Rockwell Automation MV SMC Flex Motor Controller User Manual

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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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

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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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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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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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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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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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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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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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