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)
77
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
– 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
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 : 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 (Seconds)
Approximate Trip Time (Seconds)
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
100000
Product Overview Chapter 1
1000
1000
100
100
10
10
1
1
0
0
100% 1000%
100% 1000%
Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 9
Chapter 1 Product Overview
TIP
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%.
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.
(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.
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.
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.
Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 11
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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Product Overview Chapter 1
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 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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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
4000
4000
4000
1330
1330
1330
1330
550
550
550
550
250
250
250
250
100
100
100
100
20
20
20
20
10
10
10
10
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.
14 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
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).
on
(8) Phase reversal protection is functional only at pre-start.
Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 15
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.
16 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
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
#2
Opt
Input
#1
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
a
20
11 12
23
13
25
24
15
14
26
27
17
16
28
29
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.
19
18
30
31
21
22
33
32
34
18 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
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.
Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 19
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.
20 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
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