • DPI Control – With Controlled Stop . . . . . . . . 166

Bulletin 1560E • Basic Control – Controlled Start only . . . . . . . . 167

Bulletin 1560E • Basic Control – With Controlled Stop . . . . . . . 168

Bulletin 1560E • DPI Control – Controlled Start only . . . . . . . . . 168

Bulletin 1560E • DPI Control – With Controlled Stop . . . . . . . . 168

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 7

Table of Contents

Appendix D

ArcShield Unit Information

ArcShield Plenum Installation Instructions

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

ArcShield Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Exhaust Systems: Chimney or Plenum Option . . . . . . . . . . . . . . . . . . . . . 180

Plenum Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Plenum Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Additional Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Chimney Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Chimney Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Appendix E

Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Plenum Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

General Plenum Layout for ArcShield Line-up. . . . . . . . . . . . . . . . . . . . . 187

STEP 1 – Mounting a Single Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Plenum Placement on Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

STEP 2 – Alignment of “Side-by-Side” Plenums . . . . . . . . . . . . . . . . . . . 190

STEP 3 – Sequence of Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

STEP 4 – Closing the Front of the Plenum Sections. . . . . . . . . . . . . . . . 191

STEP 5 – Extension and Elbow Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 192

STEP 6 – Mounting Extension/Elbow to Plenum “Line-up” . . . . . . . . 193

STEP 7 – Additional Mounting Support . . . . . . . . . . . . . . . . . . . . . . . . . . 194

ArcShield Chimney Installation Instructions

Spare Parts

Accessories

Appendix F

Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

General Plenum Layout for ArcShield Line-up. . . . . . . . . . . . . . . . . . . . . 195

Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Chimney Placement on Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Appendix G

Power Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Appendix H

Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

8 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Preface

TIP

Service Procedure

For your convenience, the Rockwell Automation Global Manufacturing Solutions (CSM), provides an efficient and convenient method of servicing medium voltage products.

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

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

For MV SMC Flex technical support on start-up or existing installations, contact your Rockwell Automation representative. You can also call 1-519-740-4790 for assistance Monday through Friday from 9:00 a.m. to 5:00 p.m. (Eastern time zone).

Rockwell Automation Publication 7000A-UM200C-EN-P - June 2014 9

Preface

Notes:

10 Rockwell Automation Publication 7000A-UM200C-EN-P - June 2014

Product Overview

TIP

Chapter 1

Manual Objectives

Documentation

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 family of controllers. The family consists of the following Bulletin numbers: 1503E, 1560E and 1562E.

This user manual pertains to units with Series letter K or later, and firmware release 4.xxx (or later).

See Appendix D

The following Rockwell Automation publications provide pertinent information for the MV SMC Flex and components:

• MVB-5.0 General Handling Procedures for MV

• 1500-UM055_-EN-P Medium Voltage Controller Two-High Cabinet

• 1502-UM050_-EN-P 400A Vacuum Contactor, Series D

• 1502-UM052_-EN-P 400A Vacuum Contactor, Series E

• 1502-UM051_-EN-P 800A Vacuum Contactor, Series D and E

• 1560E-SR022_-EN-P Medium Voltage SMC Flex Controllers

• 1503-UM051_-EN-P IntelliVAC Contactor Control Module

, Appendix E and Appendix F for arc-resistant cabinets.

Controllers

(200A/400A) – User Manual

– User Manual

– General Specifications

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

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 1

Chapter 1 Product Overview

TIP

an existing or OEM/customer-supplied starter. It is comprised of several modular components, including:

• Frame-mounted or loose power stacks including gate driver boards

• Loose interface and voltage feedback boards

• Fiber optic cables for SCR firing

• Microprocessor based control module

• Bypass vacuum contactor

1560E – Retrofit Controller

A medium voltage solid-state controller designed to work in conjunction with an existing customer-supplied starter. It includes:

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

• A continuous, bare copper ground bus

• Power electronics

• A bypass vacuum contactor

• Three (3) current transformers

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

module

• Top and bottom plates to accommodate power cables.

Refer to Interlocking on page 49 of Chapter 2.

1562E – Combination Controller

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

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

• A continuous, bare copper ground bus

• Power electronics

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

• An isolation vacuum contactor

• A bypass vacuum contactor

• Three (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)

2 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Product Overview Chapter 1

Perce nt Volt age

100%

Initial

Tor qu e

Start

Time (seconds)

Run

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

Other features that offer further user benefit include:

• Extensive protection features

• Metering

• Communication capability

• I/O

(1)

Starting Modes

Innovative control option provides enhanced performance:

• Pump Control (Start and Stop Control modes)

These modes, features and options are further described in this chapter.

Soft Start

This mode has the most general application. The motor is given an initial torque setting, which is user-adjustable from 0 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 - Soft Start

(1) This option utilizes gating patterns which result in motor and line currents that produce noise and vibration in the motor and/or

distribution transformer. This must be considered before applying this option.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 3

Chapter 1 Product Overview

Kickstart

100%

Initial

Tor q ue

Start

Time (seconds)

Run

600%

Perce nt

Full Load

Curren t

Start

Time (se conds)

50%

Selectable Kickstart

(2)

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

2.0 seconds.

Figure 2 - Selectable Kickstart

Current Limit Start

(2)

This starting mode provides a true current limit start that is used when limiting the maximum starting current is necessary. The Current Limit level is user-adjustable from 50% to 600% of the motor’s full-load ampere rating, and the current limit time is user-adjustable from 0 to 30 seconds. Once the MV SMC Flex controller senses that the motor has reached the up-to-speed condition during the current limit starting mode, the output voltage automatically switches to full voltage and the bypass contactor is closed.

Figure 3 - Current Limit Start

4 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

(2) Kickstart is also available with Current Limit Start, Dual Ramp Start and Linear Acceleration.

Product Overview Chapter 1

Perce nt Volt age

Start #1

Time (seconds)

Start #2

Ramp #2

Ramp #1

Start #2

Run #1

Run #2

Initial Torque #1

Initial Torque #2

100%

Perce nt Vol tag e

Time (seconds)

100%

Dual Ramp Start

(3)

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

Figure 4 - Dual Ramp Start

Full Voltage Start

This starting mode is used for applications requiring across-the-line starting. The output voltage to the motor will reach full voltage within 1/4 second.

Figure 5 - Full Voltage Start

(3) Dual Ramp Start is available only with the standard controller.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 5

Chapter 1 Product Overview

IMPORTANT

Forwa rd

15% – High

Time (seconds)

Start Run

10% – Low

Reverse

7% – Low

20% – High

100%

Motor

Speed

Run

Time (seconds)

Start Stop

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.

Figure 6 - Preset Slow Speed Option

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.

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.

Figure 7 - Linear Speed Acceleration

6 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Product Overview Chapter 1

IMPORTANT

Kickstart

100%

Initial

Tor qu e

Perce nt Vol tag e

Run

Time (seconds)

Start Soft Stop

Coast- to-rest

Soft Stop

TIP

Linear deceleration does not need to be used, even if linear acceleration is used. The stop time can be programmed for 0 to 120 seconds. Linear deceleration cannot brake the motor/load and reduce the stop time.

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.

ATT EN TI ON : 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.

Soft Stop

This feature can be used in applications that require an extended coast-to-rest time. The voltage ramp-down time is user-adjustable from 0 to 120 seconds and is adjusted independently from the starting time. The load will stop when the output voltage drops to a point where the load torque is greater than the developed motor torque.

Figure 8 - Soft Stop Option

ATT EN TI ON : 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.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 7

Chapter 1 Product Overview

IMPORTANT

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 (Refer to Chapter 4, value reaches 100%. The parameters below provide application flexibility and easy setup.

Parame ter Range

Overload Class Disable, 10, 15, 20, 30

Overload Reset Manual – Auto

Motor FLC 10 – 2200 amps

Service Factor 0.01 – 1.99

Programming). An Overload Fault will occur when this

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. 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.

2. Automatic reset of an overload fault requires the start input to be cycled in a 2-wire control scheme.

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

Figure 9

and Figure 10 provide the overload trip curves for the available trip

classes.

8 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Figure 9 - Overload Trip Curves

Class 10 Class 15 Class 20 Class 30

Multiples of FLC Multiples of FLC Multiples of FLC

Approximate Trip Time (Seconds)

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

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

Percent Full Load Current Setting

Seconds

Class 10 Class 15 Class 20 Class 30

Auto Reset Times:

Class 10 = 90 s Class 15 = 135 s Class 20 = 180 s Class 30 = 270 s

Figure 10 - Restart Trip Curves after Auto Reset

100000

Product Overview Chapter 1

1000

100

100% 1000%

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 9

Chapter 1 Product Overview

TIP

Underload

(4)

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.

Undervoltage

(5)

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

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

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

(5)

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.

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

(4) Underload protection is disabled during slow speed and braking operations. (5) Undervoltage, overvoltage and voltage unbalance protection are disabled during braking operation.

10 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Product Overview Chapter 1

Perce nt

Full Loa d

Curren t

600%

Programmed Start Time

Stall

Time (seconds)

Unbalance

(6)

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.

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.

Figure 11 - Stall Protection

(6) Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.

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Chapter 1 Product Overview

Perce nt

Full Loa d

Curren t

100%

Running

Jam

Time (seconds)

Figure 12 - Jam Detection

(7)

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 can be provided with 1562E units).

Ground Fault Trip

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

• No trip currently exists

• Ground fault protection is enabled

• GF Inhibit Time has expired

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

greater than the GF Trip Delay

Parameter 75, Gnd 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.

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.

(7) Jam Detection is disabled during slow speed and braking operation.

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IMPORTANT

The ground fault inhibit timer starts after the maximum phase of load current transitions from 0A to 30% of the device’s minimum FLA Setting or the GF Curre nt 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.

Ta b l e 1

Table 1 - PTC Input Ratings

defines the MV SMC Flex PTC thermistor input and response ratings:

Response Resistance 3400 ± 150

Reset Resistance 1600 ± 100

Short-circuit Trip Resistance 25 ± 10

Maximum Voltage at PTC Terminals (R

Maximum Number of Sensors 6

Maximum Cold Resistance of PTC Sensor Chain 1500

Response Time 800 ms

- 4k) < 7.5V

PTC

= open) 30V

PTC

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 13

Chapter 1 Product Overview

TNF + 15K

TNF + 5K

TNF - 20K

TNF - 5K

TNF

-20°C 0°C

Figure 13 illustrates the required PTC sensor characteristics, per IEC-34-11-2.

Figure 13 - PTC Sensor Characteristics per IEC-34-11-2

4000

1330

550

550 250

250

250 100

100

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.

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. The Open Gate detection is active during starting or stopping only.

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Product Overview Chapter 1

TIP

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

(8)

Phase reversal protection

can be toggled either ON or OFF.

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.

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 fiber-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 (Refer toTroubleshooting

page 113 for instructions).

(8) Phase reversal protection is functional only at pre-start.

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Chapter 1 Product Overview

TIP

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 (full speed %, 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%.

I/O

The SMC Flex has the ability to accept up to two (2) inputs and four (4) outputs controlled over a network. The two inputs are controlled at terminal 16 (Option Input #1), and terminal 15 (Option Input #2). For these two inputs, refer to Chapter 4 identification. By using these two terminals as inputs, the Stop Input will need to be programmed to meet the desired stop functionality.

The four (4) outputs are Aux #1, Aux #2, Aux #3 and Aux #4. All auxiliary contacts are programmable to the function found on page 83 Network or Network NC, they can be controlled over a Network. Please see

Table 16 on page 109

for the parameter settings and refer to Chapter 8 for the bit

. If programmed to

which defines the Logic Command Word (Control).

For MV applications, some of the I/O are assigned to specific functions. Please refer to Status Indication

on page 18 for additional details.

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Product Overview Chapter 1

DPI

Port 2

Ports 2 and 3 when two HIMs

are connected with a splitter

Port 5 – DPI Communications

Communication

A serial interface port (DPI) is provided as standard, which allows connection to the Bulletin 20-HIM LCD human interface modules.

Figure 14 - DPI Location

ATT EN TI ON : 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.

Figure 15 - Built-in Keypad and LCD

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Chapter 1 Product Overview

TIP

SMC Flex Controller Terminals

Opt

Input

Opt

Input

Start Input

Stop

Input

(External

Bypass)

Aux #1

PTC

Input

TACH Input

Ground

Faul t

(Fault

Contac t)

Aux 2 Aux 3 Aux 4

(Alarm

Contac t)

(Normal)

Status Indication

All auxiliary contacts can be programmed as NO or NC for the following states except External Bypass, which can only be programmed as NO.

Normal/Normal NC: The contact state changes when the unit receives a Start/Stop signal

Up-to-Speed/Up-to-Speed NC: The contact state changes when the motor approaches rated speed

Alarm/Alarm NC: The contact state changes when an Alarm condition is detected

Fault/Fault NC: The contact state changes when a Fault condition is detected

Network Control/Network Control NC: The contact state is controlled over

the network. (Refer to Table 16 on page 109

, which describes logic command

word to control auxiliary outputs)

External Bypass: This contact controls the Bypass contactor for MV applications.

The tag name without a suffix indicates a NO state (e.g. Normal). On the other hand, a tag name followed by NC indicates a normally closed state (e.g. Normal NC).

Figure 16 - Control Terminals

11 12

Note:

• The Aux #1 contact is always programmed for External Bypass (NO) to

control the bypass contactor in MV applications.

• The Aux #2 contact is typically programmed for fault indication in MV applications (it can be configured for NO/NC).

• The Aux #3 contact is typically programmed for alarm indication in MV applications (it can be configured for NO/NC).

• The Aux #4 contact is always configured as Normal (NO) to control the line contactor for MV applications.

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Product Overview Chapter 1

IMPORTANT

Network inputs can be obtained through proper programming of Option Input #1 and Option Input #2. (refer to page 159

MV applications have special requirements for isolation and bypass contactors (or circuit breakers). For Firmware up to and including 5.001 the following issues must be considered:

1. AUX1 must be used to control the fully-rated bypass contactor.

Parameters #107 will not be displayed, and defaults to “Ext Bypass”. The functionality of AUX1 is modified for MV operation and behaves similar to, but different from, the “Ext Bypass” or “Up-To-Speed” function of any other AUX relay.

2. AUX4 must be used to control the isolation contactor. Parameter #109

must be set to “Normal”. The functionality of AUX4 is modified for MV operation and behaves similar to, but different from, the “Normal” function of any other AUX relay.

For Firmware 6.001 and later, the definitions of all AUX relays will be the same, and for MV applications will perform with the modified MV functionality.

and page 163 for available options.)

Control Options

1. AUX1 should be used for bypass contactor control, and must be set for

“Ext Bypass”.

2. AUX4 should be used for isolation contactor control, and must be set for

“Normal”.

The MV SMC Flex controller offers the control options described below.

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.

Kickstart is available with this option.

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Chapter 1 Product Overview

100%

Motor

Speed

Run

Pump StopPump Start

Time (seconds)

Pump Application Considerations

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

2. The Pump Control option functions only for centrifugal pumps. It is not suited for positive displacement, piston, or other types of pumps.

3. The Pump Stop option functions only 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.

Figure 17 - Pump Control Option

ATT EN TI ON : Pump stopping is not intended to be used as an emergency stop.

Refer to the applicable standard for emergency stop requirements.

ATT EN TI ON : 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.

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Product Overview Chapter 1

Braking Control Options

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

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

Figure 18

and Figure 19, Typical MV SMC Flex Power System.

Power Module

The controller consists of three power modules, one for each phase. Each power module consists of incoming and outgoing terminals for cables, SCRs, heatsink and clamp assembly. The SCRs are connected in inverse parallel (and in series for 12- or 18-SCR assemblies) to form a three-phase, AC line controller configuration.

Each power module includes a snubber circuit to limit the rate of rise in voltage across each SCR pair. The module also includes patented current loop gate driver circuits which derive their power primarily from the snubber circuit.

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

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

Current Loop Gate Driver (CLGD) Board

This board provides the turn-on capability for SCR devices. The board also provides optical fiber isolation between itself and the gating source logic. It is primarily powered by recovering energy from the snubber circuit, so it is fully isolated from the control and logic circuits. The board also receives short-term power from the current loop power supply.

The MV SMC Flex has three heatsinks fitted with a thermistor to monitor temperature rise. The circuitry on the gate driver board accepts the thermistor, and drives a fiber-optic cable if the temperature is below the setpoint (85°C). If the temperature rises above the setpoint, the driver is turned off, and the MV SMC Flex is signaled to stop gating and initiate a temperature fault.

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Chapter 1 Product Overview

Interface Board

This circuit board takes current transformer signals plus line-side and load-side voltage feedback signals from the voltage sensing board and passes them to the SMC Flex for processing. The control module produces gating signals for the SCRs, which are received on the interface board, and used to drive fiber-optic transmitters. The gating signals are sent to the gate-driver circuit board via fiber-optic cables. The interface board also receives temperature feedback from the gate-driver board via fiber-optic cable(s). If the heatsink temperature rises above a 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 37 on page 63

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Product Overview Chapter 1

-+ +- -+ +-

4160V AC, 3Ø, 60Hz

L1 L2 L3 GND

ISOLATING SWITCH

DOOR INTERLOCK

CURRENT LIMITING

POWER FUSES

CURRENT LIMITING

PRIMARY FUSES

100:1

GFCT

(OPTIONAL)

F2F2

H2H1

120V

CPT

500VA

ISa

X3 X2 X4

4200V

TO CONTROL CIRCUIT

TO SMC Flex

(27, 28)

BLK

RR1 RR2

OV1

OV2OV1 OV2OV2 OV3 OV4

S1 S2 S3 S4

RS1 RS2CS1 CS2

C2 C3 C4

OV S C

TEST

CLGD

RX1 TX1

G C T

OV S C

TEST

CLGD

RX1 TX1

G C T

OV S C

TEST

CLGD

RX1 TX1

G C T

OV S C

TEST

CLGD

RX1 TX1

G C T

CT2

CT1

CT3

MTR

CAUTION MAXIMUM TWO STARTS PER HOUR WITH A MINIMUM OF

FIVE MINUTES BETWEEN STARTS.

WIRE CONNECTIONS FOR PHASE A

WIRE CONNECTIONS FOR PHASE B

CONNECTIONS SHOWN FOR PHASE C

CONNECT TO GROUND ONLY IF POWER SYSTEM IS GROUNDED

CURRENT LOOP CONDUCTORS PASS THROUGH THE C.T.'S ON

THE GATE DRIVER BOARDS (CLGD)

REMOTE EQUIPMENT

SMC Flex INTERFACE BOARD SMC

FlexIB

VOLTAGE SENSING BOARD

VSB

GATE TRANSMITTERS

PHASE A PHASE B

OUTPUTS

TX1

TX2

TX3

TX4

TX5

TX6

TX7

TX8

TX9

TX10

TX11

TX12

TX13

TX14

TX15

TX16

TX17

TX18

U16

U18

U20

TEMP.

POWER

OUT

FROM CONTROL

CIRCUIT

TB1

L2/N

TO SMC Flex

(11, 12)

TB5

A-

A+

B-

B+

C-

C+

TB6

TB21

VSB

Vcom

GDPS FROM CLT

24C

L1T1L2T2L3

GND1 GND2

1B2B3B4B5B

A: 4800-7200V

B: 2500-4799V

C: 1450-2499V

D: 800-1449V

PHASE C

Figure 18 - Typical MV SMC Flex Power System • Bulletin 1562E (3300/4160V shown)

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Chapter 1 Product Overview

+- -+

A IN

RR1 RR2

OV1

OV2 OV3 OV4

S1 S2 S3 S4

RS1 RS2CS1 CS2

C2 C3 C4

OV S C

TEST

CLGD

RX1 TX1

G C T

CT2

CT1

CT3

MTR

A OUT

CAUTION MAXIMUM TWO STARTS PER HOUR WITH A MINIMUM OF

FIVE MINUTES BETWEEN STARTS.

WIRE CONNECTIONS FOR PHASE A

WIRE CONNECTIONS FOR PHASE B

CONNECTIONS SHOWN FOR PHASE C

CONNECT TO GROUND ONLY IF POWER SYSTEM IS GROUNDED

CURRENT LOOP CONDUCTORS PASS THROUGH THE C.T.'S ON

THE GATE DRIVER BOARDS (CLGD)

REMOTE EQUIPMENT

SMC Flex INTERFACE BOARD SMC

FlexIB

VOLTAGE SENSING BOARD

VSB

GATE TRANSMITTERS

PHASE A PHASE B

OUTPUTS

TX1

TX2

TX3

TX4

TX5

TX6

TX7

TX8

TX9

TX10

TX11

TX12

TX13

TX14

TX15

TX16

TX17

TX18

U16

U18

U20

TEMP.

POWER

OUT

FROM CONTROL

CIRCUIT

TB1

L2/N

TO SMC Flex

(11, 12)

TB5

A-

A+

B-

B+

C-

C+

TB6

TB21

VSB

Vcom

GDPS FROM CLT

24C

L1T1L2T2L3

GND1 GND2

1B2B3B4B5B

A: 4800-7200V

B: 2500-4799V

C: 1450-2499V

D: 800-1449V

PHASE C

OV S C

TEST

CLGD

RX1 TX1

G C T

OV S C

TEST

CLGD

RX1

TX1

G C T

OV S C

TEST

CLGD

RX1 TX1

G C T

B IN

C IN

B OUT

C OUT

Figure 19 - Typical MV SMC Flex Power System • Bulletin 1560E (3300/4160V shown)

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Product Overview Chapter 1

Functional Description

The following functional descriptions and associated control circuits are for units using IntelliVAC contactor control modules. For units with electromechanical (relay) control, refer to Appendix C

ATT EN TI ON : The control circuit schematics shown below assume that control power is fed from the same source as the primary circuit. If external control power is used, additional control interlocking may be required to avoid unexpected motor start-up. The control interlock should ensure that a motor start request is not inadvertently applied when the primary circuit is disconnected.

Bulletin 1562E • Basic Control – Controlled Start only

When wired as shown in Figure 20, the controller operates as follows:

Pressing the “Start” button initiates the start sequence. Relay “CR” closes and applies control power to terminal 17 of the SMC Flex module. The Aux #4 (“Normal”) closes, energizing “M-IV” and “MCX”, which completes the hold-in circuit on the start button, and closes the main contactor.

The SMC Flex module examines the line voltage, looks for fault conditions, checks phase rotation, calculates zero crossing information, and begins gating the SCRs to start the motor.

When the motor approaches rated speed, the SMC Flex module closes the “Aux #1” (Ext. Bypass) 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 “Aux #1” contact is held closed for a short time by the control module. This holds the bypass contactor closed for about 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits.

Bulletin 1562E • Basic Control – With Controlled Stop

When wired as shown in Figure 21, the controller operates in much the same manner as in Figure 20

Terminal 16 on the SMC Flex module now controls the start and stop maneuvers. Terminal 16 must remain energized for the module to run. When the “Stop” button is pressed, and “CR” opens, the SMC Flex module will initiate the option stop. An uncontrolled, or coast stop, is achieved by opening the connection to terminal 17. This contact should remain open to ensure all hold-in contacts clear, to prevent a re-start.

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Chapter 1 Product Overview

If the motor has started, the unit is in the bypass mode, and a trip occurs within the SMC Flex module or from an external protection relay; “Aux #4” will open the line contactor immediately, and “Aux #1” will remain closed for 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits. A trip due to an overload or fault condition will result in a “coast” stop.

Bulletin 1562E • DPI Control – Controlled Start only

The control scheme shown in Figure 22 allows the MV SMC Flex to be controlled using DPI (Drive Programming Interface). (Table 16 on page 109 Logic Command Word bits assignment for DPI control.) This special usage of DPI includes provisions for a “Local” mode of control as well.

With the Local-Off-Remote selector switch in the “Remote” position, terminal 18 of the SMC Flex module is energized, allowing a start command to be executed via DPI. When a “Start” is executed, the “Aux #4” contact closes, energizing both “M-IV” and “MCX”. The line contactor closes and the unit initiates a start sequence.

for

When the motor approaches rated speed, the SMC Flex module closes “Aux #1”, energizing “B-IV”, which closes the bypass contactor.

To run in “Local” mode, the “CR” contact is used to initiate a start sequence (similar to Figure 20

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

Bulletin 1562E • DPI Control – With Controlled Stop

The control scheme shown in Figure 23 allows the MV SMC Flex to be controlled using DPI (Drive Programming Interface). (Table 16 on page 109 Logic Command Word bits assignment for DPI control). This special usage of DPI includes provisions for a “Local” mode of control as well.

With the Local-Off-Remote selector switch in the “Remote” position, terminal 18 of the SMC Flex module is energized, allowing start and stop maneuvers to be executed via DPI. When a “Start” is executed, the “Aux #4” contact closes, energizing both “M-IV” and “MCX”. The line contactor closes and the unit initiates a start sequence.

for

When the motor approaches rated speed, the SMC Flex module closes “Aux #1”, energizing “B-IV”, which closes the bypass contactor. When a “Stop” is executed, the unit opens “Aux #1”. The bypass contactor opens and the unit initiates a controlled stop sequence, followed by opening of “Aux #4”, which opens the line contactor.

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Product Overview Chapter 1

An uncontrolled, or coast stop, can be achieved via DPI or by opening the connection on terminal 18 (i.e. by pressing “Coast Stop” button).

When using the optional HIM, pressing the “Jog” button will initiate the optional stop maneuver, and pressing the “O” button will initiate a coast stop.

To run in “Local” mode, the “CR” contact is used to initiate a start and stop sequence (similar to Figure 21

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

If the motor has started, the unit is in bypass mode, and a trip occurs within the SMC Flex module or from an external protection relay, “Aux #4” will open the line contactor immediately, and “Aux #1” will remain closed for 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits. A trip due to an overload or fault condition will result in a “Coast” stop.

Bulletin 1560E • Basic Control – Controlled Start only

The Bulletin 1560E is intended for addition to an existing motor controller, which provides circuit isolation, motor switching, and overload and overcurrent protection. When wired as shown in Figure 24

, the controller operates as follows:

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

When stopping the motor, the contactor in the existing controller will open, removing power from the motor, and then the “CR” relay. The bypass hold-in rung will keep the bypass contactor closed for 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits.

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

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Chapter 1 Product Overview

Bulletin 1560E • Basic Control – With Controlled Stop

When wired as shown in Figure 25, the controller operates much the same as described above for the Standard module. The control signal uses terminal 16 instead of 17, and a “coast” stop can be achieved by opening the connection to terminal 17.

It is more important in this configuration to integrate the control circuit of the 1560E with the existing controller, for better control of the Stop option. The “start signal” for this scheme cannot be a slave of the main contactor, since it must remain closed to accomplish the option stop maneuver. The SMC Flex module can be used to control the main contactor such that it will close when a start is initiated, and remain closed until it has sensed the motor has stopped following an option stop maneuver.

Bulletin 1560E • DPI Control – Controlled Start only

The control scheme shown in Figure 26 allows the MV SMC Flex to be controlled using DPI. (Refer to Table 16 on page 109 bits assignment for DPI control.) This special usage of DPI includes provisions for a “Local” mode of control as well.

for Logic Command Word

With the Local-Off-Remote selector switch in the “Remote” position, and closure of the existing starter main contactor, terminal 18 is energized, allowing a start command to be executed via DPI. When a “Start” is executed, the “Aux #4” contact closes, which serves as an interlock with the main contactor (or breaker) in the existing starter.

As with the other control schemes, the SMC Flex module closes “Aux #1”, energizing “B-IV”, as the motor approaches rated speed.

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

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

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Bulletin 1560E • DPI Control – With Controlled Stop

The control scheme shown in Figure 27 allows the MV SMC Flex to be controlled using DPI (Drive Programming Interface). (Refer to Table 16 on

page 109 for Logic Command Word bits assignment for DPI control). This

special usage of DPI includes provisions for a “Local” mode of control as well.

With the Local-Off-Remote selector switch in the “Remote” position, terminal 18 of the SMC Flex module is energized, allowing start and stop maneuvers to be executed via DPI. When a “Start” is executed, the “Aux #4” contact closes, which serves as an interlock with the main contactor (or breaker) in the existing starter.

As with the other control schemes, the SMC Flex module closes “Aux #1”, energizing “B-IV”, as the motor approaches rated speed. When a “Stop” is executed, the unit opens “Aux #1”. The bypass contactor opens and the unit initiates a controlled stop sequence, followed by opening of “Aux #4”, which opens the main contactor (or breaker) in the existing starter.

When using the optional HIM, pressing the “Jog” button will initiate the optional stop maneuver, and pressing the “O” button will initiate a coast stop.

An uncontrolled, or coast stop, can be achieved via DPI or by opening the connection on terminal 18 (i.e. by energizing “Coast Stop” relay in the existing starter).

To run in “Local” mode, the “CR” contact is used to initiate a start and stop sequence (similar to Figure 25

). Closure of the “Start” relay from the existing starter, allows the unit to initiate motor soft starting. Likewise, opening of “Start” relay from the existing starter will initiate a controlled stop. An uncontrolled, or coast stop, is achieved by opening the connection on terminal 17 (i.e. by energizing “Coast Stop” relay in the existing starter). This contact should remain open to ensure all hold-in contacts clear, to prevent a re-start.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 29

Chapter 1 Product Overview

BYPASS CONTACTOR (B)

CONTROL RELAY (CR)

BYPASS CONTACTOR AUXILI ARY RELAY ( BCX)

MAIN CONTACTOR AUXILIARY RELAY (MCX)

MAIN CONTACTOR (M)

MCX

M-IV

AUX.1

EXTERNAL BYPASS

AUX.4

NORMAL

AUX.3

ALARM

AUX.2 FAULT

GROUND

FAULT

TACH

INPUT

PTC

INPUT

SMC Flex

CONTRO L TERMINA LS

DPI

FROM GFCT

(OPTIO NAL)

SMC FlexIB

INPUT POWER

L1 L2/N

FROM SMC

FlexIB-J3

B-IV

BCX

STOP

MCX

BCX

START

M-IV

CONTACTOR

STATUS

M-IV

B-IV

M-IV

AUX.

CCO

TCO

L1 G L2/N

MOV

ØA

115V

CLT

TO SMC LEXIB -TB6

B-IV

0.6V

ØB ØC

A M B

H3 H2 H4

AUX.

CCO

TCO

CONTACTOR

STATUS

MODULE

STATUS

MODULE

STATUS

Figure 20 - Typical Bulletin 1562E IntelliVAC Control Circuit • Without Stop Control

13 1413 14

15 16

11 12

4 32

6 5

4 32

6 5

15 16

910

11 12

15141613

25242623 33 34

29 3028

31 32

201918

21 22

910

30 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Figure 21 - Typical Bulletin 1562E IntelliVAC Control Circuit • With Stop Control

BYPASS CONTACTOR (B)

CONTROL RELAY (CR)

BYPASS CONTACTOR AUXIL IARY RELAY (B CX)

MAIN CONTACTOR AUXIL IARY RELAY (M CX)

MAIN CONTACTOR (M)

MCX

M-IV

AUX.1

EXTERNAL BYPASS

AUX.4

NORMAL

AUX.3

ALARM

AUX.2 FAULT

GROUND

FAULT

TACH

INPUT

PTC

INPUT

SMC Flex

CONTRO L TERMINA LS

DPI

FROM GFCT

(OPTIO NAL)

SMC FlexIB

INPUT POWER

L1 L2/N

FROM SMC

FlexIB-J3

B-IV

BCX

OPTION STOP

MCX

BCX

START

M-IV

CONTACTOR

STATUS

M-IV

B-IV

M-IV

AUX.

CCO

TCO

L1 G L2/N

MOV

ØA

115V

CLT

TO SMC LEXIB -TB6

B-IV

0.6V

ØB ØC

A M B

H3 H2 H4

AUX.

CCO

TCO

CONTACTOR

STATUS

MODULE

STATUS

MODULE

STATUS

COAST STOP

Product Overview Chapter 1

4 32

11 12

6 5

4 32

13 1413 14

15 16

11 12

6 5

15 16

910

15141613

201918

25242623 33 34

29 3028

31 32

21 22

11 12

910

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 31

Chapter 1 Product Overview

29 3028

25242623 33 34

201918

151416

11 12

21 22

31 32

15 16

13 1413 14

910

BYPASS CONTACTOR (B)

CONTROL RELAY (CR)

BYPASS CONTACTOR AUXILI ARY RELAY ( BCX)

MAIN CONTACTOR PILOT RELAY (MCX)

MAIN CONTACTOR (M)

MCX

M-IV

AUX.1

EXTERNAL BYPASS

AUX.4

NORMAL

AUX.3

ALARM

AUX.2

FAULT

GROUND

FAULT

TACH

INPUT

PTC

INPUT

SMC Flex

CONTROL TERMINALS

DPI

FROM GFCT (OPTIONAL )

SMC FlexIB

INPUT POWER

L1 L2/N

FROM SMC

FlexIB-J3

B-IV

BCX

STOP

MCX

BCX

START

M-IV

CONTACTOR

STATUS

M-IV

B-IV

M-IV

AUX.

CCO

TCO

L1 G L2/N

MOV

ØA

115V

CLT

TO SMC LEXIB -TB6

B-IV

0.6V

ØB ØC

A M B

H3 H2 H4

AUX.

CCO

TCO

CONTACTOR

STATUS

MODULE

STATUS

MODULE

STATUS

OFF

REMOTELOCA L

DEVICENET

ADAPTER

DEVICENET

CONNEC TOR

PORT MOD Net A

24V+

CAN H

CAN L

24V-

BLK

TO DEVICENET NETWORK

Figure 22 - Typical Bulletin 1562E IntelliVAC Control Circuit without Stop control • With DeviceNet (or DPI) Communication and Optional Local/Off/Remote

32 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Figure 23 - Typical Bulletin 1562E IntelliVAC Control Circuit with Stop control • With DeviceNet (or DPI) Communication and Optional

29 3028

25242623 33 34

201918

151416

11 12

21 22

31 32

15 16

13 1413 14

910

BYPASS CONTACTOR (B)

CONTROL RELAY (CR)

BYPASS CONTACTOR AUXILIARY RELAY (BCX)

MAIN CONTACTOR PILOT RELAY (MCX)

MAIN CONTACTOR (M)

MCX

M-IV

AUX.1 EX TERNAL BYPASS

AUX.4

NORMAL

AUX.3

ALARM

AUX.2 FAULT

GROUND

FAULT

TACH

INPUT

PTC INPUT

SMC Flex

CONTROL TERMINALS

DPI

FROM GFCT

(OPTIO NAL)

SMC FlexIB

INPUT POWER

L1 L2/N

FROM SMC

FlexIB-J3

B-IV

BCX

OPTION STOP

MCX

BCX

START

M-IV

CONTACTOR

STATUS

M-IV

B-IV

M-IV

AUX.

CCO

TCO

L1 G L2/N

MOV

ØA

115V

CLT

TO SMC LEXIB -TB6

B-IV

0.6V

ØB ØC

A M B

H3 H2 H4

AUX.

CCO

TCO

CONTACTOR

STATUS

MODULE

STATUS

MODULE

STATUS

OFF

REMOTELOCA L

DEVICENET

ADAPTER

DEVICENET

CONNECTOR

PORT MOD Net A

24V+

CAN H

CAN L

24V-

BLK

COAST STOP

*NOTE: EXTRA CONTACTS FROM "STOP" BUTTONS SHOULD BE

MONITORED BY THE CONTROLLING PLC FOR REMOTE OPERATION TO ENSURE UNIT WILL STOP WHEN COMMANDED.

Local/Off/Remote

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 33

Product Overview Chapter 1

Chapter 1 Product Overview

BYPASS CONTACTOR (B)

CONTROL RELAY (CR)

BYPASS CONTACTOR AUXILIARY RELAY (BCX)

AUX.1 EXTERNAL BYPASS

AUX.4

NORMAL

AUX.3

ALARM

AUX.2

FAULT

GROUND

FAULT

TACH

INPUT

PTC INPUT

SMC Flex

CONTROL TERMINALS

DPI

SMC FlexIB

INPUT POWER

L1 L2/N

FROM SMC

FlexIB-J3

B-IV

BCX

START/STOP

SIGNAL FROM

EXISTING STARTER

B-IV

L1 G L2/N

B-IV

MOV

ØA

115V

CLT

TO SMC LEXIB -TB6

0.6V

ØB ØC

H3 H2 H4

AUX.

CCO

TCO

CONTACTOR

STATUS

MODULE STATUS

BCX

Figure 24 - Typical Bulletin 1560E IntelliVAC Control Circuit • Without Stop Control

4 32

13 14

11 12

15141613

201918

25242623 33 34

29 3028

31 32

6 5

15 16

21 22

910

34 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Figure 25 - Typical Bulletin 1560E IntelliVAC Control Circuit • With Stop Control

29 3028

25242623 33 34

201918

15141613

11 12

21 22

31 32

15 16

13 14

910

BYPASS CONTACTOR (B)

CONTROL RELAY (CR)

BYPASS CONTACTOR AUXILIARY RELAY (BCX)

AUX.1 EXT ERNAL BYPASS

AUX.4

NORMAL

AUX.3

ALARM

AUX.2 FAULT

GROUND

FAULT

TACH

INPUT

PTC INPUT

SMC Flex

CONTRO L TERMIN ALS

DPI

SMC FlexIB

INPUT POWER

L1 L2/N

FROM SMC

FlexIB-J3

B-IV

BCX

START/STOP

SIGNAL FROM

EXISTING STARTER

B-IV

L1 G L2/N

B-IV

MOV

ØA

115V

CLT

TO SM CLEX IB-TB6

0.6V

ØB ØC

H3 H2 H4

AUX.

CCO

TCO

CONTACTOR

STATUS

MODULE

STATUS

BCX

NOTE: LINE CONTACTOR (OR BREAKER) MUST REMAIN

CLOSED DURING THE OPTION STOP PERIOD. IT IS RECOMMENDED THAT THE LINE CONTACTOR BE CONTROLLED BY THE "AUX.4 NORMAL" CONTACT. (SEE 1562E CONTROL SCHEME)

COAST STOP

Product Overview Chapter 1

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 35

Chapter 1 Product Overview

29 3028

25242623 33 34

201918

151416

11 12

21 22

31 32

15 16

13 14

910

BYPASS CONTACTOR (B)

CONTROL RELAY (CR)

BYPASS CONTACTOR AUXILI ARY RELAY ( BCX)

AUX.1

EXTERNAL BYPASS

AUX.4

NORMAL

AUX.3

ALARM

AUX.2 FAULT

GROUND

FAULT

TACH

INPUT

PTC

INPUT

SMC Flex

CONTRO L TERMIN ALS

DPI

SMC FlexIB

INPUT POWER

L1 L2/N

FROM SMC

FlexIB-J3

B-IV

CONTACTOR

STATUS

BCX

START/STOP

SIGNAL FROM

EXISTING STARTER

MODULE

STATUS

B-IV

AUX.

CCO

TCO

L1 G L2/N

MOV

ØA

115V

CLT

TO SM CLEX IB-TB6

B-IV

0.6V

ØB ØC

H3 H2 H4

OFF

REMOTELOCA L

DEVICENET

ADAPTER

TO DE VICE NET

NETWORK

BLK

24V+

24V-

CAN H

CAN L

PORT

MOD NetA

DEVICENET

CONNEC TOR

BCX

Figure 26 - Typical Bulletin 1560E IntelliVAC Control Circuit without Stop Control • With DeviceNet (or DPI) Communication and optional Local/Off/Remote

36 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Product Overview Chapter 1

29 3028

25242623 33 34

201918

151416

11 12

21 22

31 32

15 16

13 14

910

BYPASS CONTACTOR (B)

CONTROL RELAY (CR)

BYPASS CONTACTOR AUXILIARY RELAY (BCX)

AUX.1

EXTERNAL BYPASS

AUX.4

NORMAL

AUX.3

ALARM

AUX.2 FAULT

GROUND

FAULT

TACH

INPUT

PTC

INPUT

SMC Flex

CONTROL TERMINALS

DPI

SMC FlexIB

INPUT POWER

L1 L2/N

FROM SMC

FlexIB-J3

B-IV

CONTACTOR

STATUS

BCX

START/STOP

SIGNAL FROM

EXISTING STARTER

MODULE STATUS

B-IV

AUX.

CCO

TCO

L1 G L2/N

MOV

ØA

115V

CLT

TO SMC LEXIB -TB6

B-IV

0.6V

ØB ØC

H3 H2 H4

OFF

REMOTELOCA L

DEVICENET

ADAPTER

TO DEV ICENE T

NETWORK

BLK

24V+

24V-

CAN H

CAN L

PORT MOD NetA

DEVICENET

CONNECTOR

BCX

COAST

STOP

NOTE: LINE CONTACTOR (OR BREAKER) MUST REMAIN CLOSED

DURING THE OPTION STOP PERIOD. IT IS RECOMMENDED THAT THE LINE CONTACTOR BE CONTROLLED BY THE "AUX.4 NORMAL" CONTACT. (SEE 1562E CONTROL SCHEME)

Figure 27 - Typical Bulletin 1560E IntelliVAC Control Circuit with Stop Control • With DeviceNet (or DPI) Communication and optional Local/Off/Remote

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 37

Chapter 1 Product Overview

Notes:

38 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Installation

IMPORTANT

ATT EN TI ON : Perform the installation duties correctly. Errors may cause

commissioning delays, equipment damage or personal injury.

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.

Chapter 2

Receiving

Safety and Codes

Unpacking and Inspection

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.

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

After unpacking the material, check the item(s) received against the bill of lading to ensure that the nameplate description of each item agrees with the material ordered. Inspect the equipment for physical damage, as stated in the Rockwell Automation Conditions of Sale.

Remove all packing material, wedges, or braces 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.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 39

Chapter 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.

ATT EN TI ON : 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.

ATT EN TI ON : 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.

ATT EN TI ON : 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

Installation Site

The controller must be transported on a pallet or via use of the lifting angles supplied as part of all 2.3 m (90 inch) high cabinets or frame units.

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

Round rollers can be used to assist in moving the controller to the installation site. Once at the final site, the pipe rolling technique can be used to place the cabinet in the desired position.

ATT EN TI ON : Care must be exercised when using either a forklift, or the pipe rolling technique, for positioning purposes to ensure that the equipment is not scratched, dented or damaged in any manner. Always exercise care to stabilize the controller during handling to guard against tipping and injury to personnel.

Consider the following when selecting the installation site:

A. The operating ambient temperature should be between 0°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 buildup.

40 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Installation Chapter 2

IMPORTANT

C. The equipment must be kept clean. Dust buildup inside the enclosure

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

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

access to it.

E. 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 1 km (3,300 feet) 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.

ATT EN TI ON : 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 the drawings supplied with your order for mounting requirements.

Grounding Practices

The purpose of grounding is to:

A. Provide safety for Personnel.

B. Limit dangerous voltages to ground on exposed parts.

C. Facilitate proper overcurrent device operation under ground fault

conditions.

D. Provide for electrical interference suppression.

Generally, grounding should be in accordance with the Canadian Electrical Code (CEC) or National Electrical Code (NEC) and other local codes.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 41

Chapter 2 Installation

TIP

Each power feeder from the substation transformer to the controller must be equipped with properly sized ground cables. Simply utilizing the conduit or cable armor as a ground is not adequate. The conduit or cable armor and ground wires 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 6.1 m (20 feet) of its location and tied to the controller’s ground bus by ground wires within the power cables and/or conduit. The conduit or cable armor should be bonded to ground at both ends.

ATT EN TI ON : 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

Power Connections

When reinstalling components or when reassembling the cabinet, tighten the following bolt sizes to the specified torque values:

Hardware Recommended Torque

1/4 in. (M6) 8 N-m (6 lb-ft)

5/16 in. (M8) 15 N-m (11 lb-ft)

3/8 in. (M10) 27 N-m (20 lb-ft)

1/2 in. (M12) 65 N-m (48 lb-ft)

Control Wire Terminals 2.5 - 4.0 N-m (2.0 - 3.3 lb-in)

CLGD Power Assembly Terminals 5.6 N-m (50 lb-in)

SMC Flex Control Module Terminals 0.6 N-m (5 lb-in)

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

The controller requires a three-phase supply and an equipment grounding conductor to earth ground. A neutral conductor of the three-phase supply is not necessary and is usually not routed to the 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 4160V)

2. A combination of a one-high full voltage non-reversing (FVNR) cabinet

and a 1560E unit (600A, 2400 to 4160V, and 180/360/600A, 5500 to 6900V)

42 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Installation Chapter 2

TIP

To make power connections for a two-high cabinet, refer to Figure 28 to

Figure 30

, and Publication 1500-UM055_-EN-P (Chapter 2).

ATT EN TI ON : Bulletin 1562E units provided with an arc resistant enclosure must be installed in accordance with instructions in Publication 1500-UM055_-EN-P. Failure to do so may result in damage to equipment or personal injury.

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

• Make line connections within the one-high cabinet

• Make load connections at the 1512 CT terminals

Bulletin 1560E

Refer to Figure 31 to Figure 33 to make power connection for a 1560E unit (depending on the rating of the unit).

• Make line connections to the line connection terminals

• Make load connections to the current transformer terminals

The CT assembly can be oriented to allow either top or bottom load cable exit.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 43

Chapter 2 Installation

Terminal Block

Assembly

Load Cable

Connection Point

(top exit)

Power Stack A ssembl y

Bypass Vacuum Contactor

Voltage Sensing Module

Non Load Break Isolation Switch

Line Vacuum Contactor

Current Transformers

Bulletin 1562E

Figure 28 - Cabinet Layout • 1562E – 180/360A, 2400V to 4160V (with LV panels not shown) (Non arc-resistant cabinet shown)

44 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Installation Chapter 2

Power Cable Lugs

Ground Bus Lug

Cable Duct Boot

Cable Duct Barrier

Motor Cable Terminals

Figure 29 - Incoming Line Cable Connections (viewed from the rear with power bus access cover removed) (Non Arc-resistant cabinet shown)

Figure 30 - Bottom Cable Exit Configuration (with LV panel swung open) (Non Arc-resistant cabinet shown)

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 45

Chapter 2 Installation

Phase 3 Power Stac k Assem bly

Voltage Sensing Module

Load Connections

(top exit shown)

Phase 1 (front)

through 3 (back)

Current Transfo rmers

Bypass Vacuum Contactor

Line Connections Phase 1 (top) through 3 (bottom)

Phase 2 Power Stack Assembly

Phase 1

Power Stac k Assembly

Bulletin 1560E

Figure 31 - Power Connections • 1560E – 180/360A, 2400 to 4160V (Not available in an Arc-resistant design)

46 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Figure 32 - Power Connections • 1560E – 180/360A, 5500 to 6900V (Not available in an Arc-resistant design)

Voltage Sensing Module

Bypass Vacuum Contactor

Phase 1 Line Connections

Phase 1

Power Stac k Assembly

Phase 2

Power Stack Assembly

Phase 3

Power Stac k Assembly

Phase 2 Line Connections

Phase 3 Line Connections

Load Connect ions (top exit shown) Phase 1 (front) through 3 (back)

Current Transformers

Installation Chapter 2

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 47

Chapter 2 Installation

Voltage Sensing Module

Bypass Vacuum Contactor

Phase 1 Line Connections

Phase 1

Power Stac k Assembly

Phase 2

Power Stack Assembly

Phase 3

Power Stac k Assem bly

Phase 2 Line Connections

Phase 3 Line Connections

Load Connections (top exit shown) Phase 1 (front) through 3 (back)

Current Transformers

Figure 33 - Power Connections • 1560E – 600A, 2400 to 6900V (Not available in an Arc-resistant design)

48 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Installation Chapter 2

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.

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

Bulletin 1503E

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

Power Wiring

Interlocking

The wire sizes must be selected individually, observing all applicable safety and CEC or NEC regulations. The minimum permissible wire size does not necessarily result in the best operating economy. The minimum recommended size for the wires between the controller and the motor is the same as that used if a main voltage source connection to the motor was used. The distance between the controller and motor may affect the size of the conductors used.

Consult the wiring diagrams and appropriate CEC or NEC regulations to determine correct power wiring. If assistance is needed, contact your area Rockwell Automation Sales Office.

Hinged doors and panels, which provide access to medium voltage components, must be 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.

ATT EN TI ON : 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.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 49

Chapter 2 Installation

TIP

IMPORTANT

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.

An auxiliary cabinet may be attached to the main structure. It will be raminterlocked with the main power cell door, which will not allow it to be opened until the main power cell door is opened.

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) [1/4 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.

Refer to 2-high, Series B drawings in Publication 1500-UM055_-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.

50 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Installation Chapter 2

TIP

Control Cables

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

Fiber-Optic Cables

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

Power Factor Correction Capacitors

The controller can be installed on a system with power factor correction capacitors. The capacitors must be located on the line side of the controller. This is required to prevent damage to the SCRs in the MV SMC Flex controller. A separate switching contactor is recommended to apply the capacitors only after the bypass contactor has closed, and to remove them when the bypass contactor opens. See Figure 34

for two different acceptable connection methods.

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.

ATT EN TI ON : 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.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 51

Chapter 2 Installation

Bypass

Contac tor

di/dt Inductor

PFCC

Contac tor

Fuse

Isolation Switch

Power Bus

Isolation Switch

Fuse

Isolation Contactor

di/dt Inductor

PFCC (Power Factor Correction Capacitor)

Contactor

Capacitor

Motor

Figure 34 - Typical One-Line Diagram (Showing 2 Different Styles of Power Factor Capacitor Connections)

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.

52 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Installation Chapter 2

• 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.

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.

ATT EN TI ON : Overload protection should be properly coordinated with the motor to avoid damage to equipment.

Two special applications require consideration: Two-speed Motors, and Multimotor 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.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 53

Chapter 2 Installation

EMC Compliance

ATT EN TI ON : 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

Tac h In pu t Ground Fault Input

• Terminate shielded wires to terminal 14.

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

54 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Installation Chapter 2

• 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.

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

Ta b l e 2 provides the control terminal wire capacity and the tightening torque

requirements. Each control terminal will accept a maximum of two wires.

Table 2 - Control Wiring and Tightening Torque

Wire Size Torque

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

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 55

Chapter 2 Installation

Control Terminal Designations

As shown in Figure 35, the SMC Flex controller contains 24 control terminals on the front of the controller.

Figure 35 - SMC Flex Controller Control Terminals

Ter min al Number

11 Control Power Input

12 Control Power Common

13 Control Enable Input

14 Control Module Ground 26 Tach Input (+)

15 Option Input #2

16 Option Input #1

17 Start Input

18 Stop Input

19 Aux. Contact #1 (Ext. Bypass)

20 Aux. Contact #1 (Ext. Bypass)

21 Not Used 33 Aux. Contact #4 (Normal)

22 Not Used 34 Aux. Contact #4 (Normal)

Description Terminal

Number

(1)

(2)

(1)(2)

(1)(3)

23 PTC Input

24 PTC Input

25 Tach Input (-)

27 Ground Fault Transformer Input

28 Ground Fault Transformer Input

29 Aux. Contact #2

30 Aux. Contact #2

31 Aux. Contact #3

32 Aux. Contact #3

Description

(2)

(1)

(1)(4)

(1) RC snubbers are required on inductive loads connected to auxiliary. (2) Do not connect any additional loads to these terminals. These “parasitic” loads may cause problems with operation, which may

result in false starting and stopping. (3) Aux. Contact #1 is always programmed for Ext. Bypass (NO) to control the bypass contactor in MV applications. (4) Aux Contact #4 is always programmed for “Normal” (NO) to control the isolation contactor in MV applications.

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

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Commissioning Procedure

Chapter 3

Preliminary Setup

A. Ensure the work area is clean and tidy. Pathways to main disconnect and

emergency stop push button must be clear and unobstructed.

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

• Test power supply, supplied with each controller

• Multimeters

• Hi-Pot Tester (recommended) or Megger

• Oscilloscope with memory (optional)

C. Complete drawing package and parts list.

D. Specification of project.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 57

Chapter 3 Commissioning Procedure

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 Procedure Chapter 3

IMPORTANT COMMISSIONING CHECKS

ATT EN TI ON : When commissioning a MV SMC Flex, it is critical that following

important checks are completed. For more details, follow the commissioning guidelines that follow this page.

• Inspect the equipment for any signs of physical damage.

• Verify SMC Flex physical installation is complete.

• Verify the integrity and operation of all safety interlocks.

• Verify that motor mechanical installation is complete.

• Verify that Incoming Power wiring to SMC Flex is complete and all

connections are tight.

• Verify that Motor cabling to SMC Flex is complete and that all connections are tight.

• Verify that Control wiring to SMC Flex is complete.

• Check for any damaged components and verify that electrical clearances

have not been reduced while installing power cables.

• Verify Incoming Power System Grounding (Floating/Solid-Ground/Resistive Ground) and determine if Vcom on the interface board should be connected to a ground reference or not (refer to Resistance Checks

• Check if there are any Power Factor Correction Capacitors (refer to Power

Factor Correction Capacitors on page 51 of Chapter 2 for correct

installation requirements of these capacitors).

• Check if Surge Capacitors and/or Surge Arrestors are installed at the motor. Open motor junction box and verify it by yourself. These must be disconnected from the circuit. (refer to Surge Arrestor Protection Devices

on page 52 of Chapter 2).

• Verify fiber-optic cables are connected at the right location (FO cables on Phase-A power pole go to Phase-A on the Interface board, Phase-B of power pole to Phase-B on the Interface board and Phase-C of power pole to Phase-C on the interface board) and the connectors are fully seated in their sockets.

on page 68).

• Verify that circuit board plug connectors are installed and fully inserted in their sockets.

• Verify that the cooling fan (if supplied) is secured and the rotor is not obstructed.

• Complete device resistance checks per user manual (refer to Resistance

Checks on page 68 of Chapter 3).

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 59

Chapter 3 Commissioning Procedure

IMPORTANT

• Complete Power Supply Tests (refer to Power Supply Tests on page 64 of

Chapter 3).

• Program the module with correct parameter settings.

• Start the unit and record scope waveforms (line voltage, motor voltage and

motor current).

Preliminary Check

ATT EN TI ON : Ensure that all sources of power are isolated and locked out before

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

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

tight.

B. Verify power fuse ratings and condition.

C. Verify control fuse ratings and condition.

D. Check that power cable installation has not damaged components, and

that electrical spacings have not been reduced.

E. Check that fiber-optic cables are fully seated in their connectors.

F. Check that circuit board plug connectors are installed and fully inserted in

their sockets.

G. Check that the cooling fan (if supplied) is secured and the rotor is not

obstructed.

H. Verify integrity and operation of all interlocks.

I. In the case of the 1503E, verify wiring and perform all tests in conjunction

with OEM documentation.

Programming

60 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

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.

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 Pump Application

Considerations on page 20 of Chapter 1.

Commissioning Procedure Chapter 3

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

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.

ATT EN TI ON : Solid-state devices can be destroyed by high voltage. Use jumper wires between heatsinks to short out the SCRs before applying high test voltages to the power circuit. Disconnect the white wires (L1, T1, L2, T2, L3, T3) from the voltage sensing board and remove the plug connector. If voltage transformers are present, remove one primary fuse from each device. On the 1503E, consult OEM documentation for location of voltage sensing board.

ATT EN TI ON : 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 VLL is the rated line-to-line voltage of the power system. The leakage current may be recorded for future comparison testing, and must be less than 20 mA.

If a Megger is used, it should indicate 50 k megohms or greater if it is isolated as explained in the next paragraph. If the motor is connected, the Megger should indicate 5 k megohms or greater.

If a 1560E is being tested, it is recommended that the input and output cables be disconnected for each phase. If a 1562E is being tested, it is recommended that the main contactor be in the open position, and that the output cables be disconnected for each phase. (See points marked with an asterisk * in Figure 36 This will ensure the unit is isolated from the line and the motor. The line and the motor may be tested separately to locate problem areas. If a 1503E is being tested, consult OEM documentation.

After completing the test, remove all semiconductor jumpers and test the devices with a multimeter to ensure 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.

ATT EN TI ON : Failure to reconnect all wires and cables correctly may result in equipment damage, personal injury or death.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 61

)

Chapter 3 Commissioning Procedure

654321

TO C.T.'S

TO SMC F lex

MODULE

POWER

OUT

CT INPUTS

A-

A+

B-

B+

C-

C+

TB5

TB6

GDPS

SMC Flex INTERFACE BOARD

VBS

TB21

GATE TRANSMITTERS

PHASE A

Vcom

PHASE B PHASE C

TX1

TX2

TX3

TX4

TX5

TX6

TX7

TX8

TX9

TX10

TX11

TX12

TX13

TX14

TX15

TX16

TX17

TX18

POWER

TB1

U16

U18

U20

L2/N

115/230V AC

FIBRE OPTIC CABLES

HS1

G1C1G1

HS2

HS3

G1C1G3

HS4

HS5

HS6

HS7

LINE

LOAD

THERMISTOR

RR1

RR2

RR3

OV2

OV3

OV1

OV4

OV5

OV6

GATE DRIVER BOARDS

RX1 TX1 GD1

OV1

RX1 TX1

GD3

OV3

RX1 TX1

GD4

OV4

RX1 TX1 GD5

OV5

RX1 TX1

GD6

OV6

THERMISTOR

RX1 TX1

GD2

OV2

S2L1C2

RS1 RS2

CS1 CS2

RS3

CS3

SE B PHASE C

CURRENT LOOP CT

CURRENT LOOP

TRANSFORMER

115/230V AC

50/60Hz

VOLTAGE SENSING BOARD

GND2 GND1 J1

T3 L3

T2 L2

T1 L1

TEMP.

Figure 36 - Typical MV SMC Flex Power System Wiring Diagram (5500/6900V shown)

62 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Figure 37 - Connection and Test Information for Interface Board

+5 +15

ROCKWELL

AUTOMATION

SW2: When ON (up) provides test pulses to gate driver circuits. NOTE: Must be OFF (down) for normal operation.

LED (Red): ON when test pulses on

SMC Flex control module

Ribbon connec tors to connect to SMC Flex control module (underneath control module)

Current feedback test points

Ribbon connector to Voltage Sensing Board

TB5: Curren t transformer connections

LED (Green):

ON when

power is

present

LED (Green):

ON when current

loop power

supply is present

Module common: Do not connect to

this terminal.

Volt age

feedback

test points

Current loop power supply sensor input

LED (Yellow): ON when Phase C gate signal active

TP18, 19, 20: Power supply test points.

LED (Green): ON when signal present at temperature feedback fibre optic receiver s

TP15: Common for Gate/Pulse TPs

TP13: Phase C gate signal

TP11: Phase B gate signal

LED (Yellow): ON when Phase B gate signal active

TP11: Phase B gate signal

TP8: Common for Gate/Pulse TPs

TP4: Phase A gate signal

LED (Yellow): ON when Phase A gate signal active

Phase A

Fibre Optic

Transmitters send

gate signals to

driver boards

Phase B

Fibre Optic

Transmitters

Phase C

Fibre Optic

Transmitters

Temperature

Feedba ck

Fibre Optic

Receivers

Temp A

Temp B

Temp C

L N G

Control Power

110-240 VAC

L N

Power out to

SMC Flex

Serial Number

Replacement Part Number

SW3: Used to detect temp erature feedback channels

TEMP DEFEAT

Notes: 1. ICOM is the common connection for Gate and Pulse test points.

2. VCOM is the common connection for Current and Voltage feedback test points. Do not connect J2 (VCOM) to earth ground; do not connect ICOM and VCOM together, either directly or through test probes, meter or scope common.

ICOM

GATE

PULSE

GATE

PULSE

GATE

PULSE

ICOM

VCOM

TB21

I-A I-B I-C

LINE A

LOAD A

LINE B

LOAD B

LINE C

LOAD C

VCOM

TB6

TB5

A-

A+

B-

C-

C+

B+

VCOM

Commissioning Procedure Chapter 3

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 63

Chapter 3 Commissioning Procedure

SW2 – Close (slide up) to initiate test pulses Red LED – ON when test pulses ac tive

SW2

Power Supply Tests

ATT EN TI ON : Servicing energized industrial control equipment can be

hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment. Before proceeding, ensure that all sources of power are isolated and locked out. Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device. Any covers or barriers removed during this procedure must be replaced and securely fastened before energizing equipment. Where appropriate, the case of test equipment should be connected to ground.

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. Check voltage on each gate driver board by connecting a DC voltmeter at TP4(+) and TP3(-). (See Figure 39

.) The voltage should be 18 - 22V DC.

5. Locate the SMC Flex Interface board in the control section (See Figure 37 and Figure 38

). This circuit board has the control module mounted on it. Locate the switch labeled 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 fiber optic cables to the gate driver boards. A red LED beside the switch, and the three yellow LEDs on the left side of the Interface board should be lit. (Note: They may appear dim, depending on ambient light conditions).

Figure 38 - Interface PCB

64 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Commissioning Procedure Chapter 3

Tem pera tur e si gn al fiber-optic transmitter

Gate signal

fiber-optic receiver

Plug-in test

power supply

Current loop CT

Snubber

terminal

Cathode

terminal

Common

test point

+20V test point

+5V test point

Yellow LED

Thermistor connector

Gate signal test point

Overvoltage sense terminal

TP3 TP4

TP2

TP1

RX2RX1

6. With the gate pulses on, check the voltage again on each gate driver board as described in Step 4 above. The voltage should be 4 - 5V DC.

7. Locate the Portable Test Power Supply that was included with the equipment, and verify that the rating corresponds to the available power system (i.e. 110/120 VAC or 220/240 VAC). Plug the unit into the power source, and plug the green connector into J1 on each of the gate driver boards (see Figure 39

Figure 39 - Test Power Application on Gate Driver Board

8. 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). While the gate pulses are still on, check the voltage on each gate driver board as described in step 4 above. The voltage should be 10-12V DC. If the voltage is less than 5V, then you have a bad gate drive board. Do not leave the Portable Test Power Supply connected to a bad gate driver board. The power supply adapter will burn up if the gate driver board is shorted.

9. A more detailed check is performed by verifying the actual gate pulses by connecting an oscilloscope between TP1 and TP3 (-) (see Figure 39 check gate pulses, the pulse generator must be enabled (i.e. SW2 toggled up) and the Portable Test Power Supply should be connected to J1. The pulse should appear as shown in Figure 40

). To

and Figure 41.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 65

Chapter 3 Commissioning Procedure

Microseconds

Volt s

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

Milliseconds

Figure 40 - Gate Pulse Detail – Typical SCR (ABB)

Figure 41 - Gate Pulse Test Waveform

10. If no pulse is observed, and the yellow LED is lit, check for a shorted gate on the SCR by removing the green plug and connecting an ohmmeter to the gate leads. If the LED is not lit, and the circuit voltage is as specified in step 8 (above), pinch the tab on the blue fiber-optic connector and carefully pull it straight out of the receiver. The end of the connector 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 gray transmitter is emitting red light. If it is, the fiber-optic cable must be replaced. If it isn’t, the interface board should be replaced.

11. When each gate driver circuit has been checked, disconnect the power supply and remove it from the cabinet.

ATT EN TI ON : 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.

66 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Commissioning Procedure Chapter 3

12. Open the switch SW2 on the interface board (see Figure 38) before returning the unit to service. Ensure the red LED is off.

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

13. Check that all plugs and connectors are secure. Retrieve all hardware and tools from the equipment. Replace and secure any barriers removed during servicing and close all doors before applying power.

Control Function Tests

ATT EN TI ON : 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.

1. Apply rated control voltage to the control circuit.

2. Using the control schematic, apply control signals to cause relays and

contactors to energize, to verify operation.

3. Remove any jumpers used in the test and restore all circuits to normal when finished.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 67

Chapter 3 Commissioning Procedure

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.

ATTENTION: 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 - Power Circuit Resistance Measurements

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

Cathode to Cathode (KOhms)

Cathode to Gate (Ohms) 10-40 10-40 10-40 10-40 10-40 10-40 10-40 10-40

(1) Measured between terminals “Cathode” on CLGO Boards, upper two or between two within a phase. (2) Measured between terminals “Cathode” on CLGO Boards, top to bottom within a phase. (3) Measured between line and load terminals within a phase.

(1)

----22-3023-3121-2924-32

(2)

17-23 19-25 20-27 21-29 40-53 43-57 60-90

(3)

64-84

(3)

Voltage Sensing Module

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

on page 123 of Chapter 9.

The voltage-sensing module consists of a voltage sensing board and mounting plate (refer to Figure 48 on page 120

). The voltage sensing board has six independent channels, with different sized resistors base on voltage range, which convert voltages up to 10800V (7.2 kV @ 1.5 pu) down to low voltage levels which can be used by the SMC Flex control logic.

Ta b l e 4

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

68 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Commissioning Procedure Chapter 3

Software will be used to scale the output to show the correct value on the SMC Flex front panel display. (See Parameter #106 – MV Ratio)

Table 4 - Input Voltage Ranges

Module Rated Voltage Voltage Range MV Ratio

1500 800-1500 1200

2500 1501-2500 580

4800 2501-4800 324

7200 4801-7200 195

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

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 69

Chapter 3 Commissioning Procedure

Notes:

70 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Programming

TIP

Sel

Esc

Sel

Chapter 4

Overview

Keypad Description

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.

This User Manual pertains to SMC Flex control modules with version 4.xx firmware (or later).

The keys found on the front of the SMC Flex controller are described in Ta b l e 5 .

Table 5 - Keypad Descriptions

Escape Exit a menu, cancel a change to a parameter value, or

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

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

Enter Enter a menu, enter edit mode in a parameter screen, or save a

acknowledge a fault/alarm.

screen.

change to a parameter value.

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 42

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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Chapter 4 Programming

Select language being deployed

Power-up and Status Display

Lang

or or or or

Choose Mode

OPERATION LEVEL

Memory

Storage

Preferences Diagnostics

Log

(3)

Device SelectParameter

Monitoring Set Up Motor Protection Communications Utility Linear List

SMC Flex Reset to Defaults

Save to EEPROM Recall EEPROM

Change Password User Dspl Line User Dspl Time User Dspl Video Reset User Display

Alarms Fau lts Device Revision

Parameter menu continued in Fi gure 43

MAIN MENU

(1)

GROUP MENU

Esc

Sel

(1) The SMC Flex controller does not support EEPROM, Link, Process or Start-up modes. (2) Steps back one level. (3) Shown if password protection is configured

(2)

Figure 42 - Menu Structure Hierarchy

72 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Motor

Protection

Communications Utility

Set Up

Monitoring

Metering

Volt s Phas e A-B Volt s Phas e B-C Volt s Phas e C-A Current Phase A Current Phase B Current Phase C Watt M eter Megawatt Hours Elapsed Time Meter Reset Power Factor Mtr Therm Usage Motor Speed

Esc

Linear List

Parame ter

(1),(3)

Basic

SMC Option Motor Connection Line Voltage MV Ratio Starting M ode Ramp Time Initial Torque Cur Lim it Lvl Kickstart Time Kickstart Lvl Stop Input Option 1 Input Option 2 Input Stop Mode Stop Time Braking Current Overload Class Service Factor Motor FLC CT Ratio Overload Reset Aux1 Config Aux2 Config Aux3 Config Aux4 Config Backspin Timer Parameter Mgt. (4)

Dual Ramp (Option 2 Input = Dual Ramp)

Starting M ode 2 Ramp Time 2 Initial Torque 2 Cur Lim it Lvl 2 Kickstart Time 2 Kickstart Lvl 2 Parameter Mgt. (4)

Preset SS (Option 2 Input = Preset SS)

Slow Speed Sel Slow Speed Dir Slow Speed Acc Slow Running Cur Parameter Mgt. (4)

(Option 2 Input = Accu-Stop)

Braking Current Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cur Stopping Current Parameter Mgt. (4)

Overload

Overload Class Service Factor Motor FLC Overload Reset Overload A Lvl Parameter Mgt. (4)

Underload

Underload F Lvl Underload F Dly Underload A Lvl Underload A Dly Parameter Mgt. (4)

Undervoltage

Undervolt F Lvl Undervolt F Dly Undervolt A Lvl Undervolt A Dly Parameter Mgt. (4)

Overvoltage

Overvolt F Lvl Overvolt F Dly Overvolt A Lvl Overvolt A Dly Parameter Mgt. (4)

Unbalance

Unbalance F Lvl Unbalance F Dly Unbalance A Lvl Unbalance A Dly Parameter Mgt. (4)

Jam

Jam F Lvl Jam F Dly Jam A Lvl Jam A Dly Parameter Mgt. (4)

Stall

Stall Dly Parameter Mgt. (4)

Ground Fault

Gnd Flt Enable Gnd Flt Lvl Gnd Flt Dly Gnd Flt Inh Time Gnd Flt A Enable Gnd Flt A Lvl Gnd Flt A Dly Parameter Mgt. (4)

PTC

PTC Enable Parameter Mgt. (4)

Phase Reversal

Phase Reversal Parameter Mgt. (4)

Restart

Starts Per Hour Restart Attempts Restart Dly Parameter Mgt. (4)

Comm Masters

Logic Ma sk Parame ter Mgt. (4)

Data Links

Data In A1 Data In A2 Data In B1 Data In B2 Data In C1 Data In C2 Data In D1 Data In D2 Data Out A1 Data Out A2 Data Out B1 Data Out B2 Data Out C1 Data Out C2 Data Out D1 Data Out D2 Parame ter Mgt. (4)

Language

Language Parameter Mgt. (4)

Motor Data

Motor Flc Motor ID CT Ratio MV Ratio Parameter Mgt. (4)

Linear LIst

All parameters Parame ter Mgt. (4)

(1) Depending upon SMC option selected, some parameters may not appear in product display. (2) Steps back one level (3) For further information on parameters, refer to Appendix B

(4) For further information on parameter management, refer to Parameter Management

on page 76.

(2)

Figure 43 - Menu Structure Hierarchy

Programming Chapter 4

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Chapter 4 Programming

Table 6 - Parameter Linear List

(1)

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

1 Volts Phase A-B 46 Motor FLC 91 Data In B2

2 Volts Phase B-C 47 Overload Reset 92 Data In C1

3 Volts Phase C-A 48 OL Shunt Time 93 Data In C2

4 Current Phase A 49 OL Trip Enable 94 Data In D1

5 Current Phase B 50 Overload A Lvl 95 Data In D2

6 Current Phase C 51 Underload F Lvl 96 Data Out A1

7 Watt Meter 52 Underload F Dly 97 Data Out A2

8 Kilowatt Hours 53 Underload A Lvl 98 Data Out B1

9 Elapsed Time 54 Underload A Dly 99 Data Out B2

10 Meter Reset 55 Undervolt F Lvl 100 Data Out C1

11 Power Factor 56 Undervolt F Dly 101 Data Out C2

12 Mtr Therm Usage 57 Undervolt A Lvl 102 Data Out D1

13 Motor Speed 58 Undervolt A Dly 103 Data Out D1

14 SMC Option 59 Overvolt F Lvl 104 Motor ID

15 Motor Connection

(2)

60 Overvolt F Dly 105 CT Ratio

16 Line Voltage 61 Overvolt A Lvl 106 MV Ratio

17 Starting Mode 62 Overvolt A Dly 107 Aux1 Config

18 Ramp Time 63 Unbalance F Lvl 108 Aux3 Config

19 Initial Torque 64 Unbalance F Dly 109 Aux4 Config

20 Cur Limit Level 65 Unbalance A Lvl 110 Aux2 Config

21 Reserved 66 Unbalance A Dly 111 Language

22 Kickstar t Time 67 Jam F Lvl 112 Timed Start

23 Kickstar t Level 68 Jam F Dly 113 I Shutoff Level

(2)

24 Option 2 Input 69 Jam A Lvl 114 UTS Level

25 Starting Mode 2 70 Jam A Dly 115 Parameter Mgmt

26 Ramp Time 2 71 Stall Delay 116 Backspin Timer

27 Initial Torque 2 72 Gnd Flt Enable 117 V Shutoff Level

28 Cur Limit Level 2 73 Gnd Flt Level 118 OL Reset Level

29 Reser ved 74 Gnd Flt Delay 119 Ambient Temp.

30 Kickstar t Time 2 75 Gnd Flt Inh Time 120 Notch Position

(2)

31 Kickstart Level 2 76 Gnd Flt A Enable 121 Notch – Maximum

32 Stop Mode 77 Gnd Flt A Lvl 122 Start Delay

33 Stop Time 78 Gnd Flt A Dly 123 Bypass Delay

34 Pump Pedestal

(1)

79 PTC Enable 124 Fault 1

(2)

35 Braking Current 80 Phase Reversal 125 Fault 2

36 Braking Time

(3)

81 Star ts Per Hour 126 Fault 3

37 Load Type 82 Restart Attempts 127 Fault 4

38 High Eff Brake 83 Restart Delay 128 Fault 5

39 Slow Speed Sel 84 Line Fault 129 Start Time E

40 Slow Speed Cur 85 Emergency Run 130 Start Time 2E

41 Slow Accel Cur 86 Current Loss 131 Stop Time E

42 Slow Running Cur 87 Logic Mask 132 Option 1 Input

43 Stopping Current 88 Data In A1 133 Stop Input

44 O verload Class 89 Data In A2 134 Elapsed Time 2

45 Service Factor 90 Data In B1

(1) Pump Control module only – see Troubleshooting section for guidance. (2) Do not change these parameters from the default settings.

(3) Brake module only – Consult factory.

(2)

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Programming Chapter 4

TIP

Sel

Esc

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.

(1) To complete the programming process, re-enter the Main Menu mode to log out. This will eliminate unauthorized process to the

programming system.

(1)

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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Chapter 4 Programming

Esc Sel

EEPROM RAM ROM

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 44

Figure 44 - Memory Block Diagram

and explanations below.

Esc

Sel

Random Access Memory (RAM)

This is the work area of the controller after it is powered up. When you modify parameters in the Setup mode, the new values are stored in RAM. When power is applied to the controller, parameter values stored in the EEPROM are copied to RAM. RAM is volatile and the values stored in this area are lost when the controller is powered down.

Read-Only Memory (ROM)

The SMC Flex controller comes with factory default parameter values. These settings are stored in nonvolatile ROM and are displayed the first time you enter the Program mode.

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Programming Chapter 4

TIP

Electrically Erasable Programmable Read-Only Memory (EEPROM)

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

Using Parameter Management with DPI HIM

The SMC Flex will automatically save any parameter changes made during the programming process.

Memory Storage and Parameter Management perform the same function of resetting to defaults.

Description Action Display

Recalling Defaults After parameter values have been modified, factory

default settings can still be re-initialized.

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Chapter 4 Programming

Sel

Esc

Parameter Modification

All parameters are modified using the same method. The basic steps to performing parameter modification are described below.

Notes:

1. Parameter values modified while the motor is operating are not valid until

the next start sequence begins.

2. If the password is set, parameters cannot be adjusted without logging in.

3. Use the Sel key to highlight a single digit.

Description Action Display

——

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.

(2)

—

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.

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

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.

(1) The SMC Option advises the user if any control opti on (i.e., Pum p Control) is resident. This parameter is factory set and cannot be

modified by the user.

(2) 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.

(1)

—

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Programming Chapter 4

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

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.

(1) If the controller senses that the motor has reached full speed before completing the Soft Start, it will automatically switch to

(2) For ramp times greater than 30 s, set “Ramp Time” to zero and program “Ramp Time E” (parameter 129) to the new time. Do not

(1)

providing full voltage to the motor.

exceed the thermal capacity of the controller.

Soft Start

(2)

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

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.

(1) If the controller senses that the motor has reached full speed before completing the Soft Start, it will automatically switch to

(2) For ramp times greater than 30 s, set “Ramp Time” to zero and program “Ramp Time E” (parameter 129) to the new time. Do not

(1)

providing full voltage to the motor.

exceed the thermal capacity of the controller.

Current Limit

(2)

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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Chapter 4 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 Setup programming mode. To obtain Dual Ramp control, Ramp #1 is located in the Basic Setup and Ramp #2 is located in the Option 2 Input (Dual Ramp).

Parameter 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 Input 2 (Dual Ramp)

This allows the user the option to choose between two Soft Start profiles defined by:

1. Start Mode/Ramp Time/Initial Torque, and

2. Start Mode 2/Ramp Time 2/Initial Torque 2.

When this feature is turned on, the ramp time/initial torque combination is determined by a hard contact input to terminal 15. When this input signal is low, ramp time/ initial torque are selected. When input signal is high, ramp time 2/initial torque 2 are selected. Once the Option 2 input has been set to Dual Ramp, you must ESC back to the Parameter (File) menu. Re-enter into the Set Up menu to show both Basic Set Up and Dual Ramp.

Basic Set Up/Start Mode

This selects the start mode for option #1.

Basic Set-up/Ramp Time

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

Basic Set-up/Initial Torque

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

Dual Ramp/Start Mode 2

This selects the start motor for option #2.

Dual Ramp/Ramp Time 2

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

Dual Ramp/Initial Torque 2

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

(1)

(2)

0 to 30 s

0 to 90% locked rotor torque

(3)

0 to 30 s

0 to 90% locked rotor torque

–

(1) The Dual Ramp feature is available on the standard controller. (2) Kickstart can be programmed for both start modes. (3) For ramp times greater than 30 s, set “Ramp Time 2” to zero and program “Start Time 2E” (parameter 130) for the new time. Do not

exceed the thermal capacity of the controller.

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Programming Chapter 4

TIP

Full Voltage Start

Linear Speed

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

The SMC Flex provides the user the ability to control the motor speed during starting and stopping maneuvers. A tach input is required as specified in Linear

Speed Acceleration and Deceleration on page 6 of Chapter 1.

Parameter Option

Starting Mode

This must be programmed for Linear Speed.

Ramp Time

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.

(1)

Linear Speed

(1)

0 to 30 s

0.0 to 2.2 s

0 to 90% locked rotor torque

Stop Control

(1) For ramp times greater than 30 s, set “Ramp Time” to zero and program “Ramp Time E” (parameter 129) to the new time. Do not

exceed the thermal capacity of the controller.

The SMC Flex can be programmed to extend the motor stop time beyond the normal coast-to-rest time. There are two standard stop modes: Soft Stop and Linear Speed Deceleration.

Parameter Option

Stopping Mode This may be set to one of two

standard choices.

Stop Time Allows the user to set the time period

for the stopping function.

(1) Refer to Chapter 6 for optional stop control modes. (2) A motor tachometer is required (refer to Linear Speed Ac celeration and Decelerat ion on page 6). (3) Consult factory if settings over 30 seconds are required. The base rating of the MV SMC Flex is two starts (or one start/stop

combination) per hour, thirty seconds maximum for each operation. A stopping operation counts as a start for purposes of thermal capacity calculations.

(1)

Soft Stop Linear Speed

(3)

0 to 120 s

(2)

Options that control the stopping of the motor (Soft Stop, Pump Stop, Linear Speed, Braking) require the self-powered gate drivers to be pre-charged by the current loop power supply. If this supply is not present, an alarm symbol will appear at the upper right corner of the control module display, and the options will be inhibited. When the motor is stopped, it will coast. If the supply is restored, the alarm symbol will be cleared and the module will perform the programmed sequence.

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Chapter 4 Programming

Preset Slow Speed

Basic Setup

This control mode may be configured to allow slow speed operation of the motor.

Parameter Option

Slow Speed Select Allows the user to program the slow

speed that best fits the application.

Slow Speed Direction This parameter programs the slow

speed motor rotational direction.

Slow Accel Current Allows the user to program the

required current to a ccelerate the motor to slow speed operation.

Slow Running Current Allows the user to program the

required current to operate the motor at the slow speed setting.

Low: 7% – Forward

10% – Reverse

High: 15% – Forward

20% – Reverse

Forward, Reverse

0 to 450% of full load current

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 location of the SMC in relation to the motor windings.

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

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

Current Limit Level

The current limit level that is applied for the Ramp time selected.

(1)

(2)

Standard

Line or Delta

–

1 to 10000 (Refer to Table 4 in Chapter 3

Soft Start, Current Limit, Full Voltage, Linear Speed

0 to 30 s

0 to 90% locked rotor torque

50 to 600% FLC

(3)

)

(1) Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter. (2) Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter. (3) This is not to indicate how the motor windings are configured. Do not select “Delta” for MV applications.

82 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Parameter Option

Kickstart Time

0.0 to 2.0 s

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

Kickstart Level

0 to 90% of locked rotor torque

Adjust the amount of current applied to the motor during kickstart.

Stop Input

Coast, Stop Option

Allows the user to select the operation of terminal 18, Stop Input.

Option 1 Input

Disable, Stop Option, Fault, Fault NC, Network

Allows the user to select the operation of terminal 16, Option Input #1.

Option 2 Input

Allows the user to select the operation of terminal 15,

Disable, Preset Slow Speed, Dual Ramp, Fault, Fault NC, Network, Clear Fault, Emergency Run

Option Input #2.

Stop Mode

Soft Stop, Linear Speed

Allows the user to program the SMC Flex controller 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). Example: CT Ratio = 150:5, program 150

Aux1 Config

Contact is provided as standard with the SMC Flex controller. This contact is located at terminals 19 and 20.

(1) (2)

Normal, Normal NC, Up-to-Speed, Up-to-Speed NC, Fault, Fault NC, Alarm, Alarm NC, Network, Network NC, External Bypass

Aux Contacts 1 allows the user to configure the operation of the contacts.

Aux2 Config

Contact is provided as standard with the SMC Flex controller. The contact is located at terminals 29 and 30.

Normal, Normal NC, Up-to-Speed, Up-to-Speed NC, Fault, Fault NC, Alarm, Alarm NC, Network, Network NC, External Bypass

Aux. Contacts 2 allows the user to configure the operation of the contacts.

Aux3 Config

Contact is provided as standard with the SMC Flex controller. The contact is located at terminals 31 and 32.

Normal, Normal NC, Up-to-Speed, Up-to-Speed NC, Fault, Fault NC, Alarm, Alarm NC, Network, Network NC, External Bypass

Aux. Contacts 3 allows the user to configure the operation of the contacts.

Aux4 Config

Contact is provided as standard with the SMC Flex controller. The contact is located at terminals 33 and 34.

(2)

Normal, Normal NC, Up-to-Speed, Up-to-Speed NC, Fault, Fault NC, Alarm, Alarm NC, Network, Network NC, External Bypass

Aux. Contacts 4 allows the user to configure the operation of the contacts.

Parameter Mgmt

Ready, Load Default

Recall of factory default parameter values.

Programming Chapter 4

(3)

(1) Not accessible in MV applications for Firmware up to 5.001. (2) Refer to I/O (3) When programmed for ‘Emergency Run’ and the Option 2 input is energized, a ‘Start’ command will first close the bypass contactor,

on page 16 of Chapter 1 and Note: on page 18 of Chapter 1 for MV specific functionality.

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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Chapter 4 Programming

TIP

Motor Protection

While the Basic Setup group allows the user to get started with a minimum number of parameters to modify, the Motor Protection group allows full access to the SMC Flex controller’s powerful parameter set. Following is a listing of the additional setup parameters provided.

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

Parameter Option

Overload

Allows the user to select the operation of the overload.

(1) (2)

(4)

(1) (2)

(1)

(3)

Underload

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

Undervoltage

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

Overvoltage

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

Unbalance

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

Jam

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

Allows the user to enable the ground fault level in amps, delay time and inhibit time. A separate core balance current transformer is required.

PTC

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.

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

(1) The delay time must be set to a value greater than zero when Undervoltage, Overvoltage and Unbalance are enabled. (2) For Jam and Underload detection to function, the Motor FLC must be programmed in the Motor Protection group. See Motor

Information on page 86.

(3) See details in Ground Fault on page 12. (4) See details in Thermistor/PTC Protection on page 13.

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Programming Chapter 4

Example Settings

Undervoltage

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

Overvoltage

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

(2)(3)

Jam

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

Underload

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

(1)

(2)

(1) The average value of the three phase-to-phase voltages is utilized. (2) The largest value of the three phase currents is utilized. (3) The SMC Flex will self-protect.

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Chapter 4 Programming

Motor Information

The Basic Setup and Overload programming group allows the user to set parameters indicating to the controller which motor is connected. It is important to correctly input the data to achieve the best performance from your controller.

ATT EN TI ON : 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

The factor default setting disables overload protection. To enable it, enter the desired trip class in this parameter.

Service Factor

Enter the value from the motor’s nameplate.

Motor FLC

Enter the value from the motor’s nameplate.

(1) (2)

(1) (2) (3)

Disable, 10, 15, 20, 30

0.01 to 1.99

1.0 to 2200A

Overload Reset

Allows the user to select either a manual or auto reset after an overload.

Motor Connection

Enter the type o f motor being connected to t he SMC Flex: Line or Delta

Line Voltage

Enter the system voltage in this parameter. This must be done to ensure optimum motor performance and correct operation of undervoltage and overvoltage protection.

(1) Found in Overload programming group. Only one location needs to be programmed. (2) Found in Basic Set Up programming group. (3) Refer to the SMC Flex controller nameplate for maximum ratings. Exceeding these could result in damage to the controller. (4) This is not to indicate how the motor windings are configured. Do not select “Delta” for MV applications.

(1) (2)

(2) (4)

(2) (3)

Manual, Auto

Line, Delta

1 to 10,000 V

86 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Metering

Sel

Esc

Chapter 5

Overview

Viewing Metering Data

While the SMC Flex controller operates your motor, it also monitors several different parameters, providing a full function metering package.

To access the metering information, follow the procedure below:

Description Action Display

––

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.

(1)

–

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

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

(1) Refer to Metering on page 16 of Chapter 1 or Figure 43 on page 73 of Chapter 4 for details on the metering functions.

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 87

–

Chapter 5 Metering

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.

The metering values that are displayed on the SMC Flex can be modified to show you desired values by accessing Main Menu/Preferences.

88 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Options

TIP

Sel

Jog

Sel

Jog

Chapter 6

Overview

Human Interface Module

The SMC Flex controller offers a variety of unique control programming and communication options that provide enhanced capabilities (refer to Chapter 1 for brief descriptions of each option).

Only one option can reside in a controller.

The control buttons available with the Bulletin 20-HIM Human Interface Modules are compatible with the SMC Flex controller’s control options. The following table details the functionality of each button with regards to each option.

Notes:

1. The logic mask port must be enabled prior to initiating control commands

to the SMC Flex controller. Refer to Control Enable

on page 106 of

Chapter 8 for instructions.

2. The control terminals must be wired according to Figure 36 on page 62 and Figure 37 on page 63

Option Action Operation

Standard

Soft Stop Current Limit Full Voltage Linear Speed

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

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

The jog button, when pressed, will initiate the

Preset Slow Speed

Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 89

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.

Chapter 6 Options

Sel

Jog

Sel

Jog

Sel

Jog

Sel

Jog

Option Action Operation

Pump Control

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

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

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

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

Braking Control

(1)

Smart Motor Braking

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

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

Accu-Stop

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

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

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

Slow Speed with Braking

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

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

The jog button will initiate a brake stop.

(1) Bra king Control is not offere d for standa rd use in MV a pplications. Please consult factory for further assistance.

* Slow Speed cannot be operated via the HIM.

ATT EN TI ON : 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.

90 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013

Rockwell Automation MV SMC Flex Motor Controller User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Preface

Service Procedure

Manual Objectives

Documentation

Description

1503E – OEM Controller

1560E – Retrofit Controller

1562E – Combination Controller

SMC Flex™ Control Module

Starting Modes

Soft Start

Selectable Kickstart

Dual Ramp Start

Full Voltage Start

Preset Slow Speed

Linear Speed Acceleration and Deceleration

Soft Stop

Protection and Diagnostics

Overload

Underload

Undervoltage

Unbalance

Stall Protection and Jam Detection

Ground Fault

Thermistor/PTC Protection

Open Gate

Line Faults

Excessive Starts/Hour

Overtemperature

Metering

Communication

Programming

Status Indication

Control Options

Pump Control Option

Braking Control Options

Hardware Description

Power Module

Current Loop Gate Driver (CLGD) Board

Interface Board

Functional Description

Bulletin 1562E • Basic Control – Controlled Start only

Bulletin 1562E • Basic Control – With Controlled Stop

Bulletin 1562E • DPI Control – Controlled Start only

Bulletin 1562E • DPI Control – With Controlled Stop

Bulletin 1560E • Basic Control – Controlled Start only

Bulletin 1560E • Basic Control – With Controlled Stop

Bulletin 1560E • DPI Control – Controlled Start only

Bulletin 1560E • DPI Control – With Controlled Stop

Receiving

Safety and Codes

Unpacking and Inspection

General Precautions

Transportation and Handling

Installation Site

Mounting

Grounding Practices

Recommended Torque Values

Power Connections

Bulletin 1562E

Bulletin 1560E

Bulletin 1503E

Power Wiring

Interlocking

Installation

Physical Location

Ground Bus Bar

Power and Control Wiring

Control Cables

Fiber-Optic Cables

Power Factor Correction Capacitors

Surge Arrestor Protection Devices

Motor Overload Protection

Two-speed Motors

Multi-motor Protection