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User Manual - Rockwell Automation

1. Pu oan a w A SEITE 2 3svHd X04 NADHS SNDILO3NNU2O J 8 359 4 X04 SNDILO3NNE2 IA 8 210 9 359 4 X04 SNDILO3NNEO A V 3219 al lt p NI 12 OL FZ 3 Rena a T E I 3 nu OXL Sed 9t lt lt sam He 69 exc p gt 20 9 9er z LXL 29 L 9XL 1 CXL m Ew ipu a E SS 66r poora Alexi E u ES j asa gt n ote IXL SIXT TANS Ha Cavo INISNIS 39VL IDA GMVDE 32938 1 X314 2NS AlddNS n JAIE 3199 CILVIOSI z LININO Lt 7TUBANUO OL L n E 9 4 ad ics s TX LT I ss 45 INOW Wy ale X314 0HS OL TW Inv 4 S3SN ABVWDNd 5 Sati 24 84 1 2 AlddNS BBA 3199 31V1TUSI A hu 3 4 3ADd f iN3BBn2 ve ne 1949 007 sr sng Figure 1 19 Typical MV SMC Flex Power System Bulletin 1562E With Stop Control 123 B RJ 2 BKMTGkd 0 1 26 Product Overview
2. Ble ozn 1N3WdInO3 310434 V 3SvHd 404 NADHS SNHILO3NNU3 B 359 ND SNOLLISNNOD JALMA EU V 3SVHd X04 SNOLLISNNOD IMA V 313 LS gt y SEL e m z 5449 r m d n e EL rm 9X1 SXL 21 rz 55 66 0018 x n 8T ESA exi Tea TX mre ESA 1X3140WS TavOE SNISN3S 3591 IDA BUDE 32934 1 X314 2WS n 21 Lt LINIAII Ed 7OSLNO9 OL s 4 TES S ex 1 Dn SS 14 aonaow CY SIX3130NS X474 OWS OL SH 53504 ABVWIMd 23 ONILINIT LN32J3n3 n br 53504 1 W ONILINIT 1N322403 gt mE XOUTH3ANI s quo sna N3A Ud g Figure 1 18 Typical MV SMC Flex Power System Bulletin 1562E Without Stop Control 23 BR 2 0 1 25 Product Overview mit AIDOBEIO IRIANDIO woes E
3. 3 Heatsink Assembly 600A with Thermistor 80187 285 51 R Note Due to stringent torquing specifications in this application it is MANDATORY that the entire heatsink assembly be replaced Contact the Rockwell Automation factory 9 SCR Gate Driver Board 80165 898 52 2 devices 80165 898 55 3 IGDPS Board 80026 044 03 R 1 Voltage Sensing Module 81000 199 55 R 1 MV SMC Interface Circuit Board 80190 440 01 R 18 Snubber Resistor 80025 642 04 R 9 Snubber Capacitor 1 0 UF 80025 812 01 R 9 Sharing Resistor 32 5K 225W 80025 753 01 R 25 80025 549 03 R 21 Fiber optic Cable 50m 80025 549 01 R 2 Bridge Rectifier 24808 451 01 R 120 V 80145 581 02 R 2 More 230 V 80145 581 07 Y Test Power Supply 120V AC North America 80187 051 51 R Universal 80187 245 51 R 6 Voltage Divider Resistors 74K 100W 80025 588 05 R P Contactor Relay Control 110 120 V AC 80154 991 59 R Panel 220 230 V AC 80187 226 54 3 Power Fuses Consult Engineering Data 2 CPT Primary Fuses Consult Engineering Data 1 LV Fuses Consult Engineering Data 3 Heater Elements Consult Engineering Data 2 20 Amp Contact Cartridge for Isolation Switch Auxiliary 700 CPM 3 Isolating Switch Blade Assembly aun aw Mos 1 pole moving blade assembly 800 A Automation factory 3 Isolating Switch Blade Assembly ous et a 1 pole fixed blade assembly 800 A Automation factory
4. Fuse Types R Rated 2R to 24R A480R 5 0 2 4 kV 2R to 24R A072 7 2 kV 19R 38R A051B 5 0 2 4 kV Interrupting Ratings 2 4 kV to 7 2 kV 50 kA RMS SYM 80 kA RMS ASYM Mounting Center Dimensions Clip On 304 8 mm 12 0 in Bolt On 454 2 mm 17 88 in Maximum Heat Dissipation kW Convection Start or Stop Cycle 450 Starting Duty Continuous 180A 360A 600A 2500 V 135 192 453 250 5000V 27 0 38 5 90 5 250 7200V 40 5 57 7 136 0 250 Power Losses Losses kW Current A Fuse Size 10 90 6R 125 Power Cell Losses 180 12R 350 240 18 510 360 248 1 000 600 57X 1 500 Fully Loaded Bus Losses 915 mm 36 Bus Rating p Section Power Bus Losses Watts 1200 150 2000 200 3000 200 The losses from a 500 VA control power transformer fully PoweriTrensiormen Losses loaded are approximately 50 W per controller Low Voltage Panel Losses The losses from the standard control circuit are approximately 25 W per controller 1560E UM050B EN P June 2013 A 8 Specifications Table A 8 Control Wire and Power Wire Description Specifications Control Wire All Medium Voltage structures shall be equipped with control wire which meets the following specifications Type TEW Stranded Copper Wire Tinned AWG Size Control Circuit 14 AWG
5. n 2 23 22 18 12 m 1 1 38 DNI3VHS 454 D IN3D31 dITENNS 1 9 Xd AD Tall 3199 x9 L 343 Ud 22 722 4135 TEND G x 1 amy 62 AGtY1 008 1 oe A66ta 0Gvl xt 2 Lh ES 664 0062 4 ram 0 AD 002 008 29 Tel amj ed x2 5 oy IL Male D en D Ir 11 9 5 35 39V1TDA 2 1 ad 5 3ACOHLYI _ 5 43845 TS A TAD 11 521892 Dildo 39813 NOISSSA JIS eT Ad NAUHS S3SVHd 338HL d 3ND LINDSID AJM usa ysy Figure 3 1 Typical MV SMC Flex Power System Diagram Without Optional Stop Control 1560E UM050B EN P June 2013 3 6 Commissioning Procedures SMC Flex control module SW2 When ON up provides LED Red ON when test pulses to gate driver circuits test pulses on NOTE Must be OFF down for normal operation Ribbon connectors to connect to SMC Flex control module underneath contro module TP1 2 3 5 7 9 AB BR b Voltage feedback test points AUTOMATION 7 A ag LED Yellow ON jut when Phase A Ribbon E CAE C gate signal active L toan A connector to Voltage Transmitters C ux B Sensing Board send gate TP
6. Table D 4 Bulletin 1503E 1560E 1562E 3300 and 4160 Volt 180 360 Amp 12 device Qty per controller Description Part Number 180A 6 SCR DCR820 or 5STP03D6500 matched set of 2 80156 893 72 R 360 A 6 SCR DCR1020 or 5STP08G6500 matched set of 2 80156 894 72 R Common Components 3 SCR Gate Driver Board e 80165 858 52 R 4 devices 9 80165 858 55 R 2 IGDPS Board 80026 044 02 R 1 Voltage Sensing Module 81000 199 55 R 1 MV SMC Interface Circuit Board 80190 440 01 R 6 Snubber Resistor 80025 588 02 R 6 Snubber Capacitor 0 68 4510 V peak 80025 812 02 R 6 Sharing Resistor 32 5 k 225 W Two 2 5 k Tap 80025 753 01 R p 1 25 80025 549 03 15 Fiber optic Cable 50m 80025 549 01 R 2 Bridge Rectifier 24808 451 01 R 120 V 80145 581 02 R 2 we 230 V 80145 581 07 1 Test Power Supply 120 V North America 80187 051 51 R Universal 80187 245 51 R 1 Contactor Relay Control 110 120 V AC 80154 991 59 R Panel 220 230 V AC 80187 226 52 3 Power Fuses Consult Engineering Data 2 CPT Primary Fuses Consult Engineering Data 2 LV Fuses Consult Engineering Data 3 Heater Elements Consult Engineering Data 2 20 Amp Contact Cartridge for Isolation Switch Auxiliary 700 CPM 3 1 pole Blade Assembly 400 Amp 80145 566 51 R Special Lubricant for Blade Assembly 400 Amp 80158 357 51 R If desired a complete factory assembled SCR heatsink ass
7. 2 2 Installation Site o ee n eer Ni in 2 3 Monting 58 sr EN 2 3 Grounding Practices ss 2 4 Recommended Torque Values eene 2 4 Power Connections ete ee Et e tete ge cete lilo 2 5 Bulletin 1562 ih eee ierit eet ee eret de 2 5 Bulletin 1500E den eee 2 8 Bulletin 1503E ui au eng teet edendi 2 11 Power fe m 2 12 Interlocking s rete tct e tette eite trea 2 12 Tostaat on e 2 13 Physical Location nni aiea 2 13 EEEE 2 13 Ground Bus Bar a ette nat 2 13 Power and Control Wiring 2 4 44001 2 13 Control Cables gea e pr el cies 2 13 Fibre Optic Cables nih etn edere ER Era 2 13 Power Factor Correction Capacitors 2 14 1560E UMO50B EN P June 2013 Table of Contents MV Dialog Plus Medium Voltage Controller User Manual iii Installation cont Chapter 2 Page Surge Arrestor Protection Devices 2 16 Motor Overload Protection ss 2 17 EMC Compliance eode tede ee ten 2 18 Control Raha A suu Q au o ten 2 19 Control Terminal Designations eee 2 20 Commissioning Procedure Chapter 3 Preliminary eit aee ete 3 1 System Characteristics a a n E E 3 2 Prelimin
8. Description 23 PTC Input 24 PTC Input 25 Tach Input 26 Tach Input 27 Ground Fault Transformer Input 28 Ground Fault Transformer Input 29 Fault Contact N 0 N C 30 Fault Contact N O N C 31 Alarm Contact N O N C 6 32 Alarm Contact N O N C 33 Aux Contact 2 Normal N O N C 34 Aux Contact 2 Normal N O N C s Description Number 11 Control Power Input 12 Control Power Common 13 Control Enable Input 14 Control Module Ground 15 Option Input 2 16 Option Input 1 17 Start Input 18 Stop Input 19 N O Aux Contact 1 Up to Speed 20 N O Aux Contact 1 Up to Speed 21 Not Used 22 NotUsed notconnect any additional loads to these terminals These parasitic loads may cause problems with operation which may result in false starting and stopping Aux Contact 1 is always programmed for Up to S peed to control the bypass contactor in MV applications Aux Contact 2 is always programmed for Normal indication in MV applications RC snubbers are required on inductive loads connected to auxiliary Note The OFF state leakage current for a solid state device connected to an SMC Flex input must be less than 6 mA 23 BR 2 0 Preliminary Set Up Chapter 3 Commissioning Procedure A Ensure the work area is clean and tidy Pathways to main disconnect and emergency stop p
9. Tad 5 192 0 5 HiVJ 1 3 ET 22 249 22 ADLSIWAIHL 192 ENNS 0 192 ENNS 0 esa E3 ES 33AIBNG 31979 esa 154 152 Figure 9 25 6900 V Module Wiring 180 360 600 Without Optional Pump Control or Soft Stop 23 B RJ 2 25 0 Troubleshootin 9 40 QV31 192 99 D 931 3195 99 D S3NISLV3H ZSH TSH ASAENNS ESO 152 MULSIS3M SSAENNS ESA ISA MDULSIS3H DNIMVHS EAA TAN N3937 93 9A0 95 192 9A0 99 99 99 H eaa esa o SAU SAO ss ZEE Eo c3 S3 A a 1531 93 95 9SH 5 59 anna 2 A0 B TE 200 29 v3 N3AUd 5 1 SIR 3195 s SH 2 e9 7019 ZE z 5 158 ESH Yo AO 9 1531 ETT lt 1A0 TAO 152 109 9 HLVO
10. B IN RS1 CS1 44 46 47 SPGDB G 13 Le L1 SMC FLEX INTERFACE BOARD VOLTAGE SENSING BOARD SMCFLEXIB VSB lt 1 1 lt VSB 0 7 Ji BAN lt TX3 81000 199 55 cT 4800 7200V TXS 2500 4799V C 1450 2499V TX6 D 800 1449V a 63 5 cnot anae alt 22 B lt 5 E A g CIRCUIT 2 LEGEND us 5 WIRE CONNECTIONS FOR PHASE 8 WIRE CONNECTIONS FOR PHASE 8 4 6 POWER CONNECTIONS SHOWN FOR PHASE 8 REMOTE EQUIPMENT U20 w pur Sd 1 s FROM CONTROL CIRCUIT Figure 1 20 Typical MV SMC Flex Power System Bulletin 1560E Without Stop Control 23 BR 2 BKMTG ko 0 1 27 Product Overview aq SION 3 3SVHd 403 NADHS SNOILO3NNO9 3SVHd 404 SNOILISANNOD JAM 9 3SVHd 204 SNDILO3NNDO JAA 39537 S3M dans 21 54001 AlddNS 33 AZA 3199 1319151 8 9 24 28
11. 12 OL 5 20 Lte maa 2 mana 14 2 AlddNS AzA 3199 C3ILVIOSI zano A6VvT 008 A66F2 0S 1 2 AGGLb 00G2 D0024 008p SG 661 00018 N d tayga SA DNISN3S 3991101 IDBAiNOO ay Mo SANNI 12 2 3SvHd SABLLIWSNVAL 3199 8 3SVHd V 3SVHd ESA SIX3 149NS 329 4331NI X314 3NS 21 1 LA v ao en n aaas 1534 1531 3 gt An 3 aq La olo DE ts esu m es Figure 1 21 Typical MV SMC Flex Power System Bulletin 1560E With Stop Control 23 B RJ 2 gt 1 28 Product Overview Functional Description 23 BR 2 BKIMTG ko 0 The following functional descriptions and associated control circuits are for units using IntelliV AC contactor control modules For units with electromechanical relay control refer to Appendix C Bulletin 1562E Basic Control Controlled Start only When wired as shown in Figure 1 22 the controller operates as follows Pressing the Star
12. 0 BYPASS CONTROL B IV CR CONTACTOR STATUS u ie 13 14 18 19 20 21 SMC FLEX CONTROL TERMINALS AUX1 UP TD SPEED SMC FLEX DPI CONTACTOR STATUS FAIL SAFE MODULE STATUS FAIL SAFE FAULT ALARM NORMAL TACH GROUND H INPUT INPUT FAULT 23 32 34 WIRE TO MAIN CONTACTOR TO FREQUENCY CONDITIONER OPTION 13TSC IF REQUIRED FOR LINEAR ACCEL DECEL FAN SUPPLIED Figure 1 26 Bulletin 1560E IntelliVAC Control Circuit With Stop Control 23 BR 2 BK AMYG ko 0 Product Overview 1 37 P EMC FILTER N s Nt m B IV EN M 1 4 gt E EC TCD S BYPASS CONTACTOR 8 xd C lt N aux lt 3 gt 12 Sk es L N START STUP SIGNAL B IV FROM EXISTING STARTER ia STATUS BC MASTER CONTROL B IV jo close BYPASS CONTROL MAIN CONTACTOR CONTACT HAND AUTE FRUM EXISTING STARTER B IV CR d o M BH BYPASS CONTROL AUX CONTACTOR STATUS u 1 14 19 20 21 22 SMC FLEX TM 24 CONTROL TERMINALS AUX gt UP TO SPEED CAN H TO DEVICENET DPI T NETWORK FAULT ALARM CAN L NORMAL oy 24v 33 WIRE MAIN CONTA
13. 12 FT m so 19 cm N3AUd 1531 15 m TSH EAD 22 Figure 9 26 6900 V Module Wiring 180 360 600 With Optional Pump Control or Soft Stop 23 BR 2 BKOMTG 0 Safety and Preventative Periodic Inspection Chapter 10 Maintenance The Maintenance Technician should become familiar with the layout and be aware of the basic system parameters Only qualified technicians should be allowed to work with this equipment under competent supervision General housekeeping is the key to maintaining power electronic and electrical equipment They are to be kept as dust free as possible A scheduled program of inspection will reduce the possibility of problems Servicing energized industrial control equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Recommended practice is to disconnnect and lock out control equipment from power sources and allow any stored energy in capaci tors to dissipate If it is necessary to work in the vicinity of energized equipment the safety related work practices of NFPA 70E Electrical Safety Requirements for Employee Workplaces must be followed Note For OEM supplied components refer to documentation provided by the OEM for recommended periodic maintenance procedures Industrial control equipment should be inspected periodically Insp
14. DPI AUX 2 FAULT ALARM NORMAL PTC TACH GROUND H H INPUT INPUT FAULT 34 CONTACTOR STATUS FAIL SAFE MODULE STATUS FAIL SAFE WIRE MAIN CONTACTOR FAN CIF SUPPLIED Figure C 4 Bulletin 1560E Relay Control Circuit Without Stop Control BYPASS CONTACTOR MASTER CONTROL BYPASS CONTROL 15602 5 June 2013 C 8 1560E and 1560E Relay Control 50 2 IGDPS BOARDS BYPASS CONTACTOR BC BE H H RECTIFIER REC MOV 1 START STOP SIGNAL FROM EXISTING STARTER BC ie on 4 F bsa MASTER CONTROL COAST STOP N 0 BYPASS CONTROL SMC FLEX TM CONTROL TERMINALS UP TO SPEED SMC FLEX DPI CONTACTOR STATUS FAIL SAFE AUX 2 FAULT ALARM MODULE STATUS FAIL SAFE PTC TACH GROUND INPUT INPUT FAULT WIRE MAIN CONTACTOR TO FREQUENCY CONDITIONER OPTION 13TSC IF REQUIRED FOR LINEAR ACCEL DECEL FAN IF SUPPLIED Figure C 5 Bulletin 1560E Relay Control Circuit With Stop Control 15602 5 June 2013 1560E and 1560E Relay Control C 9 RECTIFIER REC MOV 1 START STOP SIGNAL FROM EXISTING STARTER MAIN CONTACTOR CONTACT FROM EXISTING STARTER BYPASS CONTACTOR BC MASTER CONTROL BYPASS CONTROL
15. 0 Troubleshooting 9 33 HS1 O LINE LOAD HS3 G1 C1 Ge Ce THERMISTOR u QU 05 9 v o ex 06 or r A eai uU 9 gt a x E E E wam Ce Se Figure 9 22A 1500 2400 V Module Wiring 180 360 With Optional Pump Control or Soft Stop 123 B RJ 2 BKMTG 0 Troubleshootin 9 34 8 e ESH e gt ISH 22 22 25 NOLSINASHL 2SH e avon 19 I3 19 p Ta 53 Sal 2s 192 29 zu 209 ER A o 0 1531 192 _ 109 u 0 o O d xm al AJA avoa JAIA 3179 Figure 9 22B 1500 2400 V Module Wiring 600 With Optional Pump Control or Soft Stop 23 BR 2 0 9 35 Troubleshootin SSH L gt avo ESH z 3NUI ec SH TSH ead va 15
16. esters 1 11 Undetvoltage u ec et 1 11 Overvoltdge d et eem PE teni 1 11 Sua bia ii sn er ii ies 1 12 Stall Protection and Jam Detection 1 12 Ground enan 1 13 Thermistor PTC Protection 1 14 Open Gate esee tme eee ehe tite ee repa 1 16 Eine Faults in u Sa 1 16 Excessive Starts Hour ss 1 17 Overtemperat te eot ost ette eH pen 1 17 tete ete edat Qa t ete ee a 1 17 Communicati li u S n u q i 1 18 ProsSfaminmine ie ere teet Up eie pce e Ee ed 1 18 Status INdication u na dune u eno neri 1 19 Control Options i eee tetro teet Ene e botte 1 19 Pump Control Option ss 1 19 Application Considerations eee 1 20 Braking Control Option ss 1 21 Hardware Description iin rene eet tette cen Peine 1 22 Power Module e Ree oer e Usu 1 22 Self Powered Silicon Controlled Rectifier Gate Driver Board 1 22 25 det Pere e 1 23 1560E UMO50B EN P June 2013 ii Table of Contents MV Dialog Plus Medium Voltage Controller User Manual Product Overview cont Chapter 1 Page Typical MV SMC Flex Power System Diagrams Bulletin 1562E Without Stop Contro
17. 0 Rockwell Automation highly recommends that motor surge capacitors and or motor surge arresters not be located on the load side of the SMC The issues that warrant this are Motor and system inductance limits the rate at which the current can change through the SMC If capacitance is added at the motor the inductance is negated The surge capacitors downstream of the SMC represent a near zero impedance when presented with a step voltage from the turn on of the SCRs near the line voltage peak This causes a high level of di dt to occur due to the fact that the motor cables are generally short in length There is very little impedance between the capacitor and SCR to limit the di dt of this capacitor charging current This can result in damage to the power semiconductors SCRs in the SMC It is essential to understand the clamping voltage of the arresters and type of grounding used in the distribution system The switching of the SCRs generates slightly higher than nominal peak line to ground voltages The typical peaks are 1 5 times the nominal line to ground peak voltages These may cause the arresters to conduct which could affect the operation of the SMC and result in faults Depending upon the instance at which the arresters conduct this could also result in SCR damage The capacitance in combination with the line and motor impedance could also be excited by the voltage steps from SCR switching to create resonant voltage swings
18. 9 Line Connection 9 Load Connection Note SCRI SCR2 and SCR5 a matched set SCR3 SCR4 and SCR6 are a matched set Heatsink 7 Heatsink 1 Heatsink 6 Heatsink 5 gt Spacer block must be flat Minimum Height 30 mm 1 25 in Maximum Width 200 mm 8 0 in Minimum Length 400 mm 16 0 in Figure 9 14 6900V Heatsink Assembly 180 360 A Positioned on bench for SCR replacement 123 B RJ gt BKMTG Ktj 0 9 24 Troubleshooting Do not loosen Centre Nut To remove clamp pressure loosen lower centre nut so that the gap between the clamp surface and the heatsink is approximately 6 mm 0 25 inch T Locking Nut A 21 mm open end wrench is required p Do not adjust ji He s Indicating Washer Do notloosen Gap Figure 9 15 6900V SCR Replacement 180 360 A SCR5 Heatsink 3 Heatsink 6 Locating Pin Heatsink 2 To Remove SCR1 Remove shorting bar hardware Heatsinks 1 and 2 apart Extract SCR To Insert New SCR Apply thin film of electrical joint compound to surfaces of SCR Install SCR so that itis seated in locating pin of heatsink note orientation of SCR Pry heatsinks to
19. a ball E Q 2400 to 4160 V 180 360 A Figure 9 4 Upper Low Voltage Panel and Power Cell Detail 1562E 123 BAR 2 BKMTG 0 9 18 Troubleshootin NE Heatsink 1 SCR 1 Heatsink 2 O gt SCR 2 Heatsink 3 Q Figure 9 5 Power Module Assembly one phase 1000 1300 1500 2400 V 180 360 Do not loosen Centre Nut Locking Nut Do not adjust Indicating Washer To remove clamp pressure loosen lower center nut so that the gap between the clamp surface and the heatsink is approximately 6 mm 0 25 in Figure 9 6 Heatsink Clamp 23 BR 2 0 Troubleshooting 9 19 To Remove SCR Remove shorting bar hardware Pry opposing Heatsinks apart ExtractSCR To Insert New SCR Apply thin film of electrical joint compound to surfaces of SCR Install SCR so thatitis seated in locating pin of heatsink note orientation of SCR Pry heatsinks to close gap ensuring that SCR is seated properly in both its locating pins Rotate SCR so that all leads have same direction SCR 2 SCR
20. 249 149 MOLSIWASHL 193 NNS A0 192 ENNS 0 H1 9 8nNS A0 192 amp NNS A0 ASAIN 3199 ES 22 29 es 12 15 TAO Figure 9 23A 3300 4160 V Module Wiring 180 360 Without Optional Pump Control or Soft Stop 123 B RJ 2 BKOMTG 0 Troubleshootin 9 36 SSH avol 3NII SH TAA eda O TSH 12 9 854 3 852 aa 159 TSA 3 vO s vao D 62 ap 19 _ D eJ 249 de g9 12 Rond 149 Le ID 1 AOLSIWYSHL dJAING 3199 HLVO NNS 192 amp fINS 0 HLVYO amp fINS 192 ENNS 0 Figure 9 23B 3300 4160 V Module Wiring 600 A Without Optional Pump Control or Soft Stop 23 BR 2 0 9 37 Troubleshootin SSH v2 43 12 19 FSH avon 2 9
21. Allen Bradley Medium Voltage SMC Flex Motor Controller Bulletins 1503E 1560E and 1562E User Manual Rockwell Automation Important User Information 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
22. gt ESH 29 AOLSIWASHL gt cSH 3NI1 TSH Taal caa 254 259 159 TSA 00 Hiva 15 192 Ox 209 H1v9 oC 189 92 04 1 AOLSTWASHL 31 9 With Optional Pump Control or Soft Stop Figure 9 24A 3300 4160 V Module Wiring 180 360 123 B RJ 2 0 Troubleshootin 9 38 avo SSH SH AOLSINWSSHL a TSH Tas ead AOLSIWASHL aqavog 33AI3G 3199 Figure 9 24B 3300 4160 V Module Wiring 600 With Optional Pump Control or Soft Stop 23 BR 2 0 9 39 Troubleshootin daa 4931 3 DHiVO 93 00 GLIHA 0937 3195 99 TD SONISLW3H ZSH TSH 129492 33880NS ESI ISI BDLSIS3B 388nNS ESA ISA 20151530 ONRIVHS N3D31 SOLSIWASHL II 29 2 ESH al 5 TSH
23. Check that circuit board plug connectors are installed and fully inserted in their sockets G Check that the cooling fan if supplied is secured and the rotor is not obstructed H Verify integrity and operation of all interlocks I Inthe case of the 1503E verify wiring and perform all tests in conjunction with OEM documentation MV SMC Flex Module Refer to Chapter 4 for programming procedures The default factory parameter settings are as shown in Appendix B Settings may be different on engineered orders or when option modules or customer requirements dictate different settings Important The module should be programmed with an understanding of how the SMC functions and the characteristics of the motor and driven load Inappropriate settings may elicit unexpected results such as lack of acceleration torque or full voltage starting For Pump Control applications refer to Application Considerations on page 1 20 If the factory settings are not suitable for the application program the module to meet the application requirements Contact your local Rockwell Automation representative or the factory if assistance is required 15602 5 June 2013 3 4 Commissioning Procedures Hi Pot and Megger Test 1560E UMO50B EN P June 2013 It is recommended that insulation levels be checked before energizing power equipment This may be done with a High Voltage AC insulation tester HI POT or a Megger
24. 1 5 mm AWG Size Current Transformer Circuit 12 AWG 2 5 mm Number of Strands 19 Maximum Voltage Rating 600 V Maximum Rated Temperature 105 C 221 F Terminal Blocks 1492 CA1 CA3 Power Wire Power wire used to feed the primary of the control power transformer or potential transformers is as follows AWG Size 8 AWG Type Alcatel Excelene XLPE MV90 Insulation Rating 5 0 kV Maximum Temperature Rating 90 C 194 F The controller shall be wired with the following non shielded stranded wire type based on the current ratings een en Le s 200 2 EP CSPE MV90 8 0 kV 90 C 194 F 400 4 0 EP CSPE MV90 8 0 kV 90 C 194 F 600 2 x 4 0 EP CSPE 90 8 0 kV 90 C 194 F For 7 2 kV rated controllers 8 AWG 8 0 kV EP CSPE 90 non shielded stranded cable is used For7 2 kV rated controllers 2 AWG 4 0 AWG or 350 kcmil MCM 8 0 kV EP CSPE 90 non shielded stranded cable is used 15602 5 June 2013 Appendix B Parameter Information Table B 1 Parameter List Group Parameter Description eens Units Min Max SN Volts Phase A B 1 V Volts Phase B C 2 V Volts Phase C A 3 V Current Phase A 4 A Current Phase B 5 A Current Phase C 6 A Watt Meter 7 KW MW Metering K
25. 11 SMC FLEX TM CONTROL TERMINALS DPI INPUT CONTACTOR STATUS FAIL SAFE MODULE STATUS FAIL SAFE TACH INPUT Pie 14 15 6 17 ig 19 GROUND FAULT AUX UP TO SPEED AUX 2 FAULT ALARM NORMAL WIRE TO MAIN CONTACTOR TO DEVICENET NETWORK QF SUPPLIED Figure 6 Bulletin 1560E Relay Control Circuit With DeviceNet or Communication and Optional Hand Auto 15602 5 June 2013 C 10 1560E and 1560E Relay Control11 1560E UMO50B EN P June 2013 Spare Parts Table D 1 Bulletin 1503E 1000 1500 Volt 180 360 Amp 6 device Qty per controller Description Part Number 180A 6 Individual SCR 5STP04D5200 matching not required 80156 815 61 R 360A 6 Individual SCR 5STP08G6500 matching not required 80156 894 71 R Common Components 3 SCR Gate Driver Board 80165 898 52 R 2 devices 80165 898 55 R 1 IGDPS Board 80026 044 02 R 1 Voltage Sensing Module 81000 199 55 R 1 SMC Interface Circuit Board 80190 440 01 R 9 Snubber Resistor 80025 588 02 R 3 Snubber Capacitor 1000 V 1 0 UF 80025 812 01 R 4 5 kV peak 1300 1500V 0 68 80025 812 02 R 3 Sharing Resistor 32 5 k 225 W Two 2 5 k Tap 80025 753 01 R 25 80025 549 03 R 9 Fiber optic Cable 50m 80025 549 0
26. SMC FLEX TM CONTROL TERMINALS AUX L UP TO SPEED SMC FLEX DPI CONTACTOR STATUS FAIL SAFE AUX 2 MODULE STATUS FAIL SAFE FAULT ALARM NORMAL PTC TACH GROUND INPUT INPUT FAULT 1H 23 24 25 26 27 28 29 30 31 32 33 3 FREQUENCY CONDITIONER OPTION 13TSC IF REQUIRED FOR LINEAR ACCEL DECEL MAIN CONTROL MAIN CONTROL AUX FAN CIF SUPPLIED Figure 1 23 Bulletin 1562E IntelliVAC Control Circuit With Stop Control 123 B RJ 2 BKMTG Kt 1 34 Product Overview M IV 23 2 0 E EC I gt l MAIN CONTACTOR TCO 4 gt BYPASS CONTACTOR AUX B IV START STATUS STOP 14 o o MODULE MODULE STATUS MASTER CONTROL M IV R MC BC He CONTACTOR STATUS AUTO ba BYPASS CONTROL B IV BYPASS CONTROL AUX Hee CONTACTOR STATUS SMC FLEX CONTROL TERMINALS AUXA CAN H UP TO SPEED DEVICENET DPI NETWORK O FAULT ALARM norma CAN TACH GROUND INPUT INPUT FAULT r H r H 1 H 24 25 26 27 28 29 30 31 32 33 34
27. 5 Repeat Thyristor SCR resistance checks page 9 12 and Power Supply Tests page 3 7 123 B RJ 2 2 0 9 30 Troubleshooting Snubber Resistor Replacement When replacing the ceramic wire wound type snubber resistors use caution when handling the parts The resistor element is under a thin coating on the ceramic tube and it may be damaged if dropped struck or scraped 23 BR 2 25 0 Troubleshooting 9 31 d b OO 29 Go THERMISTOR RR1 THERMISTOR GATE DRIVER BOARD Figure 9 21A 1500 2400 V Module Wiring 180 360 Without Optional Pump Control or Soft Stop 123 B RJ 2 BKMTG Ktj 0 9 32 Troubleshooting HS1 LINE LOAD HS3 n Va G1 C1 Ge Ce THERMISTOR 2 x aan Dh aj ou Go G 5 lo Y m o gt 72 lt u Q A I 5 Y gt A c A m m 5 D E D E gt lt gt Z lt 6 6 u gt ol Oo a 910 2 Figure 9 218 1500 2400 Module Wiring 600 Without Optional Pump Control or Soft Stop 23 BR 2
28. 7500 44 36 91 600A 2051 2984 3357 5595 5595 1117 914 2315 1980 590 Bulletin 1562E 800 1000 1250 200A E 600 746 932 36 36 91 1400 636 400 A 1500 2250 2750 914 914 2315 1119 1679 2051 u 7 Bulletin 1562E 2250 2500 200A 1676 1865 62 36 91 2505 1056 400 A _ _ 4500 5000 1575 914 2315 3357 3730 Bulletin 1562E 2750 4000 4500 80 36 91 09 2984 6357 2032 914 2315 2329 1056 7500 7500 100 36 91 i 5595 5595 2540 914 2315 24816 Weights and dimensions are approximate Certain options such as PFCC will change weight and dimensions Contact factory for certified dimensions and weights 1560E UMO50B EN P June 2013 A 6 Specifications Table A 6 Power Bus and Ground Bus Description Specifications Main Horizontal Power Bus Bus Bar Material Tin plated copper Optional Bus Bar Material Silver plated copper Continuous Current Rating at 40 C 104 F 1200 2000 and 3000 A Maximum Full Load Temperature Rise 65 C 149 F Maximum Full Load Temperature 105 C 221 F Fault Withstand Current Rating 4 5 Cycles grecs Molded glass polyester Type of Bus Bracing Anti hygroscopic 1200A Qty 1 6 x 100 mm 1 4 x 4 in Dimensions per Phase 2000 A Qty 2 6
29. Check motor overload condition Overload parameters are not Check programmed values for overload class and matched to the motor motor FLC Underload 23 Broken motor shaft Repair or replace motor Broken belts toolbits etc Check machine Pump cavitation Check pump system Jam 24 Motor current has exceeded the Correct source of jam user programmed jam level Check programmed time value Stall 25 Motor has not reached full speed by Correctsource of stall the end of the programmed ramp time Prestartfault indication 23 BAR 2 BKMTG 0 9 4 Troubleshooting Table 9 A Fault Display Explanation cont Display Fault Code Possible Causes Possible Solutions Phase Reversal 26 Incoming supply voltage is not in Check power wiring the expected ABC sequence Disable protection if not needed Comm Loss 27 28 29 Communication disconnection at e Check for a communication cable disconnection to the the serial port SMC Flex controller Network 30 31 32 DPI network loss Reconnect for each DPI connected device Ground Fault 33 Ground fault current level has Check power system and motor correct if necessary exceeded programmed values Check programmed ground fault levels to match application requirements Excess Starts Hr 34 Number of starts in a one hour Waitan appropriate amount of time to restart period has exceeded th
30. Contamination te en en een 10 1 Vacuum Bottles Sau RE i 10 2 a ee ete ne erede ce 10 2 CollS ie e ete ettet iei c tell ER 10 2 Solid State Devices a a eee st wes epe 10 3 Static Sensitive Items 10 3 Overload Maintenance After a Fault Condition 10 3 Pinal Check Out eerie ni tin tt terrent 10 3 Keep Good Maintenance Records 10 4 Power Components a sua EE 10 4 Control Components Electronic 10 4 Fans EE 10 4 tas 10 4 Barriers ir aii eC oo a at 10 4 Environmental Considerations 0 0 0 0 eeeeeeeeseeeseeeseecssecesecsseenseeees 10 5 Hazardous Materials eese 10 5 Disposal ete temere sua 10 6 1560E UMO50A EN P August 2004 vi Table of Contents MV Dialog Plus Medium Voltage Controller User Manual Appendix A Appendix B Appendix C Appendix D Appendix E 1560E UMOSOA EN P August 2004 1560E 1562E SMC Flex Specifications Page Specifications Table 1 0 11111 1 Altitude Derating Table 2 A 3 Area Available for Cable Entry Exit Table A 3 A 3 Cable Quant
31. When using an external HIM or DPI interface a core should be added to the HIM cable near the SMC Flex control module The recommended core is Fair Rite no 0431167281 or equivalent When using DeviceNet two cores need to be added to the DeviceNet cable near the SMC Flex control module The recommended cores are TDK ZCAT2033 0930H and TDK ZCAT2035 0930 or equivalent Control Voltage The SMC Flex controller will accept a control power input of 100 to 240V AC 15 10 1 phase 50 60 Hz Refer to the product nameplate to verify the control power input voltage Connect control power to the controller at terminals 11 and 12 The control power requirement for the control module is 75 VA Depending on the specific application additional control circuit transformer VA capacity may be required Control Wiring Table 2 C provides the control terminal wire capacity and the tightening torque requirements Each control terminal will accept a maximum of two wires Table 2 Control Wiring and Tightening Torque Wire Size Torque 0 75 to 2 5 mm 18 to 14 AWG 0 6 Nm 5 Ib in 23 BR 2 BKMTG 0 2 20 Installation Control Terminal Designations As shown in Figure 2 10 the SMC Flex controller contains 24 control terminals on the front of the controller Me UR Figure 2 10 SMC Flex Controller Control Terminals
32. 11 To save modifications to memory scroll to Parameter Mgmt press Enter twice and scroll to User m a F Glad P 115 Store Press the Enter key again T m to save the new settings to EEPROM The SMC Option advises the user if any control option i e Pump Control is resident This parameter is factory set and cannot be modified by the user The display will indicate that the second line is now active by highlighting the first character If the LCD display does not provide a highlighted cursor then the controller is in the Display mode 1560E UMO50B EN P June 2013 Programming 4 9 Soft Start The following parameters are specifically used to adjust the voltage ramp supplied to the motor Parameter Option Starting Mode Soft Start This must be programmed for Soft Start Ramp Time 0 to 30s This programs the time period that the controller will ramp the output voltage up to full voltage from the initial Torque level programmed Initial Torque The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter 0 to 90 locked rotor torque Kickstart Time A boost of current is provided to the motor for the programmed time period 0 0 to 2 0 s Kickstart Level Adjusts the amount of current applied to the motor during the kickstart time 0 to 90 locked rotor torque Current Limit Start will automatically
33. 14 13 12 11 10 9 8 7 1 Control Power Applied 0 No Control Power Runnin 1 Power Applied to Motor 9 0 Power not Applied to Motor 1 ABC Phasing Phasing o CBA Phasing Phasing 1 3 phase is valid Active 0 valid 3 phase is detected Starting 1 Performing Start Maneuver Accel 0 Not performing a Start Maneuver Stopping 1 Performing a Stop Maneuver Decel 0 Not performing a Stop Maneuver AYA 1 Alarm Present 0 Alarm Present X Fault 1 Fault Condition Exists 0 No Fault Condition 1 Full Voltage Applied o Not Full Voltage Applied X Start 1 Start Isolation Contactor Enabled Isolation 0 Start Isolation Contactor Disabled 1 Bypass Contactor Enabled Bypass 0 Bypass Contactor Disabled 1 Ready A Ready Not Ready Bits 12 to 15 Not Used Table 8 H Logic Command Word Bit 4 Jes Status Description 15 14 13 12 11 10 9 8 7 1 Stop Inhibit Stop 0 No Action 1 Start Stari 0 No Action Option 1 1 Stop Maneuver Inhibit Input 0 Action Clear 1 Clear Faults Faults 0 Action Option 2 1 Perform Option 2 function Input 0 No Action Bits 5 to 15 Not Used 1560E UMO50B EN P June 2013 Reference Feedback Parameter Information Scale Factors for PLC Communication Display Text Unit Equivalents Communications 8 9 The SMC Flex do
34. BR 2 0 Bulletin 1560 Basic Control Controlled Start Only The Bulletin 1560E is intended for addition to an existing motor controller which provides circuit isolation motor switching and overload and overcurrent protection When wired as shown in Figure 1 25 the controller operates as follows When a start is initiated in the existing motor controller and the contactor or breaker closes a contact must be supplied to tell the 1560E to start also A contact will apply control voltage to terminal 17 of the SMC Flex module When stopping the motor the contactor in the existing controller will open removing power from the motor and then the CR relay The bypass hold in rung will keep the bypass contactor closed for a short time The Fault contact on the SMC Flex module should be wired into the existing controller to trip the main contactor or breaker in the event of a fault condition sensed by the SMC Flex module If possible it is better to have the SMC Flex module control the main contactor directly In this case the control circuit would look like and function like the descriptions above for the Bulletin 1562E Bulletin 1560E Basic control With Controlled Stop When wired as shown in Figure 1 26 the controller operates much the same as described above for the Standard module The control signal uses terminal 16 instead of 17 and a coast stop can be achieved by
35. CONTACTOR STATUS FAIL SAFE M IV MODULE STATUS FAIL SAFE E CLOSE MAIN CONTROL 4 MAIN CONTROL AUX 23 2 BK MTG Kd 0 FAN SUPPLIED Figure 1 24 Bulletin 1562E IntelliVAC Control Circuit With DeviceNet or DPI Communication and optional Hand Auto START STOP SIGNAL FROM EXISTING STARTER BC Product Overview 1 35 BYPASS CONTACTOR MASTER CONTROL ULE STATUS B IV CR BYPASS CONTROL BYPASS CONTROL AUX Ht CONTACTOR STATUS SMC FLEX CONTROL TERMINALS AUX UP TO SPEED DPI FAULT ALARM NORMAL PTC TACH GROUND INPUT INPUT FAULT 33 34 CONTACTOR STATUS FAIL SAFE MODULE STATUS FAIL SAFE O WIRE TO MAIN CONTACTOR Figure 1 25 Bulletin 1560E IntelliVAC Control Circuit Without Stop Control FAN SUPPLIED 123 B RJ 2 gt 0 1 36 Product Overview P dj N P EMC FILTER S0VDC IGDPS BOARDS B BYPASS CONTACTOR START STUP SIGNAL FROM EXISTING STARTER BC o e KE MASTER CONTROL MODULE STATUS CR COAST STOP o
36. CONTROL TERMINALS DPI INPUT AUXL UP TO SPEED FAULT ALARM HE SMC FLEX CONTACTOR STATUS FAIL SAFE MODULE STATUS FAIL SAFE AUX2 NORMAL TO FREQUENCY CONDITIONER OPTION 137 IF REQUIRED FOR LINEAR ACCEL DEC SC EL MAIN CONTROL Figure C 2 Bulletin 1562E Relay Control Circuit With Stop Control 15602 5 June 2013 C 6 1560E and 1560E Relay Control MC ME ME ME RECTIFIER REC MOV 1 BC BC RECTIFIER REC MOV 2 SMC FLEX CONTROL TERMINALS AUX1 UP TO SPEED DPI AUX 2 FAULT ALARM NORMAL PTC TACH GROUND FAULT CONTACTOR STATUS FAIL SAFE MODULE STATUS FAIL SAFE 24V CAN H CAN L R BLK 24V TO DEVICENET NETWORK FAN GF SUPPLIED MAIN CONTACTOR BYPASS CONTACTOR MASTER CONTROL BYPASS CONTROL MAIN CONTROL Figure C 3 Bulletin 1562E Relay Control Circuit With DeviceNet or DPI Communication and Optional Hand Auto 15602 5 June 2013 1560E and 1560E Relay Control C 7 RECTIFIER REC MOV L START STOP SIGNAL FROM EXISTING STARTER BC CR s SMC FLEX CONTROL TERMINALS AUXA
37. Displacement Power Factor Tachometer Input Control Module Voltage 0 4 5 VDC Current 1 0 mA For stop maneuvers the gate driver boards are powered using a 50 VDC supply 1560E UMO50B EN P June 2013 Specifications 3 Table A 1 Specifications cont Environmental Ratings UL CSA NEMA IEC Operating Temperature Range 0 C to 40 C 32 F to 104 F Storage and Transportation Temperature Range 20 C to 75 C 4 F to 149 F Altitude 0 1000 meters 3 300 feet without derating Humidity 5 to 95 non condensing Pollution Degree 2 Seismic UBCRating 1 2 3 4 Some units may require special bracing Contact factory for more information O Starter Deratings are in Table A 2 Table A 2 Altitude Derating Power Cell Rating Reduce Altitude Range TRE s 180 A 360 A 600 A Withstand Rating By 1000 to 2000 m Reduce Max Continuous Current Rating By Bo 3 300 to 6 600 ft 5A 10A 15A ree 10 20 30A 12 0 kV 3001 to 4000 m 9 901 to 13 200 ft 15A 30A 45 18 0 kV 4001 to 5000 m 13 201 to 16 500 ft 20A 40A 60 24 0 kV Table A 3 Area Available for Cable Entry Exit To Bottom Voltage Line Load Line Load 5 68 X 9 00 mM 5 68 X 9 00 ME 4 60 2300 4160 V 144 X 229 Combined with line 144 X 229 Combined with line 5 68 12 55 5 68 X 12 55 es 4 62 6900 V 144 X 319 Combined
38. If the temperature rises above the setpoint the driver is turned off and the MV SMC Flex is signalled to stop gating and initiate a temperature fault Due to the self powered nature of the circuits this function is active only while the SMC is active While the starter is off or in bypass no power is dissipated in the SCRs and the temperature of the SCRs can only decrease Product Overview 1 23 Interface Board This circuit board takes current transformer signals plus line side and load side voltage feedback signals from the voltage sensing board and passes them to the SMC Flex for processing The control module produces gating signals for the SCRs which are received on the interface board and used to drive fibre optic transmitters The gating signals are sent to the gate driver circuit board via fibre optic cables The interface board also receives temperature feedback from the gate driver board via fibre optic cable s If the heatsink temperature rises above a set value a signal is sent to the SMC Flex to stop gating the SCRs and initiate a temperature fault For a detailed layout of this circuit board refer to Figure 3 2 on page 3 6 23 B RJ 2 BKMTG Ktj Product Overview 1 24 2412 TWALNOD WOH
39. Regardless of the type of interface being used the information below can be used to configure the rest of the system Communications 8 7 Default Input Output The default configuration for I O is 4 bytes in and 4 bytes out TX Configuration 4 bytes RX 4 bytes and is arranged according to the following table Table 8 Produced Data Consumed Data Status Control Word 0 Logic Status Logic Command Word 1 Feedback Reference The feedback word is always Current in Phase The reference word is not used with the SMC Flex however the space must be reserved Variable Input O utput The SMC Flex supports 16 bit DataLinks Therefore the device can be Configuration configured to return additional information The I O message size depends on how many DataLinks are enabled The following table summarizes the I O data sizes Table 8 F Rx Tx Logic Status Reference Data Links Size Size Command Feedback RETE 16 bit 16 bit 4 4 X X 8 8 X X X 12 12 X X X X 16 16 X X X X X 20 20 X X XIX X X To configure DataLinks refer to Configuring Data Links on page 8 10 1560E UMO50B EN P June 2013 8 8 Communications SMC Flex Bit Identification Table 8 6 Logic Status Word Bit Status Description 15
40. 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 gt P IMPORTANT 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 ARCFLASH 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 Foll
41. it is recommended that the main contactor be in the open position and that the output cables be disconnected for each phase See points marked with an asterisk in Figure 3 1 This will ensure the unit is isolated from the line and the motor The line and the motor may be tested separately to locate problem areas If a 1503E is being tested consult OEM documentation After completing the test remove all semiconductor jumpers and test the devices with a multimeter to ensure no damage has occurred from the insulation test Reconnect the system as it existed prior to this section Perform the power supply and resistance checks in the following sections ATTENTION Failure to reconnect all wires and cables correctly may result in equipment damage personal injury or death o 2 5 o 2 1o1deu9 19j91 51591 10 JOd IH JO SJUIOd JTA IVA 0 2 0 d3MOd 1 1 E E 51100420 19 OL dOLS 14 204 W3AUd 33A130 3199 V JACI Sal 1 3 SYSLLIWSNYSL g 2 ASWHd L V sinaNt JSNV31 INANI LIWSNYAL 981 dsvHd UU 2 SYSLLINSNVSL V aSWHd Teal 80444 32 1831 1109319 1041 5990 3981 3
42. optimum motor performance and correct operation of undervoltage and overvoltage protection Refer to the SMC Flex controller nameplate for maximum ratings Exceeding these could result in damage to the controller Found in Overload programming group Only one location needs to be programmed Found in Basic Set Up programming group 1560E UMO50B EN P June 2013 4 16 Programming 1560E UMO50B EN P June 2013 Chapter 5 Overview Viewing Metering Data Metering While the SMC Flex controller operates your motor it also monitors several different parameters providing a full function metering package To access the metering information follow the procedure below Description Action Display MTU Press any key to access the Main menu Main Menu Parameter Memory Storage Scroll with the Up Down keys until the Parameter option is shown Main Menu Parameter Memory Storage Press the Enter key to access the Parameter option Scroll with the Up Down keys until the Monitoring option is displayed Fie Monitorin Press the Enter key to access the Monitoring group Press the Enter key to access the Metering group 02028 FEP Group Metering Refer to Metering on page 1 16 or Figure 4 2 on page 4 3 for details on the metering functions 1560E UM
43. 3 Sharing Resistor 32 5K 225 W 80025 753 01 R i 25 80025 549 03 R 9 Fiber optic Cable 50m 80025 549 01 R 2 Bridge Rectifier 24808 451 01 R 120 V 80145 581 02 R Mov e 230 V 80145 581 07 1 Test Power Supply 120V AC North America 80187 051 51 R Universal 80187 245 51 R Contactor Relay Control 110 120 V AC 80154 991 59 R Panel 220 230 V AC 80187 226 54 3 Power Fuses Consult Engineering Data 2 CPT Primary Fuses Consult Engineering Data 1 LV Fuses Consult Engineering Data 3 Heater Elements Consult Engineering Data 2 20 Amp Contact Cartridge for Isolation Switch Auxiliary 700 CPM 3 Isolating Switch Blade Assembly wer a 1 pole fixed blade assembly 800 Automation factory 3 Isolating Switch Blade Assembly SUA 2a EI 1 pole moving blade assembly 800 Automation factory Special Lubricant for Blade Assembly 80158 357 51 1562E only Reference only 1503 For OEM products refer to OEM supplied documentation for specific spare parts list 1560 1562E are Allen Bradley manufactured starters Refer to Service Manual for specific spare parts list Used when options 13XG Stop Control or 13XB Pump Control are not provided Used when options 13XG Stop Control or 13XB Pump Control are provided Not provided if IntelliVAC control is used refer to Publication 1503 UM051B EN P for spare part information for IntelliVAC 1560E UMO50B EN P June 2013 D 4 Spare Parts
44. 36 inch wide two high cabinet only see the low voltage panel Fig 9 4 3 Unplug all fibre optic cables from the gate driver board Unplug gate lead connectors and thermistor connectors Remove leads from the left side of the circuit board The grey fibre optic cables can be damaged if struck or bent sharply They have a locking feature which requires pinching the tab on the connector and gently pulling straight out The component on the printed circuit board should be held to prevent damage 4 Remove gate driver board by compressing the locking tabs of the nylon circuit board supports and carefully pulling the board off the supports 5 Disconnect the power cables from the terminals on the left side of the heatsink assembly Use care not to damage components The sharing resistors are fragile 23 B RJ 2 gt 0 9 14 Troubleshooting Power Circuit SCR Replacement Procedure cont Troubleshooting cont 6 Remove two 2 nuts at bottom front of heatsink assembly so the module can be removed using the pull handle Phase C requires angling the module to clear the front cabinet flange Position fibre optic cables and wiring so they will not be damaged as the module is removed from the cabinet 7 Pull module out slowly and slide onto a platform lift or lift the module out of the cabinet The heatsink assembly is heavy approx 25 kg 55 Ib or greater To avoid injury always u
45. EN P EtherNet IP 20 COMM E 20COMM UM010 EN P Denotes revision level of user manual Example Publication 20COMM UM002C EN P is at revision C The SMC supports three DPI ports for communication Ports 2 and 3 are supported through the serial connection on the side of the device and are typically used to interface with a Human Interface Module HIM Port 2 is the default connection with port 3 available by installing a splitter on port 2 Port 5 is supported by connecting one of the modules listed above to the internal DPI comm card connection The SMC FLEX controller can be programmed with the built in keypad and LCD display or with the optional Bulletin 20 HIM LCD human interface modules Parameters are organized in a three level menu structure and divided into programming groups 1560E UM050B EN P June 2013 8 2 Communications Human Interface Module cont Keypad Description 1560E UM050B EN P June 2013 The functions of each programming key are described below Table 8 B Keypad Descriptions Exit a menu cancel a change to a parameter value scape or acknowledge a fault alarm Select Select a digit select bit or enter edit mode in a parameter screen Up Down Scroll through options increase decrease a value Arrows or toggle a bit Enter Enter a menu enter edit mode in a parameter screen or save a change to a parameter value Note Note If a human interface module is disconnecte
46. Lu 1 i Measure 113 D 2MQ 43MQ Tap B 95MQ TapA 5 Figure 9 20 Voltage Sensing Board 23 BR 2 0 Troubleshooting 9 29 Measure across R36 R73 R110 R147 R184 and R221 located at the bottom of each leg of the module The resistance should be 11 3 kohm The two ground connections must be connected to ground or to each other if the module has been removed If the values for each leg vary by more than 1 the voltage sensing module may need to be replaced See Renewal Parts listing in Appendix D and refer to procedure on page 9 8 ATTENTION Grounds must be reconnected on the voltage sensing boards Failure to do so may result in injury death or damage to equipment Note The white high voltage wires must be connected to the correct tap on each leg of the voltage sensing module Failure to do so may result in equipment damage The ribbon cable must be connected to J1 only on the voltage sensing board or the equipment will not function 4 When repairs are complete re assemble all parts check all fasteners and verify all connections are correct and tight Make sure all barriers and mechanical parts are in place and secured Make sure ground wires from the Voltage Sensing Module are securely connected to the ground bar in the low voltage panel Failure to do so may result in severe injury or equipment damage
47. Measure resistance to confirm state of the SCRs If the SCRs are not shorted proceed to snubber and resistor circuit testing following this procedure 4 Ifa faulty device is found the entire heatsink assembly must be removed For heatsink assemblies containing four or more SCRs the entire matched set shall be replaced Devices connected in series must have performance specifications matched for proper operation Failure to use matched sets may result in damage to the devices 23 BR 2 0 Troubleshooting 9 13 5 Complete heatsink assemblies with matched SCRs are available as a renewal part see Appendix D In most cases the assembly can be dismantled to replace the SCRs SCR Replacement Procedure Note This procedure applies to 180A and 360A units lt 5000 only Important Refer to OEM documentation for SCR stack location 1503E A Remove SCR Stack from Unit For all types of SMCs the stack requiring new SCRs must first be removed from the unit as follows 1 Remove all power from the equipment To avoid shock hazard ensure main power has been disconnected before working on the controller motor or A control devices Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Service to phase A module may require removing the medium voltage door and swinging out the low voltage panel for
48. See Vacuum Contactor User Manual for suggested HI POT testers and for test procedures for vacuum contactors If using a Megger a 5000 volt type is recommended Solid state devices can be destroyed by high voltage Use jumper wires between heatsinks to short out the SCRs before applying high test voltages to the power circuit Disconnect the white wires 11 1 I T1 112 1T2 1L3 1T3 from the voltage feedback board and remove the plug connector If voltage transformers are present remove one primary fuse from each device On the 1503E consult OEM documentation for location of voltage feedback board Use caution when performing the HI POT or Megger Test High voltage testing is potentially hazardous and may cause severe burns injury or death Where appro priate the case of the test equipment should be connected to ground Insulation may be tested from phase to phase and phase to ground The recommended level for AC HI POT testing is 2 X Volts where V is the rated line to line voltage of the power system The leakage current may be recorded for future comparison testing and must be less than 20 mA If a Megger is used it should indicate 50 k megohms or greater if it is isolated as explained in the next paragraph If the motor is connected the Megger should indicate 5 k megohms or greater If a 1560E is being tested it is recommended that the input and output cables be disconnected for each phase If a 1562E is being tested
49. Special Lubricant for Blade Assembly 80158 357 51 R 1562 only Reference only 1503 For OEM products refer to OEM supplied documentation for specific spare parts list 1560 1562E are Allen Bradley manufactured starters Refer to Service Manual for specific spare parts list Used when options 13XG Stop Control or 13XB Pump Control are not provided Used when options 13XG Stop Control or 13XB Pump Control are provided Not provided if IntelliVAC control is used refer to Publication 1503 UM051B EN P for spare part information on IntelliVAC 1560E UMO50B EN P June 2013 D 8 Spare Parts Table D 8 Accessories Qty per controller Description Part Number 1 Control Module Standard 41391 454 01 S1FX Control Module Pump Control 41391 454 01 B1FX Fan 120 V 80025 248 01 R Fan 240 V 80025 248 02 Fuse Extractor 80144 491 02 Optional equipment Note Reference only 1503E For OEM products refer to OEM supplied documentation for specific spare parts list 1560 1562E are Allen Bradley manufactured starters Refer to Service Manual for specific spare parts list 1560E UMO50B EN P June 2013 Accessories Table E 1 Accessories Description Description Used With Catalog Number Remote Door Mounted IP66 Type 4 12 Programmer Only MINES Remote 1 0 20 COMM R RS 485 DF 1 20 COMM S Communication Modules DeviceN
50. Two orthree power phases are Check power system missing Check voltage sensing module and connections Table 9 C Motor Rotates but does not accelerate to full speed Display Possible Causes Possible Solutions Fault displayed See fault description See Table 9 A addressing fault conditions Starting Mechanical problems Check for binding or external loading and correct Inadequate Current Limit setting Failed control module Check motor Adjust the Current Limit Level to a higher setting Replace control module 23 BR 2 BKOMTG 0 Troubleshooting 9 5 Table 9 D Motor Stops While Running Display Fault displayed Possible Causes See fault description Possible Solutions See Table 9 addressing fault conditions Display is blank Control voltage is absent Failed control module Check control wiring and correct if necessary Replace control module Stopped Pilot devices Check control wiring and correct if necessary 0 0 Amps Failed control module Replace control module Starting Two or three power phases are Check power system missing Failed control module Check voltage sensing module and connections Replace control module Table 9 E Miscellaneous Situations Display Motor current and voltage fluctuates with steady load Possible Causes Motor Erratic Load Possible Solutions Verity type of motor as a standard squirrel ca
51. are described below Note Parameter values modified while the motor is operating are not valid until the next start sequence begins Description Action Display Amps vo MTU 1 Press the ESC key to go from the status display to the Main menu 2 Scroll with the Up Down keys until Main Menu the Preferences option is A highlighted Memory Storage 3 Press the Enter key to access the File 4 Monitoring Parameter menu Set Up 4 Scroll with the Up Down keys until the option you want to use Gp Monitoring Motor Protection A Set Up Motor Protection etc is highlighted For this example Set Up will be used 5 Press Enter to select the Set Up group eu gt Group ae Ea 7 Scroll to the Starting Mode F Gig Parameter parameter by using the Up Down A Starting Mode Ramp Time keys and press Enter 8 Press Enter to select the option Scroll to the option of your choice P 17 by using the Up Down keys For A a Mode this example we will choose Current Limit 9 Press the Enter key to accept the new setting 10 Scroll to the next parameter by using the Down key Continue Ramp Time the process until all desired 62 Secs settings are entered
52. be adjusted from 0 to 99 seconds Underload protection is disabled during slow speed and braking operations Undervoltage Utilizing the undervoltage protection of the MV SMC Flex motor operation can be halted if a sudden drop in voltage is detected The MV SMC Flex controller provides an adjustable undervoltage trip setting from 0 to 99 of the programmed motor voltage Trip delay time can be adjusted from 0 to 99 seconds Note For medium voltage applications undervoltage protection should be set from 80 to 99 An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing Overvoltage Utilizing the overvoltage protection of the MV SMC Flex motor operation can be halted if a sudden increase in voltage is detected The MV SMC Flex controller provides an adjustable overvoltage trip setting from 0 to 199 of the programmed motor voltage Trip delay time can be adjusted from 0 to 99 seconds Note For medium voltage applications overvoltage protection should be set from 100 to 115 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 Undervoltage overvoltage and vo
53. close gap ensuring that SCR is seated properly in both its locating Shorting Bar pins Heatsink 5 Rotate SCR so that all leads have same direction Shorting Bars Proceed to replacement of other SCRs in the matched set SCR2 and 5685 Locating Pins Heatsink 1 Note You must replace all three SCRs of a matched set Figure 9 16 Removing and Replacing SCR1 SCR2 and SCR5 23 BR 2 0 Troubleshootin 9 25 Snubber Resistors Heatsink Assembly y a fii Sharing Resistor Frame Assembly Gate Driver Board Figure 9 17 Power Module Assembly one phase 2300 V 600 A Snubber Resistors Sharing Resistor Snubber Capacitors Gate Driver Board Figure 9 18 Power Module Assembly one phase 3300 4160 V 600 A 123 B RJ gt BKMTG Ktj 0 9 26 Troubleshootin Snubber Resistors Heatsink Assembly Snubber Capacitor Sharing Resistors Frame Assembly Gate Driver Board oards Snubber Capacitor Figure 9 19 Power Module Assembly one phase 5500 6900 V 600 23 BR 2 BKOMTG 0 Troubleshootin 9 27 Snubber and Resistor Circuit If the resistance checks from the Thyristor testing section were abnormal Testing and the thyristors checked out OK there may be a proble
54. correct power wiring If assistance is needed contact your area Rockwell Automation Sales Office Hinged doors and panels which provide access to medium voltage components must be mechanically interlocked to ensure circuit isolation If a combination MV SMC Flex 1562E is purchased from Rockwell Automation all medium voltage compartments will be mechanically interlocked such that they cannot be opened unless the isolating switch for the unitis open Each medium voltage door is interlocked to the isolating switch handle To open the doors move the isolating switch to the OFF position and loosen the two retaining bolts on the main power cell door Once this door is open the other doors may be opened in sequence depending on the specific interlock scheme provided The retrofit type MV SMC Flex 1560E is intended to be added to an existing motor controller and has no isolating means included For 1503E and 1560E it is the responsibility of the installer user to ensure the equipment interlocking scheme is in place and functional before energizing the equipment Inadequate interlocking could expose personnel to energized parts which could result in severe burns injury or death NOTE Rockwell Automation can assist with the selection of an appro priate interlocking method which may include mechanical modifications to the cabinet s or key type lock systems NOTE An auxiliary cabinet may be attached to the main structure It will be ram
55. front of the SMC Flex controller are described below Exit a menu cancel a change to a parameter value or acknowledge a fault alarm Select Select a digit select a bit or enter edit mode in a parameter screen Up Down Scroll through options increase decrease a value Arrows or toggle a bit Enter Enter a menu enter edit mode in a parameter screen or save a change to a parameter value Note For ease of programming values after using the Enter key to edit use the Sel key to jump to the digit that needs to be modified then use the arrow keys to scroll through the digits Parameters are organized in a three level menu structure for straightforward programming Figure 4 1 details the programming menu structure and the three level hierarchy In order to change parameters the controller must be in the STOP mode and the control voltage must be present 1560E UM050B EN P June 2013 4 2 Programmin Programming Menu cont Power up and Status Display soo 52 OPERATION LEVEL Choose Mode MAIN Log m c3 SMC Flex Reset to Defaults Change Password Alarms Save to EEPROM User Dspl Line Faults Motor Protection Recall EEPROM User Dspl Time Device Version Communications User Dspl Video Utility Term Reset User Display GROUP MENU Parameter menu continued in F
56. interlocked with the main power cell door which will not allow it to be opened until the main power cell door is opened Installation Installation 2 13 Physical Location The controller is designed for limited front access components may have to be removed and should be installed with adequate and safe clearance to allow for total door opening The back of the unit may be placed against a wall and several units may be set end to end In special cases where floor space is limited and the unit is not against a wall certain cabinet sections may be placed back to back This requirement must be stated in the speci fications in order to mechanically alter the controller Fan The controller may include a cooling fan which is used to cool the component It should be checked for free operation and no obstruction of the airflow Ground Bus Bar Controllers which are delivered in two or more sections or retrofit controllers will require that the ground bus bar 6 mm x 51 mm x 2 inches which runs the entire length of the equipment in the center back side be reconnected A mechanical lug for 8 10 AWG or 6 250 MCM cable is supplied at the incoming end of the line up When the sections are brought together bus links are used to connect the bus bars Important Refer to 2 high Series B drawings in Publication 1500 UMOSSB EN P for power ground bus connection Power and Control Wiring Controllers consisting of two or more
57. it may be checked as follows 1 Remove all power from the equipment To avoid shock hazard ensure the main power has been disconnected before working on the controller A motor or control devices Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Measure DC resistance per the following chart Table 9 H SCR Resistance Measurements Location of Probes 1000V 1300V 1500V 2300 3300V 4160V 5500V 6900V Cathode to Cathode KOhms 9 22 30 23 31 21 29 24 32 Cathode to Cathode KOhms 17 23 19 25 20 27 21 29 40 53 43 57 60 0060 64 84 Cathode to Gate Ohms 10 40 10 40 10 40 10 40 10 40 10 40 10 40 10 40 Measured between terminals Cathode on SPGD Boards upper two or bottom two within a phase Measured between terminals Cathode SPGD Boards top to bottom within a phase Measured between line and load terminals within a phase Note The actual resistance value depends on the ohmmeter used the particular brand rating of SCR and external circuit influences It is impossible to accurately measure the condition of the SCR when it is unclamped 3 Ifa short circuit is suspected the SCR must be isolated from all surrounding circuitry i e unplug gate and cathode leads and remove snubber and resistor circuit leads from the driver boards
58. ments to ensure that the proper environmental conditions are met F Operational altitude is 3 300 feet 1 km maximum without derating Higher altitudes may require optional components Please consult Rockwell Automation factory G The area of the controller should be free of radio frequency interference such as encountered with some welding units This may cause erroneous fault conditions and shut down the system An incorrectly applied or installed controller can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or ambient tempera tures above or below the specified temperature range may result in malfunction of the controller Mounting The 1503E 1560E and 1562E are designed to be mounted in the vertical position Standard cabinet drawings with certified dimension drawings can be obtained by contacting your local Rockwell Automation Sales office for the 1560E 1562E Please refer to OEM documentation for the 1503E Refer to drawings for mounting requirements 123 B RJ 2 BKOMTG 0 2 4 Installation Installation Site cont Recommended Torque Values 23 BR 2 BK MTG 0 Grounding Practices The purpose of grounding is to A Provide safety for Personnel B Limit dangerous voltages to ground on exposed parts C Facilitate proper overcurrent device operation under ground
59. of the energized gate driver circuit should be lit it may appear dim depending on ambient light conditions This is normally sufficient to verify that the gate drive system is functioning however a more detailed check can be made utilizing steps 7 and 8 Commissioning Procedures 3 9 7 The gate driver board voltage may be checked by connecting a DC voltmeter to TP2 and TP1 See Figure 3 4 With the specified power supply connected the voltage should be 12 2 VDC 8 The actual gate pulse may be checked by connecting an oscilloscope between TP7 and TP1 See Figure 3 4 The pulse should appear as shown in Figure 3 5 14 12 10 4 6 4 2 0 2 2 0 2 4 6 8 Microseconds Figure 3 5 Gate Pulse Detail Typical SCR ABB lid 20 15 10 05 00 05 10 15 20 25 3 0 Milliseconds Figure 3 6 Gate Pulse Test Waveform 9 If no pulse is observed and the yellow LED 15 lit check for a shorted gate on the SCR by removing the green plug and connecting an ohmmeter to the gate leads If the LED is not lit and the circuit voltage is as specified in step 7 above pinch the tab on the fibre optic connector and carefully pull it straight out of the receiver The end of the connector should glow red to indicate the presence of a gate signal If it does not remove the other end of the cable from the interface board and check that the grey transmitter is emitting red light If it is the fibre optic cable must
60. push button is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements ATTENTION ATTENTION The external HIM has a similar programming operation to the built in programmer but note that differences do exist All other controls available with the various human interface modules are non functional with the SMC Flex controller 1560E UMO50B EN P June 2013 8 4 Communications 15602 5 June 2013 Port 5 Communications Ports 2 and 3 when two HIMs are connected with a splitter Connecting the Human Interface Module to the Controller Figure 8 1 shows the connection of the SMC Flex controller to a human interface module Table 8 C provides a description of each port See Figure 1 24 or 1 27 for the control wiring diagram that enables start stop control from a human interface module Port 2 Figure 8 1 SMC Flex Controller with Human Interface Module Table 8 Description of Ports Port Description 1 Unused Not available for use 2 First 20 HIM connected to SMC Flex 3 Second 20 HIM connected to SMC Flex 5 DPI Communication Board port Control Enable To enable motor control from a connected human interface module follow the procedure below with the connected human interface module s programming keys The Bulletin 20 HIM LCD human interface modules with control panels can start and stop the SMC F
61. replace interface board check ribbon cables Motor PTC 12 Motor ventilation blocked Check for proper ventilation Motor duty cycle exceeded Check application duty cycle PTC open Waitfor motor to cool or provide external cooling Check resistance of PTC Open Bypass 13 14 15 Control voltage is low Check control voltage power supply Inoperable bypass contactor Check control circuit operation Check control plug on contactor IntelliVAC fault Check status of IntelliVAC correct the condition reset the module No load 16 17 18 40 Loss of load side power wiring Check all load side power connections and motor windings Loss of feedback Check voltage sensing module Line Unbalance 19 Supply unbalance is greater than Check power system and correct if necessary the user programmed value The delay time is too short for the Extend the delay time to match the application application requirements Unbalanced feedback Check voltage sensing module Overvoltage 20 Supply voltage is greater than user Check power system and correct if necessary programmed value Correct the user programmed value Undervoltage 21 Supply voltage is less than user Check power system and correct if necessary programmed value Correct the user programmed value The delay time is too short for the Extend the delay time to match the application application requirements Overload 22 Motor overloaded
62. requests by incorporating landing pads if room is available or cable terminating units 4 The customer is responsible to size the cables and conduits in accordance with applicable installation codes 15602 5 June 2013 1 500 1 500 1 500 2 250mcm phase 80 W X 91 H 2032 X 2311 1 750mcm phase 4 100 W X 91 H 600A 2540 X 2311 1 750mcm phase 1 500 2 250mcm phase 1 500 2 250mcm phase 1 750 2 500mcm phase 1 500 250mcm phase 1 750 2 2 500mcm phase 2 1 750 500mcm phase Max No amp Size of Exiting Load Cables 1 500 2 250mcm phase 1 500 2 350mcm phase 1 500 2 350mcm phase 1 500 2 350mcm phase 1 500 2 250mcm phase 1 500 2 350mcm phase 1 1000 2 750 4 500mcm phase Specifications 5 Table A 5 Shipping Weights and Dimensions Current Horsepower kW Dimensions in inches mm Shipping Weight Rating 2400V 3300V 4200V 6600 V 6900V Width Depth Height Ib kg Bulletin 1560E 800 1000 1250 200A s u 600 746 933 26 36 91 800 363 400 1500 2250 2750 660 914 2315 1119 1679 2051 E Bulletin 1560E 2250 2500 200A 1678 1865 36 36 91 1220 554 400 4500 5000 914 914 2315 7 E E 3357 3730 2750 4000 4500 7500
63. sections will require that the power and control wiring be connected per the schematic drawings provided Control Cables Control cable entry exit should be located near the terminal blocks customer s connections are to be routed along the empty side of the terminals Nylon cable tie loops are provided at the left front corner of the cabinet to route control cables safely behind the low voltage panel hinges Cables should be routed so they do not interfere with the swing of the low voltage panels Fibre Optic Cables The small gray fibre optic cables are fragile and must be protected during installation from sharp bends and impact 123 2 BKMTG 0 2 14 Installation Installation cont 23 BR 2 0 Power Factor Correction Capacitors The controller can be installed on a system with power factor correction capacitors The capacitors must be located on the line side of the controller This is required to prevent damage to the SCRs in the MV SMC Flex controller A separate switching contactor is recommended to apply the capacitors only after the bypass contactor has closed and to remove them when the bypass contactor opens See Figure 2 7 for two different acceptable connection methods NOTE Consult the factory if there are any capacitors on the same branch circuit as the MV SMC Flex When discharged a capacitor has essentially zero impedance For switching sufficie
64. stopping time is programmable from 0 120 seconds 123 B RJ 2 BKMTG ki 0 1 20 Product Overview Control Options cont Pump Application Considerations 1 Motor Speed 23 BR 2 BKMTG ko 0 100 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 The Pump Control option functions only for centrifugal pumps It is not suited for positive displacement piston or other types of pumps The Pump Stop option functions only for a centrifugal pump running at greater than approximately 2 3 of the motor rated horsepower 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 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 Motor overload and or upstream breaker settings may have to be adjusted to allow the star
65. the GF Trip Delay Parameter 75 Gnd 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 23 B RJ 2 gt 0 1 14 Product Overview Protection and Diagnostics cont 23 2 BK MTG Kd 0 Ground Fault Trip cont Parameter 74 Gnd Fit 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 Fit Level allows the installer to define the ground fault current at which the MV SMC Flex will trip It is adjustable from 1 0 to 5 0 A Important The ground fault inhibit timer starts after the maximum phase of load current transitions from 0 A to 30 of the device s minimum FLA Setting or the GF Current is greater than or equal to 0 5 A The MV SMC Flex does not begin monitoring for a ground fault condition until the Gnd 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 Fit 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 t
66. which could exceed the device voltage withstanding ratings or surge arrester rating or cause distorted voltage signals which may be misinterpreted by the MV SMC Flex control system Motor Overload Protection Installation 2 17 Thermal motor overload protection is provided as standard though it must be programmed with the MV SMC Flex controller If the overload trip class is less than the acceleration time of the motor nuisance tripping may occur ATTENTION Overload protection should be properly coordinated with the motor to avoid damage to equipment Two special applications require consideration Two speed Motors and Multi motor Protection Two speed Motors The MV SMC Flex controller has overload protection available for single speed motors When the MV SMC Flex controller is applied to a two speed motor the Overload Class parameter must be programmed to OFF and separate overload relays must be provided for each speed Multi motor Protection The MV SMC Flex controller provides overload protection for only one motor When the MV SMC Flex is controlling more than one motor the Overload Class Parameter must be programmed to OFF and individual overload protection is required for each motor 23 B RJ 2 BKMTG 0 2 18 Installation EMC Compliance 23 2 BEMTG kd 0 This product has been designed for Class A equipment Use of the product in domestic environments may
67. 013 4 4 Programming Table 4 Parameter Linear List Programming Menu cont Parameter No Description Parameter No Description Parameter No Description 1 Volts Phase A B 40 Slow Speed Dir 79 PTC Enable 2 Volts Phase B C 41 Slow Speed Cur 80 Phase Reversal 3 Volts Phase C A 42 Slow Running Cur 81 Starts per Hour 4 Current Phase A 43 Stopping Current 82 Restart Attempts 5 Current Phase B 44 Overload Class 83 Restart Delay 6 Current Phase C 45 Service Factor 84 Factory Use 7 Watt Meter 46 Motor FLC 85 Factory Use 8 Kilowatt Hours 47 Overload Reset 86 Factory Use 9 Elapsed Time 48 Factory Use 87 Logic Mask 10 Meter Reset 49 Factory Use 88 Data In A1 11 Power Factor 50 Overload A Lvl 89 Data In A2 12 Mtr Therm Usage 51 Underload F Lvl 90 Data In B1 13 Motor Speed 52 Underload F Dly 91 Data In B2 14 SMC Option 53 Underload A Lvl 92 Data In C1 15 Motor Connection 54 Underload A Dly 93 Data In C2 16 Line Voltage 55 Undervolt F Lvl 91 Data In D1 17 Starting Mode 56 Undervolt F Dly 95 Data In D2 18 Ramp Time 57 Undervolt A Lvl 96 Data Out A1 19 Initial Torque 58 Undervolt A Dly 97 Data Out A2 20 Cur Limit Level 59 Overvolt F Lvl 98 Data Out B1 21 Torque Limit 60 Overvolt F Dly 99 Data Out B2 22 Kickstart Time 61 Overvolt A Lvl 100 Data Out C1 23 Kickstart Level 62 Overvolt A Dly 101 Data Out C2 2
68. 1 Shorting Bar Hardware Heatsink 3 Heatsink 1 Heatsink 2 Locating Pin Figure 9 7 Removal of SCR 1000 to 2400 V 180 360 23 B RJ 2 0 20 Troubleshootin Heatsink 1 Heatsink 2 SCR1 SCR 2 Heatsink eatsin 9 Heatsink 4 SCR 3 SCR 4 0 Heatsink 5 5 Note SCR 1 and SCR 3 are a matched set SCR 2 and SCR 4 are a matched set Figure 9 8 Power Module Assembly one phase 3300 4160 V 180 360 23 BR 2 PBKMEG 0 Do not loosen Do not loosen Locking Nut Do not adjust Indicating Washer To remove clamp pressure loosen lower center nut so that the gap between the clamp surface and the heatsink is approximately 6 mm 0 25 in Figure 9 9 Heatsink Clamp Troubleshooting 9 21 To Remove SCR4 shorting bar hardware Heatsinks 4 and 5 apart Extract SCR To Insert New SCR Apply thin film of electrical joint compound to surfaces of SCR Install SCR so that itis seated in locating pin of heatsink note orientati
69. 1 R 1 Test P Suppl 120 V AC North America 80187 051 51 R Universal 80187 245 51 R If desired a complete factory assembled SCR heatsink assembly with snubber resistor and capacitor can be purchased rather than individual SCRs See table below for part numbers Qty per controller Description Part Number 3 180 Amp 1000 Volt Controller 80157 863 55 3 360 Amp 1000 Volt Controller 80157 863 56 3 180 Amp 1300V and 1500V Controller 80157 863 54 3 360 Amp 1300V and 1500V Controller 80157 863 52 Requires a thin film of electrical joint compound between base and mounting surface Available with SCR replacement parts or separately as Part Number 80025 783 51 Reference only 1503 For OEM products refer to OEM supplied documentation for specific spare parts list 1560 1562E are Allen Bradley manufactured starters Refer to Service Manual for specific spare parts list Used when options 13XG Stop Control or 13XB Pump Control are not provided Used when options 13XG Stop Control 13XB Pump Control are provided Appendix D 15602 5 June 2013 D 2 Spare Parts Table D 2 Bulletin 1503E 1560E 1562E 2300 Volt 180 360 Amp 6 device Qty per controller Description Part Number 180A 6 2 SCR DCR820 or 55 0306500 m
70. 1000 0 100 100 0 5 Approximate Trip Time seconds Approximate Trip Time seconds 1 2 4 5 6 7 8910 1 Multiples of FLC Approximate trip time for 3 phase balanced condition from cold start 100000 1000 100 0 23 BR 2 0 Class 15 2 4 5 6 7 8910 Multiples of FLC Approximate Trip Time seconds 10000 0 Class 20 1000 0 100 0 1 2 4 5678910 Multiples of FLC condition from hot start Figure 1 9 Overload Trip Curves M 100 1000 Percent Full Load Current Setting Class 10 Class 15 55 20 Auto Reset Times Class 10 905 Class 15 135s Class 20 180s Class 30 270s Figure 1 10 Restart Trip Curves after Auto Reset Class 30 10000 0 1000 0 100 0 Approximate Trip Time seconds 1 2 3 4 5 6 78910 Multiples of FLC Approximate trip time for 3 phase balanced Product Overview 1 11 Underload Utilizing the underload protection of the MV SMC Flex controller motor operation can be halted if a sudden drop in current is sensed The MV SMC Flex controller provides an adjustable underload trip setting from 0 to 99 of the programmed motor full load current rating Trip delay time can
71. 4 Phase Cowell signals to gate signal driver boards 1 z CI UNE c TP8 Common for La tome TB6 Gate driver Gate Pulse TPs Coren power supply input SMC FLEX Hn INTERFACE LED Yellow ON when Phase B Phase A gate signal active a Phase B aM 5 i TBS Fibre Optic4 11 Phase E g Current Transmitters E l gate signal aseB transformer connections o Phase 2 LED Yellow 9 when Phase C gate signal active TP13 Phase C 8 gate signal Phase C LED Green Fibre Optic lt ON Aron ponsi Transmitters TP15 Common for c3 is presen 2 Gate Pulse TPs TP18 19 20 iv sv Power supply test points SW3 Used to LEDs Green ON when signal LI defeat temperature t E present at temperature feedback feedback channels AB CAL fibre optic receivers 7 Tope E Fibre Optic tt d Receivers ETE p S 2 2 1 r 1 1 pur Ne LJ 7 LV m 80190 438 51 CJ LNG Serial Number Replacement Control Power Part Number 110 240 VAC or 110 250 VDC Figure 3 2 Connection and Test Information for Interface Board 1560E UMO50B EN P June 2013 Commissioning Procedures 3 7 Power Supply Tests SW2 Close slide up ATTENTION Servicing energized industrial control equipmen
72. 4 Option 2 Input 63 Unbalance F Lvl 102 Data Out D1 25 Starting Mode 2 64 Unbalance F Dly 103 Data Out D1 26 Ramp Time 2 65 Unbalance A Lvl 104 Motor ID 27 Initial Torque 2 66 Unbalance A Dly 105 CT Ratio 28 Cur Limit Level 2 67 Jam F Lvl 106 MV Ratio 29 Torque Limit 2 68 Jam F Dly 107 Aux Config 30 Kickstart Time 2 69 Jam A Lvl 108 Fault Contact 31 Kickstart Level 2 70 Jam A Dly 109 Alarm Contact 32 Stop Mode 71 Stall Delay 110 Aux2 Config 33 Stop Time 72 Gnd Fit Enable 111 Language 34 Factory Use 73 Gnd Fit Level 112 Factory Use 35 Braking Current 74 Gnd Fit Delay 113 Factory Use 36 Factory Use 75 Gnd Fit Inh Time 114 Factory Use 37 Factory Use 76 Gnd Fit A Enable 115 Parameter Mgmt 38 Factory Use TT Gnd Fit A Lvl 116 Backspin Timer 39 Slow Speed Sel 78 Gnd Fit A Dly 117 Factory Use 1560E UMO50B EN P June 2013 Programmin 4 5 Password The SMC Flex Controller allows the user to limit access to the programming system through password protection This feature is disabled with a factory set default of 0 To modify the password or login after a password is programmed complete the procedure below Description Action Display Amps vot MTU Press the ESC key to go from the status display to the Main menu UTR Scroll with the Up Down keys until Main Ment the Preferences option is A Preferences highlighted Diagnostics Press the Enter key to access the Preferences Pref
73. 6 SCRs per phase wa Output Rating 100 to 7500 hp 75 to 5600 kW Semi Conductor Isolation Fiber optic Operating Frequency 50 60 Hz 50 60 Hz dv dt Protection RC Snubber Network Transient Protection Integrated overvoltage trigger circuit 180A Rated Current 360 A 600A 180A 1000 V us put 360 600 A 2000 V di dt 180 360 600 A 200 A us Voltage Drop 2 5 V per SCR without bypass Line to Output Terminals Less than 1 0 V with bypass total Overall Efficiency 99 95 with bypass Starting Torque 0 to 90 of motor torque Thermal Capacity 600 10 seconds 450 30 seconds Ramp Time 0 to 30 seconds Consult Factory for Longer Time Acceleration Kick 550 for 0 0 to 2 0 seconds Approvals Safety 92 59 EEC Directive 1 061 1198 Certificate Ref BSEN 61010 1 1993 BSEN 60204 1 1997 89 336 EEC 92 31 EEC 93 68 EEC Directives T703ALB1 Certificate Ref EN 61000 6 4 2001 EN 61000 6 2 2001 UL E102991 CSA 1812235 pending 1560E UMO50B EN P June 2013 A 2 Specifications Table 1 Specifications cont Electrical Ratings cont UL CSA NEMA IEC Short Circuit Protection The power electronics unit must be protected by current limiting fuses to be included by customer in existing starter with 1560E The combination controller includes appropriate fusing coordinated with motor Fault Level Withstan
74. 6 device D 1 Bul 1503E 1560E 1562E 2300V 180 3604 6 device D 2 Bul 1503E 1560E 1562E 2300V 600A 6 device D 3 Bul 1503E 1560E 1562E 3300 4160V 180 3604 12 D 4 Bul 1503E 1560E 1562 3300 4160V 600A 12 device D 5 Bul 1503E 1560E 1562E 5500 6900V 180 3604 18 device D 6 Bul 1503E 1560 1562 5500 6900V 600A 18 device D 7 CCESSOTIES is D 8 Accessories ACC SSONES isis Eee uie Ee Aude ie ne E 1 Preface Service Procedure For your convenience the Rockwell Automation Global Manufacturing Solutions GMS provides an efficient and convenient method of servicing medium voltage products Contact your local area support office to make arrangements to have a qualified service representative come to your facility A complete listing of Area Support Offices may be obtained by calling your local Rockwell Automation Distributor or Sales Office For MV SMC Flex technical support on start up or existing installations contact your Rockwell Automation representative You can also call 1 519 740 4790 for assistance Monday through Friday from 9 00 a m to 5 00 p m Eastern time zone 1560E UMO50B EN P June 2013 Preface 1560E UM050B EN P June 2013 Manual Objectives Documentation Description Chapter 1 Product Overview This man
75. 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 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 inear Deceleration Dual Ramp Start Preset Slow Speed Full Voltage Start This option utilizes gating patterns which result in motor and line currents that produce noise and vibration in the motor and or distribution transformer This must be considered before applying this option Product Overview 1 3 2 BR 2 Starting Modes SMC Flex Control Module cont Other features that offer further user benefit include Extensive protection features Metering Communication capability Innovative control option provides enhanced performance Pump Control Start and Stop Control modes These modes features and options are further described in this chapter This option utilizes gating patterns which result in motor and line currents that produce noise and vibration in the motor and or distribution transformer The factory should be consulted before applying this option Soft S
76. B RJ 2 0 2 10 Installation Power Connections cont Phase 1 T MB i il f Power Stack Assembly tT I Hi 8 be 05 355 a Et 5 Be 000 fa 1 Phase 2 E ii Power Stack Assembly Te bi af Ga 0 e Emn al H a3 8 g P p phase 3 _ ee Power Stack Assembly 9 E E Je Voltage Sensing Module 23 2 BKMTG 0 D y P BAS a Figure 2 6 Power Connections 1560E 600A 2400 to 6900 Phase 1 Line Connection Phase 2 Line Connection Load Connections top exit shown Phase 1 front through 3 back Current Transformers Phase 3 Line Connection Bypass Vacuum Contactor Installation 2 11 Important For retrofit units Bul 1560E the CEC and NEC requi
77. CTOR PTC GROUND FAULT CONTACTOR STATUS FAIL SAFE MODULE STATUS FAIL SAFE FAN SUPPLIED Figure 1 27 Bulletin 1560E IntelliVAC Control Circuit DeviceNet or Communication and optional Hand Auto 123 B RJ 2 BKMTG ki 1 38 Product Overview 23 BR 2 BKIMTG ko 0 Receiving Safety and Codes Unpacking and Inspection Chapter 2 Installation ATTENTION Perform the installation duties correctly Errors may cause commissioning delays equipment damage or personal injury Important For the 1503E refer to applicable documentation from OEM installation grounding interlocking and wiring This manual should be utilized in conjunction with the OEM supplied documentation and is suitable for commissioning programming calibration metering serial communications diagnostics troubleshooting and maintenance of a standard solid state controller It is the responsibility of the user to thoroughly inspect the equipment before accepting the shipment from the freight company Check the item s received against the purchase order If any items are damaged it is the responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill Should any concealed damage be found during unpacking it is again the responsibility of the user to notify the freight agent The shipping container must be
78. Gate Driver Board e 80165 858 52 R 4 devices 80165 858 55 R 2 IGDPS Board 80026 044 02 R 1 Voltage Sensing Module 81000 199 55 R 1 MV SMC Interface Circuit Board 80190 440 01 R 12 Snubber Resistor 80025 642 04 R 6 Snubber Capacitor 1 0 UF 80025 812 01 R 6 Sharing Resistor 32 5K 225W 80025 753 01 R 15 Fiber optic Cable 2 5m 80025 549 03 R 15 5 0m 80025 549 01 R 2 Bridge Rectifier 24808 451 01 R 120 V 80145 581 02 R 5 NEM 230 V 80145 581 07 1 Test Power Suppi 120V AC North America 80187 051 51 R Universal 80187 245 51 R 1 Contactor Relay Control 110 120 V AC 80154 991 59 R 1 Panel 220 230 V AC 80187 226 54 3 Power Fuses Consult Engineering Data 2 CPT Primary Fuses Consult Engineering Data 1 LV Fuses Consult Engineering Data 3 Heater Elements Consult Engineering Data 2 20 Amp Contact Cartridge for Isolation Switch Auxiliary 700 CPM 3 Isolating Switch Blade Assembly EE wer ae 1 pole moving blade assembly 800A Automation factory 3 Isolating Switch Blade Assembly SOVA 907187 M wok 1 pole fixed blade assembly 800 A Wa shao Automation factory Special Lubricant for Blade Assembly 80158 357 51 R 1562E only Reference only 1503 For OEM products refer to OEM supplied documentation for specific spare parts list 1560 1562E are Allen Bradley manufactured starters Refer to Service Manual for specific spare parts list Used when options 13XG Stop Control or 13XB Pump Control are not provided Used wh
79. LEX controller However the factory default settings disable control commands other than Stop through the serial communication port To enable motor control from a connected human interface module or communication module you must take the following programming steps Communications 8 5 Series A 1 Disconnect the HIM and allow to power down 2 Reconnect the HIM On Initializing screen the bottom right corner of LCD shows Port X Note this port number 3 Go to Logic Mask found as follows Main Menu Parameter Communications Comm Mask Logic Mask 4 Set bOX equal to 1 where X is the port number noted in step 2 5 Go to Parameter Management and save as User Store Important The Logic Mask must be set to 0 prior to disconnecting a human interface module from the SMC FLEX controller If not the unit will fault on a Coms Loss 1560E UMO50B EN P June 2013 8 6 Communications Control Enable Loss of Communication and Network Faults SMC Flex Specific Information 1560E UM050B EN P June 2013 If enabling control from the built in SMC Flex programmer the Logic Mask must be set as follows Table 8 D Logic Mask Requirements Mask Code Description No external DPI devices are enabled 4 Only one HIM on port 2 is enabled 12 Two HIMs are enabled on ports 2 and 3 32 Only the DPI communication card on port 5 is enabled One HIM port 2 and the communication card on port 5 are
80. O50B EN P June 2013 5 2 Meterin Viewing Metering Data cont 1560E UMO50B EN P June 2013 Description Action Display Scroll through the Metering P Pi 1 parameters with the Up Down A keys to access the desired 5 F Gig P 2 information Press the Enter key Volts Phase B C to view that parameter Volt Volts Phase C A HHH Volt F Gig P 4 Current Phase A Amps F Gig 5 Current Phase Amps F Gig P 6 Current Phase C Amps Fo 7 Watt Meter THER KW F Gig 8 Kilowatt Hours KWH F Gig 9 Elapsed Time Hour F Gig P 10 Meter Reset No F Gig 11 Power Factor HHH F P 12 Mtr Therm Usage Chapter 6 Options Overview The SMC Flex controller offers a variety of unique control programming and communication options that provide enhanced capabilities See Chapter 1 for brief descriptions of each option Note Only one option can reside in a controller Human Interface Module The control buttons available with the Bulletin 20 HIM Human interface modules are compatible with the SMC Flex controller s control options The following table details the functionality of each button with regards to each option Notes 1 The logic mask port must be enabled prior to initiating control commands to the SMC Flex controller Refer to Co
81. Speed may cause some vibration or noise during the stopping cycle This may be minimized by lowering the braking current adjustment If this is a concern in your application please consult the factory before implementing these options 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 123 BR 2 BKCMTG 0 9 2 Troubleshooting Important In the case of the 1503E refer to applicable documentation from OEM for troubleshooting or repair This manual should be utilized in conjunction with the OEM supplied documentation and is suitable for commissioning programming calibration metering serial communications diagnostics troubleshooting and maintenance of a standard solid state controller The following flowchart is provided to aid in quick troubleshooting YES Table 9 A 23 BR 2 0 Fault Displayed NO Define Nature of Trouble Motor rotates but does not accelerate to full speed See See See Table 9 B Table 9 Table 9 D Figure 9 1 Troubleshooting Flowchart Motor will not start Miscellaneous situations Motor stops while running no output voltage to motor See See Table 9 E Troubleshooting 9 3 Table 9 A Fault D
82. TC 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 123 B RJ 2 gt 1 16 Product Overview Protection and Diagnostics cont 23 BR 2 0 Open Gate An open gate fault indicates that improper SCR firing typically caused by an open SCR gate or driver system has been detected on one of the power poles Before the controller shuts down it will attempt to start the motor a total of three times or as programmed in Parameter 82 An open gate is detected when the module sends a gate signal to the SCRs but does not detect that they turned on SCR turn on is detected when the voltage across the leg L T collapses Line Faults The MV SMC Flex controller continually monitors line conditions for abnormal factors Pre start protection includes e Line Fault with phase indication Line voltage loss Missing load connection Shorted SCR Running protection includes e Line Fault no phase indication Line voltage loss Missing load connection Phase reversal protection can be toggled either ON or OFF Phase reversal protection is functional only at pre start Product Overview 1 17 Excessive Starts Hour The MV SMC Flex module allows the user to prog
83. V ratios shown above are nominal values and may be fine tuned to achieve better accuracy on the display of the SMC Flex control module While running the motor in bypass mode compare the voltage displayed on the control module to a known accurate meter connected to the same source voltage as the motor the MV SMC Flex is controlling Parameter 106 MV Ratio may be changed up or down to match the Flex display to the external meter A small change in ratio can make a large change in the display so 5 units at a time is recommended Increasing the ratio will decrease the displayed voltage and visa versa 1 Remove any temporary jumpers or grounding devices used during commissioning 2 Check that all tools are removed from the equipment Any tools or hardware used or dropped during installation and commissioning must be retrieved and accounted for 3 Check that all barriers or covers removed during installation or com missioning have been securely mounted 4 Close and secure all doors and verify function of all interlocks that prevent access to medium voltage compartments when the unit is energized 5 controller is ready to power the motor Overview Keypad Description Programming Menu Chapter 4 Programming This chapter provides a basic understanding of the programming keypad built into the SMC Flex controller This chapter also describes programming the controller by modifying the parameters The keys found on the
84. V to 4160 V with LV panels not shown 23 BR 2 0 Installation 2 7 Power Cable Lugs Ground Bus Lug Figure 2 2 Incoming Line Cable Connections viewed from the rear with power bus access cover removed Cable Duct Barrier Cable Duct Boot Motor Cable Terminals Figure 2 3 Bottom Cable Exit Configuration with LV panel swung open 123 BAR 2 0 2 8 Installation Power Connections cont Bulletin 1560E Refer to Figures 2 4 to 2 6 to make power connections for a 1560E unit Note The CT assembly can be oriented to allow either top or bottom load cable exit Phase 2 Power Stack Assembly Phase 1 Power Stack Assembly Phase 3 Power Stack Assembly Line Connections Phase 1 top through 3 bottom Load Connections top exit shown Phase 1 front through 3 back Bypass Vacuum Contactor Current Transformers Figure 2 4 Power Connections 1560E 180 360A 2400 to 4160 V 23 BR 2 0 Installation 2 9 Phase 1 Line Connection Phase 1 Power Stack Assembly Phase 2 Line Connection Phase 2 Power Stack Assembly Load Connections top exit shown Phase 1 front through 3 back Phase 3 Current Transformers Power Stack Assembly Phase 3 Line Connection Voltage Sensing Module Bypass Vacuum Contactor Figure 2 5 Power Connections 1560E 180 360A 5500 to 6900 V 123
85. a thin film of electrical joint compound between base and mounting surface Available with SCR replacement parts or separately as Part Number 80025 783 51 1562E only Reference only 1503 For OEM products refer to OEM supplied documentation for specific spare parts list 1560 1562E are Allen Bradley manufactured starters Refer to Service Manual for specific spare parts list Used when options 13XG Stop Contrtol or 13XB Pump Control are not provided Used when options 13XG Stop Control or 13XB Pump Control are provided Not provided if IntelliVAC control is used refer to Publication 1503 UM051B EN P for spare part information on IntelliVAC ooo 60 1560E UMO050B EN P June 2013 Spare Parts D 3 Table D 3 Bulletin 1503E 1560E 1562E 2300 Volt 600 Amp 6 Device Qty per controller Description Part Number 3 Heatsink Assembly 600A with Thermistor 80187 326 51 R Note Due to stringent torquing specifications in this application itis MANDATORY that the entire heatsink assembly be replaced Contact the Rockwell Automation factory 3 SCR Gate Driver Board 80165 898 52 2 devices 80165 898 55 R 1 IGDPS Board 80026 044 02 R 1 Voltage Sensing Module 81000 199 55 R 1 MV SMC Interface Circuit Board 80190 440 01 R 6 Snubber Resistor 80025 642 04 R 3 Snubber Capacitor 1 0 UF 80025 812 01 R
86. ary Cheek saa e ose erede ta 3 3 Propramming nere ete apa uta roth teen Uo Pie 3 3 Hi Pot and Meseer Festu a aaa eene 3 4 Typical MV SMC Flex Power System Diagram 3 5 Connection and Test Information for Interface Board 3 6 Power Supply Tests itte tet Hte Eee tre ieget etie bien 3 7 Control Function Tests a anna aa nre 3 10 Resistance Checks eee 3 11 Voltage Sensing Module 3 11 Staft Up ba usa er Sages 3 12 Programming Chapter 4 OVERVIEW ane et nl de 4 1 Keypad Description sin sfc Rae h a uY 4 1 Programming 4 1 Menu Structure Hierarchy qas 4 2 Parameter Linear List unes e d e ien 4 4 PaSSWOr EL aa Su uu 4 5 Parameter Management 4 6 Parameter 4 8 NE Cd 4 9 Current Limit Statt ct tess ge RA a ei aoe 4 9 Dual Ramp Statt i pne Ete Eb rep n 4 10 Full Voltage Start a a n e teet initi eee eet 4 11 Linear Speed RS d Ue 4 11 Basic Setups ees eeu RC OR he edo i Nes 4 11 Motor Protections ie eter p D eu 4 13 Exarmple Settitigs eerte
87. atching not required 80156 893 71 R 360A 6 SCR DCR1020 or 5STP03D6500 matching not required 80156 894 71 R Common Components 3 SCR Gate Driver Board e 80165 898 52 R 2 devices 9 80165 898 55 R 1 IGDPS Board 80026 044 02 R 1 Voltage Sensing Module 81000 199 55 R 1 MV SMC Interface Circuit Board 80190 440 01 R 9 Snubber Resistor 80025 588 02 R 3 Snubber Capacitor 0 68 UF 4510 V peak 80025 812 02 R 3 Sharing Resistor 32 5 k 225 W Two 2 5 k Tap 80025 753 01 R 25m 80025 549 03 R 9 Fiber optic Cable 50m 80025 549 01 R 2 Bridge Rectifier 24808 451 01 R 120 V 80145 581 02 R 2 230 V 80145 581 07 1 Test P Siioni 120 V AC North America 80187 051 51 R SPL OWS SURRY Universal 80187 245 51 R 1 Contactor Relay Control 110 120 V AC 80154 991 59 R Panel 220 230 V AC 80187 226 52 3 Power Fuses Consult Engineering Data 2 CPT Primary Fuses Consult Engineering Data 1 LV Fuses Consult Engineering Data 3 Heater Elements Consult Engineering Data 2 20 Amp Contact Cartridge for Isolation Switch Auxiliary 700 CPM 3 1 pole Blade Assembly 400 Amp 80145 566 51 R Special Lubricant for Blade Assembly 400 Amp 80158 357 51 R If desired a complete factory assembled SCR heatsink assembly be purchased rather than individual SCRs See table below for part numbers Qty per controller Description Part Number 3 180 Amp 2400 Volt Controller 80187 302 51 3 360 Amp 2400 Volt Controller 80187 302 52 Requires
88. ation motor switching and overload and overcurrent protection When wired as shown in Figure C 4 the controller operates as follows When a Start is initiated in the existing motor controller and the contactor or breaker closes a contact must be supplied to tell the 1560E to start also A contact will apply control voltage to terminal 17 of the SMC Flex module When stopping the motor the contactor in the existing controller will open removing power from the motor and then the CR relay The bypass hold in rung will keep the bypass contactor closed for a short time The Fault contact on the SMC Flex module should be wired into the existing controller to trip the main contactor or breaker in the event of a fault condition sensed by the SMC Flex module If possible it is better to have the SMC Flex module control the main contactor directly In this case the control circuit would look like and function like the descriptions above for the Bulletin 1562E Bulletin 1560E Basic control With Controlled Stop When wired as shown in Figure C 5 the controller operates much the same as described above for the Standard module The control signal uses terminal 16 instead of 17 and a coast stop can be achieved by opening the connection to terminal 17 It is more important in this configuration to integrate the control circuit of the 1560E with the existing controller for better control of the Stop option Th
89. barriers are in place and securely fastened Environmental Considerations Maintenance 10 5 Hazardous materials Environmental protection is a top priority for Rockwell Automation The facility that manufactured this medium voltage product operates an environmental management system that is certified to the requirements of ISO 14001 As part of this system this product was reviewed in detail throughout the development process to ensure that environmentally inert materials were used wherever feasible A final review has found this product to be substantially free of hazardous material Please be assured that Rockwell Automation is actively seeking alternatives to potentially hazardous materials for which no feasible alternatives exist today in the industry In the interim the following precautionary information is provided for your protection and for the protection of the environment Please contact the factory for any environmental information on any material in the product or with any general questions regarding environmental impact Capacitor Dielectric Fluid The fluids used in the snubber capacitors are generally considered very safe and are fully sealed within the capacitor housings Shipping and handling of this fluid is not restricted under any regulations In the unlikely event that capacitor fluid leaks out avoid ingestion or contact with skin or eyes as slight irritation could result Rubber gloves are recommended for handl
90. be replaced If it isn t the interface board should be replaced 15602 5 June 2013 3 10 Commissioning Procedures 10 When each gate driver circuit has been checked disconnect the power supply and remove it from the cabinet NOTE Systems with optional Pump Control or Soft Stop include continuous gate drive power supplies IGDPS therefore step 10 does not apply The gate drive circuits operate at high voltage when the SMC is energized Failure to remove the portable test power supply will result in equipment damage and may cause severe injury or death 11 Open the switch SW2 on the interface board see Figure 3 3 before returning the unit to service Ensure the red LED is off ATTENTION If the SW2 switch is not in the open position when the SMC is energized the motor will start in an uncontrolled manner and may cause severe damage 12 Check that all plugs and connectors are secure Retrieve all hardware and tools from the equipment Replace and secure any barriers removed during servicing and close all doors before applying power Control Function Tests Servicing energized industrial control equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Recommended practice is to disconnect and lock out control equipment from power sources and allow any stored energy in capacitors to dissipate The safety related work p
91. cause radio interference in which case the installer may need to employ additional mitigation methods The following guidelines are provided for EMC installation compliance Enclosure Install the product in a grounded metal enclosure Wiring Wire in an industrial control application can be divided into three groups power control and signal The following recommendations for physical separation between these groups is provided to reduce the coupling effect Different wire groups should cross at 90 inside an enclosure Minimum spacing between different wire groups in the same tray should be 16 cm 6 in Wire runs outside an enclosure should be run in conduit or have shielding armor with equivalent attenuation Different wire groups should be run in separate conduits Minimum spacing between conduits containing different wire groups should be 8 cm 3 in For additional guidelines please refer to Wiring and Ground guidelines publication DRIVES IN001A EN P Wire earth ground to control terminal 14 Use shielded wire for PTC Input Tach Input Ground Fault Input Terminate shielded wires to terminal 14 Ground fault CT must be inside or within 3 m of metal enclosure Control Power Installation 2 19 To meet produce susceptibility requirements ferrite cores need to be added to the communication lines All cores specified below are the split core type so they can be added to existing connections
92. cont 15602 5 June 2013 Keep Good Maintenance Records This rule will be most helpful in locating possible intermittent problems by pointing to a particular area of recurring trouble within the overall system Furthermore good maintenance records will help reduce major costly shutdowns by demanding the use of proper test equipment and an appropriate inventory of spare parts For additional information see NFPA 70B RECOMMENDED PRACTICE FOR ELECTRICAL EQUIPMENT MAINTENANCE published by the National Fire Protection Association Power Components Power components should be kept clean and free of dirt and obstructions This will avoid tracking and heat build up thereby increasing the life of the device Control Components Electronic The printed circuit boards are to be kept clean and free of any accumulations of dirt and foreign materials Materials which create static electricity should never be allowed near circuit boards while in the unit or in storage Caution should be used when one is near or handling circuit boards There are no other requirements other than housekeeping standards that the maintenance program requires on the logic control components Fans Physically rotating and observing the fans for noise or binding will indicate if fan failure is evident Interlocks Verify that interlocks function as intended and have not been forced damaged or removed Barriers Verify that all
93. contains ESD electrostatic discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing the assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures refer to applicable ESD protection handbooks An incorrectly applied or installed controller can damage components or reduce product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION Only personnel familiar with the controller and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to do this may result in personal injury and or equipment damage Transportation and Handling The controller must be transported on a pallet or via use of the lifting angles supplied as part of all 90 inch 2 3 m high cabinets or frame units Ensure that the load rating of the lifting device is sufficient to safely raise the controller sections Failure to do so may result in severe injury and or equipment damage Refer to the packing slip enclosed with shipment for shipping weights Round rollers can be used to assist in moving the controller to the instal lation site Once at the final site the pipe rolling technique can be used to place the cabine
94. ct Overview 1 MAIN CONTACTOR BYPASS CONTACTOR MASTER CONTROL B IV START 13 His 13 olo o MODULE MODULE M IV STATUS STATUS CR 15 Hem CONTACTOR STATUS MC BYPASS CONTROL B IV BYPASS CONTROL AUX CONTACTOR STATUS MC FLEX TM CONTROL TERMINALS DPI O FAULT PTC TACH GROUND INPUT INPUT FAULT CONTACTOR STATUS FAIL SAFE MODULE STATUS FAIL SAFE AUX 1 UP TO SPEED ALARM H AUX 2 NORMAL 23 M IV 9 CLOSE MAIN CONTROL q MAIN CONTROL AUX FAN CIF SUPPLIED Figure 1 22 Bulletin 1562E IntelliVAC Control Circuit Without Stop Control 23 BR 2 0 Product Overview 1 33 P P EMC FILTER S0OVDC IGDPS BOARDS MAIN CONTACTOR BYPASS CONTACTOR MASTER CONTROL MODULE MODULE M IV STATUS STATUS CR CONTACTOR STATUS COAST STOP 4 BYPASS CONTROL MC BC CR 16 BYPASS CONTROL AUX CONTACTOR STATUS 11 14 19
95. ct a PTC to the SMC and enable a fault when it becomes active PTC Enable Phase Reversal Determines the proper orientation of line connections to the SMC If Enabled and phases are out of sequence a fault will be indicated Phase Reversal Restarts Allows the user to determine the maximum number of restarts per hour the unit can experience and delay time between consecutive starts Restarts Per Hour Restart Attempts Restart Delay Unbalance are enabled Protection group See Chapter 5 for instructions See details in Ground Fault on page 1 12 See details in Termistor PTC Protection on page 1 13 The delay time must be set to a value greater than zero when Undervoltage Overvoltage and For Jam and Underload detection to function the Motor FLC must be programmed in the Motor 1560E UMO50B EN P June 2013 4 14 Programming Example Settings 1560E UMO50B EN P June 2013 Undervoltage With Line Voltage programmed for 4160 V and the Undervoltage level programmed for 80 the trip value is 3328 V Overvoltage 6 With Line Voltage programmed for 3300 V and the Overvoltage level programmed for 115 the trip value is 3795 V Jam e With Motor FLC programmed for 150 Amps and the Jam level programmed for 40056 the trip value is 600 Amps Underload With Motor FLC programmed for 90 Amps and the Underload level programmed for 60 the trip value is 54 Amps The average valu
96. d Fit Level 73 A 1 0 5 0 2 5 Gnd Fit Delay 74 SEC 0 1 250 0 0 5 Ground Fault Gnd Fit Inh Time 75 SEC 2 25 10 Gnd Fit A Enable 76 Deve Disable Enable Gnd Fit A Lvl 77 1 0 5 0 2 0 Gnd Fit A Dly 78 SEC 0 250 10 PTC PTC Enable 79 Dieser Disable Enable Phase Reversal Phase Reversal 80 Disable Disable Enable Starts Per Hour 81 0 99 2 Restart Restart Attempts 82 0 5 2 Restart Delay 83 SEC 0 60 0 Comm Masks Logic Mask 87 8 bit binary Data In 1 88 Data In A2 89 Data In B1 90 Data In B2 91 Data In C1 92 Data In C2 93 Data In D1 94 Data In D2 95 pee Eins Data Out A 96 Data Out A2 97 Data Out B1 98 Data Out B2 99 Data Out C1 100 Data Out C2 101 Data Out D1 102 Data Out D2 103 Motor Data Motor ID 104 0 65535 0 1560E UM050B EN P June 2013 B 4 Parameter Information Table B 1 Parameter List cont yat Parameter Default User Group Parameter Description N mber Units Min Max Settings Settings CT Ratio 105 1 1500 MV Ratio 106 1 10000 Normal Up To Aux1 Config 107 Up to Speed Speed Basic Set Up Fault Contact 108 Ne NO NO Alarm Contact 109 NC NO NO Aux2 Config 110 NC NO English French Spanish Language Language 111 Carnan English Portuguese Mandarin Ready User Recall All Parameter Mgmt 115 User Store Ready Factory Default Basic Set Up Backspin Timer 116 SEC 0 999 0 Referto Chapter 3 Commissioning Procedures to
97. d as a Fused E2 Controller NEMA E2 2400 V 200 MVA Sym 4160 V 350 MVA Sym 4600 V 400 MVA Sym 6900 V 570 MVA Sym Control Circuit Rated Operation Voltage 120 240 V AC 15 10 110 230V 15 10 Dielectric Withstand 1600 V AC 2000 V Operating Frequency 50 60 Hz 50 60 Hz Enclosure Enclosure Type IP 10 21 52 and 34 NEMA Type 1 1G 12 and 3R Overload Characteristics Control Module Type Solid state thermal overload with phase loss Current Range 1 0 1 000 Amps Trip Classes 10 15 20 and 30 Trip Current Rating 12096 of Motor FLC Number of Poles 3 Power Requirements Control Module 75 Gate Driver Boards Self powered Contactor See Contactor Specifications page 35 Auxiliary Contacts Control Module 20 265 V 20 265 V Rated Operation Voltage Ma 5 30 V DC resistive 5 30 V DC resistive Rated Insulation Voltage N A 277 V Operating Frequency 50 60 Hz DC 50 60 Hz DC Utilization Category 300 nes 30 VDC 0 88A pilot duty DC 12 Mechanical Ratings Control Module Control Terminals 3 5 x 0 6 Pozidriv screw with self lifting clamp plate SCPD Performance Type 2 SCPD List Class CC 8A 1000 A Available Fault Current DPI Communication Control Module Maximum Output Current 280 mA Metering Functionality Control Module Voltage Current MW MWh Yes
98. d from the SMC Flex controller while the Logic Mask is set to 1 a Coms Loss will occur For ease of programming values after using the Enter key to edit use the Sel key to jump to the digit that needs to be modified then use the arrow keys to scroll through the digits The Bulletin 20 HIM LCD interface modules may be used to program and control the SMC Flex controller The human interface modules have two sections a display panel and a control panel The display panel duplicates the 3 line 16 character backlit LCD display and programming keypad found on front of the SMC Flex controller Refer to Chapter 4 for a description of the programming keys refer to Appendix E for a listing of human interface module catalog numbers that are compatible with the controller Note Note Note Bulletin 20 HIM Rev3 002 or later must be utilized with the SMC Flex Extension cables are available up to a maximum of 10 m in total length A maximum of two HIM modules can be installed Communications 8 3 The control panel provides the operator inteface to the controller Start The green start button when pressed will begin motor operation Proper setup of the HIM port is required Stop The red stop button when pressed will halt motor operation and or reset a fault Jog Jog The jog button is active only when a control option is present Pressing the jog button The Bulletin 20 HIM interface module s stop
99. determine the appropriate setting This parameter does no 15602 5 June 2013 appear for MV applications Functional Description Appendix C 1560E and 1562E Relay Control The following functional descriptions and associated control circuits are for units using electromechanical relay control Bulletin 1562E Basic Control Controlled Start only When wired as shown in Figure C 1 the controller operates as follows Pressing the Start button initiates the start sequence Relay CR closes and applies control power to terminal 17 of the SMC Flex module The auxiliary contact 2 set for normal closes picking up MC which completes the hold in circuit on the start button and closes the main contactor The SMC Flex module examines the line voltage looks for fault conditions checks phase rotation calculates zero crossing information and begins gating the SCRs to start the motor When the motor approaches rated speed the SMC Flex module closes the AUX1 up to speed auxiliary contacts closing relay BC which closes the bypass contactor The motor then runs at full line voltage When the Stop button is pressed the CR relay opens terminal 17 on the SMC Flex module The AUX2 Normal contact opens dropping out the main contactor allowing the motor to stop The AUXI contact also opens but BC is held closed for a short time by the control module This holds the bypass contacto
100. e start signal for this scheme cannot be a slave of the main contactor since it must remain closed to accomplish the option stop maneuver The SMC Flex module can be used to control the main contactor such that it will close when a start is initiated and remain closed until it has sensed the motor has stopped following an option stop maneuver Bulletin 1560E DPI Control Controlled Start only Refer to Figure C 6 and description on page 1 31 15602 5 June 2013 4 1560E and 1560E Relay Control MAIN CONTACTOR MC MC RECTIFIER REC MOV 1 MOV BYPASS CONTACTOR RECTIFIER REC MOV 2 MASTER CONTROL BYPASS CONTROL SMC FLEX TM CONTROL TERMINALS AUX 1 UP TD SPEED DPI AUX2 FAULT ALARM NORMAL PTC TACH GROUND INPUT INPUT FAULT CONTACTOR STATUS FAIL SAFE MODULE STATUS FAIL SAFE MAIN CONTROL FAN QF SUPPLIED Figure 1 Bulletin 1562E Relay Control Circuit Without Stop Control 1560E UMO50B EN P June 2013 1560E and 1560E Relay Control C 5 50 0 IGDPS BOARDS ME RECTIFIER REC MOV 1 MAIN CONTACTOR BE BE BE RECTIFIER REC MOV 2 BYPASS CONTACTOR COAST STOP START L E MC CR AA MASTER CONTROL BYPASS CONTROL SMC FLEX TM
101. e Option 2 Input Dual Ramp Parameter Option SetUp The user must select the Set Up programming mode to obtain access to the Dual Ramp parameters Basic Set Up Starting Mode Set up as stated in previous pages Option 1 Input Dual Ramp This allows the user the option to choose between two Soft Start profiles defined by 1 Start Mode Ramp Time Initial Torque and 2 Start Mode 2 Ramp Time 2 Initial Torque 2 When this feature is turned on the ramp time initial torque combination is determined by a hard contact input to terminal 15 When this input signal is low ramp time initial torque 2 are selected Once the Option 2 Input has been set to Dual Ramp you must ESC back to the Parameter File menu Re enter into the Set Up menu to show both Basic Set Up and Dual Ramp Basic Set Up Start Mode This selects the start mode for option 1 Basic Set Up Ramp Time This programs the time period during which the controller will ramp the output voltage up to full voltage for the first Start setup 0 to 30s Basic Set Up Initial Torque This parameter establishes and adjusts the initial reduced output voltage level for the first Soft Start setup 0 to 90 locked rotor torque Dual Ramp Start Mode 2 This selects the start mode for option 2 Dual Ramp Ramp Time 2 This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Star
102. e SMC Flex module will initiate the option stop An uncontrolled or coast stop is achieved by opening the connection to terminal 17 This contact should remain open to ensure all hold in contacts clear to prevent a re start If the motor has started the unit is in the bypass mode and a trip occurs within the SMC Flex module or from an external protection relay AUX2 will open the line contactor immediately and AUX1 will remain closed for 10 seconds A trip due to an overload or fault condition will result in a coast stop Bulletin 1562E DPI Control Controlled Start only The control scheme shown in Figure 1 24 allows the MV SMC Flex to be controlled using DPI Drive Programming Interface This special usage of DPI includes provisions for Hand mode of control as well With the Hand Auto selector switch in the Auto position terminal 18 of the SMC Flex module is energized allowing a start command to be executed via DPI The AUX2 contact closes energizing both M IV and MC When the motor approaches rated speed the SMC Flex module closes AUXI energizing B IV which closes the bypass contactor To run in Hand mode the CR contact is used to initiate a start sequence similar to Figure 1 22 A stop command can be generated via DPI or by opening CR depending on the control mode 123 B RJ 2 BKMTG ki 0 1 30 Product Overview Functional Description cont 23
103. e incoming power to the SMC Flex controller is in any sequence other than ABC This pre start protective feature can be disabled The SMC Flex controller disables control through the serial communication port as the factory default To enable control the Logic Mask found in the Communication programming group must be set to 4 With Series B human interface modules this can also be accomplished by enabling control logic through the Coms Loss Control Status programming group If a Bulletin 20 HIM Human interface module or Bulletin 1203 communication module is disconnected from the SMC Flex controller when control is enabled a Comm Fault will occur N tioik Network faults are faults generated on the network external to the SMC Flex and are annunciated on the LCD display Ground Fault Ground faults are based on feedback from the user supplied 825 CT detecting ground fault currents Ground fault parameters of level and time delay must be programmed for proper operation Excess Starts Hour Excess starts hour is displayed when the number of starts in a one hour period exceeds the value programmed Power Loss Power loss indicates that an input power phase is not present The controller s LCD display will identify the missing phase If all three phases are absent when a start command is issued the LCD will display Starting without motor rotation Phase loss overvoltage and undervoltage protection are d
104. e of the three phase to phase voltages is utilized O Thelargest value of the three phase currents is utilized rogrammin 4 15 Motor Information The Basic Set Up and Overload programming group allows the user to set parameters indicating to the controller which motor is connected It is important to correctly input the data to achieve the best performance from your controller ATTENTION For overload protection it is critical that the data be entered as it appears on the motor nameplate Motor Data Entry In the Program mode enter the correct values into the Overload group Description Option Display Overload Class 00 Disable 10 15 20 F 44 The factor default setting disables 30 Overload Class overload protection To enable it enter CESSE the desired trip class in this parameter Service Factor 0 01 to 1 99 PEAS Enter the value from the motor s Serice nameplate Motor FLC 1 0 to 1000A PRAG Enter the value from the motor s orne Am nameplate Overload Reset Manual Auto mE Allows the user to select either a manual Reset or auto reset after an overload Motor Connection Line Delta SH Pris Enter the type of motor being connected to the SMC Flex Line Delta Line Voltage 1 to 10 000 V o P 16 Enter the system voltage in this 1 Volt parameter This must be done to ensure
105. e value Consult factory if more than 2 starts per hour are programmed required Power 1055 35 36 37 Missing supply phase as indicated Check for open line i e blown line fuse with phase indication Loss of feedback Check CT connections replace Interface board Hall ID 38 Faulty interface Check ribbon cable connections between interface board and control module Replace interface board NVS Error 39 Data entry error Check user data and perform a User Store function Replace control module System Faults 128 to 209 Control module internal fault Cycle control power to reset the control module persists replace control module Prestart fault indication Table 9 B Motor Will Not Start No Output Voltage to the Motor Display Fault displayed Possible Causes See fault description Possible Solutions See Table 9 A addressing fault conditions Display is blank Control voltage is absent Failed control module Check control wiring and correct if necessary Replace control module Stopped Pilot devices Check wiring 0 0 Amps SMC Enable input is open at Check wiring terminal 13 Terminal 16 is open Check wiring Start Stop control has not been Follow the instructions on page 2 16 to 2 18 enabled for the human interface to enable control capability module Control voltage Check control voltage Failed control module Replace control module Starting
106. ection intervals should be based on environmental and operating conditions and adjusted as indicated by experience An initial inspection within 3 or 4 months after installation is suggested Applicable parts of the following guidelines should be used Contamination If inspection reveals that dust moisture or other contamination has reached the control equipment the source must be eliminated This could indicate an incorrect or ineffective enclosure unsealed enclosure openings conduit or other or incorrect operating procedures Dirty wet or contaminated parts must be replaced unless they can be cleaned effectively by vacuuming or wiping 1560E UMO50B EN P June 2013 10 2 Maintenance Periodic Inspection cont 15602 5 June 2013 Allen Bradley magnetic starters contactors and relays are designed to operate without lubrication do not lubricate these devices since oil or grease on the pole face mating surfaces of the operating magnet may cause the device to stick in the ON mode Erratic operation can result with injury or death Some parts of other devices are factory lubricated if lubrication during use or maintenance of these devices is needed it will be specified in their individual instructions If in doubt consult the nearest Rockwell Automation sales office for information Vacuum Bottles The contacts in a vacuum bottle cannot be seen or examined directly They rely on the high vacu
107. elected 50 to 600 FLC Kickstart Time A boost current is provided to the motor for the programmed time period 0 0 to 2 0 s Kickstart Level Adjusts the amount of current applied to the motor during kickstart 0 to 90 of locked rotor torque Option 2 Input Allows the user to select a Dual Ramp or Preset Slow Speed SS Disable Preset SS Dual Ramp Emergency Run Stop Mode Disable Soft Stop Allows the user to program the SMC Flex controller Linear Speed for the type of stopping that best fits the application Stop Time 0 0 to 1205 This sets the time period which the controller will ramp the voltage during a stopping maneuver CT Ratio 1 to 1500 Scales the CT input to actual motor current 5 amp secondary assumed Aux1 Config N O contact is provided as standard with the SMC Flex controller This contact is located at terminals 19 and 20 Aux Contacts 1 allows the user to configure the operation of the contacts Normal Up to speed Bypass Fault Contact A fault auxiliary contact is provided between terminals 29 and 30 Fault Contact allows the user to program the operation of the contact for a fault condition N O N C Alarm Contact An alarm contact is provided between terminals 31 and 32 Alarm contact allows the user to program the operation of the contact for an Alarm condition N O N C Aux2 Config This parameter provides the user with the ability to p
108. embly can be purchased rather than individual SCRs See table below for part numbers Qty per controller Description Part Number 3 180 Amp 3300 4160 Volt Controller 80187 305 51 3 360 Amp 3300 4160 Volt Controller 80187 305 52 Requires a thin film of electrical joint compound between base and mounting surface Available with SCR replacement parts or separately as Part Number 80025 783 51 1562E only Reference only 1503 For OEM products refer to OEM supplied documentation for specific spare parts list 1560 1562E are Allen Bradley manufactured starters Refer to Service Manual for specific spare parts list Used when options 13XG Stop Control or 13XB Pump Control are not provided Used when options 13XG Stop Control or 13XB Pump Control are provided Not provided if IntelliVAC control is used refer to Publication 1503 UM051B EN P for spare part information on IntelliVAC oo 1560E UMO050B EN P June 2013 Spare Parts D 5 Table D 5 Bulletin 1503E 1560E 1562E 3300 and 4160 Volt 600 Amp 12 device Qty per controller Description Part Number 3 Heatsink Assembly 600A with Thermistor 80187 309 51 R Note Due to stringent torquing specifications in this application itis MANDATORY that the entire heatsink assembly be replaced Contact the Rockwell Automation factory 3 SCR
109. en options 13XG Stop Control or 13XB Pump Control are provided Not provided if IntelliVAC control is used refer to Publication 1503 UM051B EN P for spare part information on IntelliVAC 1560E UMO50B EN P June 2013 D 6 Spare Parts Table D 6 Bulletin 1503E 1560 1562 5500 6900 Volt 180 360 Amp 18 device Qty per controller Description Part Number 180 6 180A Matched Set 3 SCRs DCR820 or 5STPO3D6500 80156 893 73 R 360A 6 360A Matched Set 3 SCRs DCR1020 or 5STP08G6500 80156 894 73 R Common Components 9 SCR Gate Driver Board e 80165 898 52 R 2 devices e 80165 898 55 R 3 IGDPS Board 80026 044 03 R 1 Voltage Sensing Module 81000 199 55 R 1 MV SMC Interface Circuit Board 80190 440 01 R 9 Snubber Resistor 80025 760 02 R 9 Snubber Capacitor 0 68 UF 80025 812 02 R 9 Sharing Resistor 32 5K 225W 80025 753 01 R 2 5m 80025 549 03 R 21 Fiber optic Cable 50m 80025 549 01 R 2 Bridge Rectifier 9 24808 451 01 R 120 V 80145 581 02 R 2 230 V 80145 581 07 Test Power Supply 120V AC North America 80187 051 51 R Universal 80187 245 51 R 6 Voltage Divider Resistors 74K 100W 80025 588 05 R P Contactor Relay Control 110 120 V AC 80154 991 59 R Panel 220 230 V AC 80187 226 52 3 Power Fuses Consult Engineering Data 2 CPT Primary Fuses Consult Engineering Data 1 LV Fus
110. en pressed will initiate a Jog brake stop Accu Stop The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault With a stopped status the jog button when pressed will initiate slow speed motor operation From an at speed condition the jog button when pressed will initiate braking to slow speed operation The controller will maintain slow speed operation as long as the jog button is pressed Jog Slow Speed with Braking The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button will initiate a brake stop Slow Speed cannot be operated via the HIM Jog 9 assistance ATTENTION 1560E UM050B EN P June 2013 Braking Control is not offered for standard use in MV applications Please consult factory for further The Bulletin 20 HIM interface module s stop push button is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements Options 6 3 Programming Parameters The following table provides the option specific parameters that are provided with each control option These parameters are in addition to those already discussed in the Basic Set Up and Metering groups Diagrams
111. enabled Two HIMs on ports 2 and 3 and the DP communication card on port 5 are enabled 36 44 The Logic Mask parameter Parameter 87 allows the user to configure whether a communication device HIM or network connection can perform control commands such as starting Each communication port can be enabled or disabled as required When a given device is enabled through the logic mask that device is allowed to execute control commands In addition disconnecting any device with the logic mask enabled will result in acommunication fault unless the communication fault is disabled When a given device is disabled through the logic mask that device cannot execute control commands but can still be used for monitoring A device that is disabled through the logic mask can be disconnected without causing a fault Stop commands override all start commands and can be initiated from the hardwired inputs or any port regardless of the logic mask The loss of communication fault will follow the functionality as defined in the DPI specification There will be separate faults for each device Since three DPI ports are supported there will be three faults that can be generated DPI provides a separate network fault for each port This fault can be generated directly by the peripheral and is separate from the Communications Loss fault which is actually generated by the SMC Flex itself The SMC is can be used with all LCD applicable DPI interface
112. er a bad connection to the board or a defective output module If all six 6 LEDs are not illuminated measure the input power to the IGDPS board s It should be 50 V DC 8 V DC Record the following measurements to ensure all six 6 outputs are functioning They should be within 1 of 20 V Table 9 G Test Point Measurement Values Measured Value Test Points pected Value Board 1 Board 3 Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Pin1 gt Pin2 Pin 1 Pin2 Pin 1 gt Pin2 Pin 1 gt Pin2 Pin 1 gt Pin2 Pin 1 gt Pin2 S J ews 20 V DC There may be more than one IGDPS board Record output voltages for all of them Troubleshootin 9 11 Circuit Board Replacement The replacement of printed circuit boards is straightforward however there are a number of precautions which must be considered when handling the boards Some circuit boards may contain CMOS components which can be destroyed by static charges generated by friction of materials made with synthetic fibres Use of damaged circuit boards may also damage related components A grounding wrist strap is recommended for handling sensitive circuit boards 1 Remove all power from the equipment To avoid shock hazard ensure the main power has been disconnected before worki
113. erences menu Uc ESL Scroll with the Up Down keys Pros until the Change Password A Change d option is highlighted Press the Enter key Press the Up Down keys to enter the desired number If you are Prefs Password modifying the password make a rs etl note of it as displayed Verification of the new password is required Press the Enter key Press the Enter key after you have completed modifying the password After you have changed your password go to Parameter Management and Save to User Store To complete the programming process re enter the Main Menu mode to log out This will eliminate unauthorized process to the programming system Note If you lose or forget the password contact your nearest Rockwell Automation sales office You can also call Rockwell Automation Medium Voltage Product Support at 1 519 740 4790 for assistance 1560E UMO50B EN P June 2013 4 6 Programmi Parameter Management 1560E UMO50B EN P June 2013 Before you begin programming it is important to understand how the controller memory is structured within the SMC Flex controller used on power up and during normal operation Refer to Figure 4 3 and explanations below EEPROM h RAM ROM OUT Figure 4 3 Memory Block Diagram Random Access Memory RAM This is the work area of the controller after it is powered up When you modify parameter
114. es Consult Engineering Data 3 Heater Elements Consult Engineering Data 2 20 Amp Contact Cartridge for Isolation Switch Auxiliary 700 CPM 3 1 pole Blade Assembly 400 Amp 80145 566 51 R Special Lubricant for Blade Assembly 400 Amp 80158 357 51 R desired a complete factory assembled SCR heatsink assembly can be purchased rather than individual SCRs See table below for part numbers Qty per controller Description Part Number 3 180 Amp 6900 Volt Controller 80187 277 51 3 360 Amp 6900 Volt Controller 80187 277 52 1562E only Reference only Requires a thin film of electrical joint compound between base and mounting surface Available with SCR replacement parts or separately as Part Number 80025 783 51 1503E For OEM products refer to OEM supplied documentation for specific spare parts list 1560 1562E are Allen Bradley manufactured starters Refer to Service Manual for specific spare parts list Used when options 13XG Stop Control or 13XB Pump Control are not provided Used when options 13XG Stop Control or 13XB Pump Control are provided Not provided if IntelliVAC is used refer to Publication 1503 UM051B EN P for spare part information on IntelliVAC 1560E UMO50B EN P June 2013 Spare Parts D 7 Table D 7 Bulletin 1503E 1560 1562 5500 6900 Volt 600 Amp 18 device Qty per controller Description Part Number
115. es not offer the analog Reference feature The analog Feedback feature is supported and will provide Parameter 1 Current in Phase A automatically as the feedback word A complete listing of the SMC Flex parameters is located in Appendix B The parameter values stored and produced by the SMC Flex through communication are unscaled numbers When reading or writing values from a PLC image table it is important to apply the proper scaling factor which is based on the number of decimal places Read Example Parameter 11 Power Factor The stored value is 85 Since this value has two decimal places the value should be divided by 100 The correctly read value is 0 85 Write Example Parameter 46 Motor FLC The value which is to be written to the SMC is 75 A Since this value has one decimal place the value should be multiplied by 10 The correctly written value is 750 Some parameters have text descriptions when viewed from a HIM or through a communication software program such as RSNetworxO When receiving or sending information from a PLC each text description has a numerical equivalent Table 8 1 has an example of Parameter 44 Overload Class and the appropriate relationship between the text descriptor and the equivalent value This relationship is identical for other similar parameters located in Appendix B Table 8 1 Text Descriptor Numerical Equivalent Disabled 0 Class 10 1 Class 15 2 3 4 Class 20 Clas
116. et 20 COMM D ControlNet 20 COMM C EtherNet 20 COMM E Appendix E 1560E UMO50B EN P June 2013 E 2 Accessories 1560E UMO50B EN P June 2013 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 120 South Second Serwer Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europc Middle East Africa Rockwell Automation Vorsdlaan Boulevand du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberpart 100 Cyberpurt Road Hong Kang Tel 852 2887 4788 Fax 852 2808 i846 Medium Voltage Business 135 Dundas Street Cambridge 5X1 Canada Tel 1 519 623 1810 Fax 1 519 623 8930 Web Site www ab com mvb Publication 1560E UM050B EN P June 2013 2013 Rockwell International Corporation All rights reserved Printed in Canada Supersedes Publication 1560E UM050A EN P August 2004
117. fault conditions D Provide for electrical interference suppression Important Generally grounding should be in accordance with the Canadian Electrical Code CEC or National Electrical Code NEC and other local codes Each power feeder from the substation transformer to the controller must be equipped with properly sized ground cables Simply utilizing the conduit or cable armour as a ground is not adequate The conduit or cable armour and ground wires should be bonded to ground at both ends Each enclosure and or frame must be bonded to ground at a minimum of two locations Each AC motor frame must be bonded to grounded building steel within 20 feet 6 1 m of its location and tied to the controller s ground bus by ground wires within the power cables and or conduit The conduit or cable armour should be bonded to ground at both ends Any instruments used for test or troubleshooting should have their case connected to ground for safety Failure to do so may result in damage to equipment or personal injury When reinstalling components or when reassembling the cabinet tighten the following bolt sizes to the specified torque values 1 4 in hardware 6 ft lb 8 N m 5 16 in hardware 12 ft lb 15 N m 3 8 in hardware 20 ft lb 27 N m 1 2 in hardware 48 ft lb 65 N m NOTE For 3 8 in hardware the T slots of aluminum heatsinks the recommended torque is 16 ft lb 22 N m Do not overtorque t
118. figuration 8 7 SMC Flex Bit Identification sess 8 8 Reterence Peedbaek iiie te e et Herten 8 0 Parameter Information ss 8 9 Scale Factors for PLC Communication 8 9 Display Text Unit Equivalents 2 8 9 Configuring g cet cig 8 10 Updating Firmware sis ertet hte ce oa 8 10 1560E UMO50B EN P June 2013 Table of Contents MV Dialog Plus Medium Voltage Controller User Manual Troubleshooting Chapter 9 Page General Notes and 9 1 Fault Display 9 3 Control Module Removal ss 9 6 Voltage Feedback Circuit Tests 9 7 Voltage Sensing Board Replacement 9 8 IGDPS Boards zc ree o ne itus 9 9 IGDPS Board LEDS Pete tette teens 9 10 Circuit Board Replacement sese 9 11 Power Circuit Troubleshooting eee 9 12 Thyristor SCR Testing 9 12 SCR Replacement Procedure 9 13 Snubber and Resistor Circuit Testing 9 27 Snubber Resistor Replacement 9 30 Wanne Diasrams sise eee 9 31 Maintenance Chapter 10 Safety and Preventative 8444 10 1 Periodic Inspection x RE CHEER ass 10 1
119. ge induction motor Check load conditions Erratic operation Loose connections Shut off all power to controller and check for loose connections Accelerates too fast Starting time Increase starting time Initial torque Lower initial torque setting Current limit setting Decrease current limit setting Kickstart Lower kickstart time or turn off Accelerates too slow Starting time Decrease starting time Initial torque ncrease initial torque setting Current limit setting ncrease current limit setting Kickstart Increase kickstart time or turn off Fan does not operate Wiring Check wiring and correct if necessary Failed fans s Replace fan s Motorstops too quickly Time setting Verify the programmed stopping time and correct if with Soft Stop option necessary Motor stops too slowly Stopping time setting Verify the programmed stopping time and correct if with Soft Stop option necessary Misapplication The Soft Stop option is intended to extend the stopping time for loads that stop suddenly when power is removed from the motor Fluid surges with pumps still occur with the Soft Stop option Misapplication Soft Stop ramps voltage down over a set period of time In the case of pumps the voltage may drop too rapidly to prevent surges A closed loop system such as Pump Control would be more appropriately suited Refer to Publication 150 911 Motor overheats Overl
120. he installer to define the time period a ground fault alarm condition must be present before a trip occurs It is adjustable from 0 1 to 25 seconds Thermistor PTC Protection The MV SMC Flex provides terminals 23 and 24 for the connection of positive temperature coefficient PTC thermistor sensors PTC sensors are commonly embedded in motor stator windings to monitor the motor winding temperature When the motor winding temperature reaches the PTC sensor s temperature rating the PTC sensor s resistance transitions from a low to high value Since PTC sensors react to actual temperature enhanced motor protection can be provided to address such conditions as obstructed cooling and high ambient temperatures The following table defines the MV SMC Flex PTC thermistor input and response ratings Product Overview 1 15 Table 1 A PTC Input Ratings Response Resistance 34000 1500 Reset Resistance 1600 0 1000 Short circuit Trip Resistance 250 100 Maximum Voltage at PTC Terminals 4 15V Maximum Voltage at PTC Terminals Rerc open 30V Maximum Number of Sensors 6 Maximum Cold Resistance of PTC Sensor Chain 15000 Response Time 800 ms The following figure illustrates the required PTC sensor characteristics per IEC 34 11 2 4000 1330 550 250 100 Figure 1 13 Sensor Characteristics per IEC 34 11 2 PTC Trip The MV SMC Flex will trip with a P
121. hese connections as the slots will be damaged and the connection will be compromised Power Connections Installation 2 5 The controller requires a three phase supply and an equipment grounding conductor to earth ground A neutral conductor of the three phase supply is not necessary and is usually not routed to the controller Three phase wiring will connect the controller to the motor Bulletin 1562E The Bulletin 1562E unit is available in two main configurations 1 A modified two high cabinet 180 360A 2400 to 4160 V 2 combination of a one high full voltage non reversing FVNR cabinet and a 1560E unit 600A 2400 to 4160 V and 180 360 600A 5500 to 6900 V To make power connections for a two high cabinet refer to Figures 2 1 to 2 3 and Publication 1500 UMOSSB EN P Chapter 2 To make power connections for a one high FVNR cabinet and a 1560E unit proceed as follows Make line connections within the one high cabinet Make load connections at the 1560E CT terminals refer to Figure 2 5 or 2 6 23 BR 2 BK MTG KH 0 2 6 Installation Power Connections cont Power Stack Assembly Bypass Vacuum Contactor Voltage Sensing Module Non Load Break Isolation Switch Load Cable Connection Point top exit Line Vacuum Contactor Current Transformers Figure 2 1 Cabinet Layout 1562E 180 360 2400
122. ication Pump Start Soft Start Current Limit Start Full Voltage 1560E UM050B EN P June 2013 6 4 Options Programming Parameters cont 1560E UMO50B EN P June 2013 Option Parameter Range Braking Control SMB Smart Motor Braking SMC Option This parameter identifies the type of control present and is not user programmable Braking Control Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 400 of full load current Accu Stop SMC Option This parameter identifies the type of control present and is not user programmable Braking Control Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 High 15 Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the required current to operate the motor at slow speed operation 0 400 of full load current Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 400 of full load current Stopping Current Allows the user to program the intensity of the braking current applied to the motor from slow speed operation 0 400 of full load current Slow Speed with Braking SMC Option This parame
123. igure 4 2 TheSMC Flex controller does not support EEPROM Link Process or Start up modes Steps back one level Shown if password protection is configured Figure 4 1 Menu Structure Hierarchy 1560E UMO50B EN P June 2013 rogrammin 4 3 Parameter Parameter Mgt Alarm Contact Parameter Mgt Aux2 Config PTC Backspin Timer Overvoltage Parameter Mgt O PTC Enable Overvolt F Lvl Parameter Mgt Dual Ramp Option 2 Overvolt F Dly Input Dual Ramp Starting Mode 2 Overvolt A Lvl Ramp Time 2 Overvolt A Dly iras Reversal Initial Torque 2 Parameter Mgt Phase Reversal Cur Limit Lvl 2 Parameter Mgt Kickstart Time 2 Unbalance Restart Unbalance F Lvl Starts Per Hour Preset SS Option 2 Unbalance F Dly Restart Attempts Input Preset SS Unbalance A Lvl Restart Dly Slow Speed Sel Unbalance A Dly Parameter Mgt Slow Speed Dir Parameter Mgt Slow Speed Acc Slow Running Cur Parameter Mgt Option 2 Input Accu Stop Braking Current Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cu Stopping Current Parameter Mgt O Metering Basic Overload Jam Comm Masks Language Linear List Volts Phase A B SMC Option Overload Class Jam F Lvl Logic Mask Language All parameters Volts Phase Mo
124. ilowatt Hours 8 KWH MWH Elapsed Time 9 Hours Ready Meter Reset 10 ETM Reset Ready KWH Reset Power Factor 11 0 00 0 99 Mtr Therm Usage 12 0 100 Motor Speed 13 0 100 Standard SMC Option 14 Brake Pump Control Motor Connection 15 Line Delta Line Line Voltage 16 V 0 10000 480 Full Voltage Starting Mode 17 Soft 4 Soft Start Pump Start Basic Set Up Ramp Time 18 SEC 0 30 10 Initial Torque 19 LRT 0 90 70 Cur Limit Level 20 FLC 50 600 350 Torque Limit 21 LRT 0 100 90 Kickstart Time 22 SEC 0 0 2 0 0 0 Kickstart Level 23 LRT 0 90 0 Disable Option 2 Input 24 m IE Disable Emergency Run Full Voltage Starting Mode 2 25 Current Limit Soft Start Soft Start Linear Speed Ramp Time 2 26 SEC 0 30 10 Dual Ramp Initial Torque 2 27 LRT 0 90 70 Cur Limit Level 2 28 FLC 50 600 350 Torque Limit 2 29 LRT 0 100 90 Kickstart Time 2 30 SEC 0 0 2 0 0 0 Kickstart Level2 31 LRT 0 90 0 Pump modules do not display this parameter Default setting for MV applications is Emergency Run 1560E UM050B EN P June 2013 B 2 Parameter Information Table B 1 Parameter List cont Group Parameter Description kala I Units Min Max XE Disable Soft Stop Basic Set Up Stop Mode 32 aes ne Disable Accu Stop Stop Time 33 SEC 0 120 0 Basic Set Up Accu St
125. independently from the starting time The load will stop when the output voltage drops to a point where the load torque is greater than the developed motor torque Percent Voltage 100 y Kickstart I 1 1 gt Coast to rest Soft Stop Initial Torque Stt Run 9 Soft Stop gt Time seconds Figure 1 8 Soft Stop Option Note Consult factory if settings over 30 seconds are required The base rating of the MV SMC Flex is two starts or one start stop combination per hour thirty seconds maximum for each operation A stopping operation counts as a start for purposes of thermal capacity calculations 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 Protection and Diagnostics Product Overview 1 9 The MV SMC Flex controller is capable of providing the following protective and diagnostic features Overload The MV SMC Flex controller meets applicable requirements as a motor overload protection device Thermal memory provides added protection and is maintained even when control power is removed The built in overload algorithm controls the value stored in Parameter 12 Motor Thermal Usage see Chapter 4 Programming An Overload Fault will occur when this value reaches 100 The paramete
126. ing To clean up soak into an absorbent material and discard into an emergency container Do not dispose into any drain or into the environment in general or into general landfill refuse Dispose of according to local regulations If disposing of an entire capacitor the same disposal precautions should be taken Printed Circuit Boards All printed circuit boards utilize lead based solder Shipping and handling of these boards is not restricted under any regulations however lead is considered a hazardous substance Circuit boards must be disposed of according to local regulations and must not be disposed of with general landfill refuse 1560E UMO50B EN P June 2013 10 6 Maintenance Environmental Considerations cont 15602 5 June 2013 Chromate Plating Some sheet steel and fasteners are plated with zinc and sealed with a chromate based dip gold coloured finish Shipping and handling of chromate plated parts is not restricted under any regulations however chromate is considered a hazardous substance Chromate plated parts must be disposed of according to local regulations and must not be disposed of with general landfill refuse In Case Of Fire This product is highly protected against arcing faults and therefore it is very unlikely it would be the cause of a fire In addition the materials used are self extinguishing i e they will not burn without a sustained external flame If however the pr
127. ion Replace the shorting bar Torque hardware to 30 N m 20 ft lb For 3 8 in hardware in the slots of aluminum heatsinks the recommended torque is 22 N m 16 ft lb Do not overtorque these connnections as the slots will be damaged and the connection will be compromised 123 B RJ 2 BKMTG 0 9 16 Troubleshooting Power Circuit Troubleshooting cont 23 BR 2 25 0 SCR Replacement Procedure cont C Install Refurbished Stack 1 Inspect all connections on the module Inspect wire insulation and components for damage 2 Install the module in the cabinet Watch for power cables and fibre optic cables as module is slid into place Tighten locking nuts at the bottom of the module 3 Connect power cables and tighten hardware to 30 20 ft lb 4 Install gate driver board ensuring that the locking tabs on the nylon circuit board supports are all engaged Plug in thermistor and gate connectors and reconnect wires to the left side of the board Plug in the fibre optic cables 5 Make sure all connections are secure Perform resistance checks according to instructions on Thyristor SCR Testing page 9 12 and test gate drive circuits by performing power supply tests in Chapter 3 page 3 6 9 17 Troubleshootin 0 4 Ge N 4 RY n e A lige TER SJ 33 a g Ps 1 d Ki Y
128. isabled during braking operation detection and underload protection are disabled during slow speed and braking operation e Additional details regarding fault definitions can be found in Chapter 1 Product Overview 1560E UM050B EN P June 2013 Overview Communication Ports Human Interface Module Chapter 8 Communications The SMC Flex provides advanced communications capabilities that allow it to be started and stopped from multiple sources as well as provide diagnostic information through the use of communication interfaces The SMC Flex uses the DPI method of communication therefore all standard DPI communication interfaces used by other devices i e PowerFlex Drives can be used in the SMC Flex Standard DPI communications cards are available for various protocols including DeviceNet ControlNet Remote I O ModBus and Profibus DP Other modules may be available in the future For specific programming examples configuration or programming information refer to the user manual for the communication interface being used A list of available interfaces is located below Table 8 A Communication Interfaces Protocol Type Cat No User Manual DeviceNet 20 COMM D 20COMM UM002Q EN P ControlNet 20 COMM C 20COMM UM003Q EN P Remote 20 COMM R 20COMM UM004 Q EN P Profibus amp 20 COMM P 20COMM UM006Q EN P RS 485 20 COMM S 20COMM UM005Q EN P InterBus 20 COMM I 20COMM UM007
129. isplay Explanation Display Fault Code Possible Causes Possible Solutions Line Loss 1 2 3 41 42 Missing supply phase Check for open line eg blown line fuse with phase indication and 43 Motor not connected properly Check for open load lead Improper or missing feedback Check current transformer connections and module programming Check voltage sensing board connections and module programming Check ribbon cable connections between Interface Board and Control Module Check voltage feedback circuits Consult factory Shorted SCR 4 5 and 6 Shorted Power Module Check for shorted SCR replace if necessary See Power Circuit Troubleshooting Open Gate 7 8 and 9 Open gate circuitry Perform power supply tests Chapter 3 with phase indication Loose gate lead Check gate lead connections to the gate driver boards and fiber optics PTC Power Pole 10 Controller ventilation blocked Check for proper ventilation Controller duty cycle exceeded Check application duty cycle Fan failure Replace fan Ambient temperature limit exceeded Waitfor controller to cool or provide external cooling Failed thermistor Check connection or replace thermistor Failed control module Replace control module Failed gate driver board Testorreplace gate driver board Failed fiber optic cable Testor replace cable Failed interface board Testor
130. ity and Size Table A 4 A 4 Shipping Weights and Dimensions Table A 5 A 5 Power Bus and Ground Bus Table A 6 A 6 Power Fuses and Losses Table A 7 sese A 7 Control Wire and Power Wire Table A 8 A 8 Parameter Information Parameter sty one ae nee ed e d Ree i B 1 1560E and 1562E Relay Control Functional Description ss 1 Bulletin 1562E Basic Control Controlled Start Only C 1 Bulletin 1562E Basic Control With Controlled Stop C2 Bulletin 1562E DPI Control Controlled Start Only C2 Bulletin 1560E Basic Control Controlled Start Only C 3 Bulletin 1560E Basic Control With Controlled Stop C 3 Bulletin 1560E DPI Control Controlled Start Only C 4 Schematics Bul 1562E Relay Control Circuit Without Stop Control C 5 Bul 1562E Relay Control Circuit With Stop Control C 6 Bul 1562E Relay Control Circuit With DeviceNet C 7 Bul 1560E Relay Control Circuit Without Stop Control C 8 Bul 1560E Relay Control Circuit With Stop Control C 9 Bul 1560E Relay Control Circuit With DeviceNet C 10 Spare Parts Bul 1503E 1000 1500V 180 3604
131. l 1 24 Bulletin 1562E With Stop Control 1 25 Bulletin 1562E Without Stop Control 1 26 Bulletin 1562E With Stop Control 1 27 Functional Descriptions naa 1 28 Bulletin 1562 Basic Control Controlled Start Only 1 28 Bulletin 1562E Basic Control With Controlled Stop 1 29 Bulletin 1562E DPI Control Controlled Start Only 1 29 Bulletin 1560E Basic Control Controlled Start Only 1 30 Bulletin 1560E Basic Control With Controlled Stop 1 30 Bulletin 1560E DPI Control Controlled Start Only 1 30 Schematics Bul 1562E IntelliV AC Control Circuit Without Stop Control 1 31 Bul 1562E Intelli V AC Control Circuit With Stop Control 1 32 Bul 1562E Intelli V AC Control Circuit With DeviceNet 1 33 Bul 1560E IntelliV AC Control Circuit Without Stop Control 1 34 Bul 1560E IntelliV AC Control Circuit With Stop Control 1 35 Bul 1560E Intelli V AC Control Circuit With DeviceNet 1 36 Installation Chapter 2 R c iVing aa nqa an nn a Re tin eee 2 1 Safety and COdeS u eee Ets ana ua ete 2 1 Unpacking and Inspection eese 2 1 General Pr cautions a a e ee e e e eec 2 2 Transportation and Handling
132. left intact and the freight agent should be requested to make a visual inspection of the equipment The Canadian Electrical Code CEC National Electrical Code NEC or other local codes outline provisions for safely installing electrical equipment Installation MUST comply with specifications regarding wire type conductor sizes branch circuit protection interlocking and disconnect devices Failure to do so may result in personal injury and or equipment damage After unpacking the material check the item s received against the bill of lading to ensure that the nameplate description of each item agrees with the material ordered Inspect the equipment for physical damage as stated in the Rockwell Automation Conditions of Sale Remove all packing material wedges or braces from within the controller Operate the contactors and relays manually to ensure that they operate freely Store the equipment in a clean dry place if it will not be installed immediately after unpacking The storage temperature must be between 20 C and 75 C 4 F and 167 F with a maximum humidity of 95 non condensing to guard against damage to temperature sensitive components in the controller 23 B RJ 2 gt 2 2 Installation General Precautions In addition to the precautions listed throughout this manual the following statements which are general to the system must be read and understood The controller
133. ltage unbalance protection are disabled during braking operation 123 B RJ 2 BKMTG ki 0 1 12 Product Overview Protection and Diagnostics cont 23 BR 2 BKMTG ko 0 Unbalance e 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 Undervoltage overvoltage and voltage unbalance protection are disabled during braking operation Stall Protection and Jam Detection The MV SMC Flex controller provides both stall protection and jam detection for enhanced motor and system protection Stall protection is user adjustable from 0 0 to 10 0 seconds enabled only after the programmed start time expires An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing Jam detection allows the user to determine the jam level up to 100096 of the mot
134. m in the snubber or resistor circuits 1 Remove all power from the equipment To avoid shock hazard ensure main power has been disconnected before working on the controller motor or control devices Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Check the snubber components and sharing resistors by isolating them and measuring values as follows See Figures 9 21 to 9 26 RS CS RRx 600 180 and 360A 300 600A 0 5 or 0 68 uF 180 and 360A 1 0 uF 600A 32 5 total taps at 2 5 k Q from each end x21 20r3 Replace any out of spec components See Renewal Parts listing in Appendix D 3 Ifthe snubbers and sharing resistors are within tolerances check the resistance of the voltage sensing module refer to Figure 9 20 Remove the ribbon connector from J1 by pressing down on the locking tabs then gently pulling the connector out Take note of which tap the white high voltage wires are connected to then remove them L1 L2 T2 L3 T3 Measure the resistance between each tap and the ground connection and compare to the values in Figure 9 20 23 B RJ 2 BKOMTG 0 9 28 Troubleshooting Ground Connections To Interface board 2 p ub lt lt d 1 23 1 Y VOLTAGE FEEDBACK ABI MADE f V P USA 080 T
135. ng on the controller motor or control devices Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Carefully detach all wires cables and connectors noting their location and orientation For the interface board remove the control module see page 9 6 The fibre optic cables can be damaged if struck or bent sharply They have a locking feature which requires pinching the tab on the connector and gently pulling straight out The component on the printed circuit board should be held to prevent damage 3 For boards mounted with hardware remove the hardware taking care not to drop anything onto other circuits For boards with nylon stand off posts squeeze the section above the board and carefully pull the board up and off the post 4 Lift out the circuit board and check that the replacement board is the correct part number and revision before installation refer to Appendix D Install the new board by replacing the hardware or pressing down onto nylon stand offs Connect all wires cables and connectors Ensure that all switch and or jumper settings on the new board are identical to those on the old board and correct for the application 123 B RJ 2 kg 0 9 12 Troubleshootin Power Circuit Thyristor SCR Testing Troubleshooting If a power semiconductor is suspected of malfunctioning
136. normal indication and is programmable for N O N C For MV applications it is configured as N O to control the line contactor 11 12 13 14 15 16 17 1 22 18 19 20 2 SMC Flex Aux 1 Control Terminals Up to S peed 23 24 25 26 27 28 29 30 31 32 33 34 PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Figure 1 16 Control Terminals The MV SMC Flex controller offers the control options described below Important The options listed in this section are mutually exclusive and must be specified when ordering An existing controller may be upgraded to another control option by replacing the control module and possibly other components Consult your nearest Rockwell Automation sales office Pump Control Option This option reduces surges during the starting and stopping of a centrifugal pump by smoothly accelerating and decelerating the motor The micro processor 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
137. nostics on page 1 9 for further details The SMC Flex controller stores in memory the five most recent faults Display the fault buffer by selecting the View Faults Queue and scrolling through the fault buffer parameters The information is stored as fault codes and fault descriptions A fault code cross reference is provided in Table 7 A Diagnostics 7 3 Fault Contact Fault Codes Table 7 A provides a complete cross reference of the available fault codes and corresponding fault descriptions Table 7 A Fault Code Cross Reference Fault Line Loss A Line Loss B Line Loss C Shorted SCR A Shorted SCR B Shorted SCR C Open Gate A Open Gate B Open Gate C PTC Pwr Pole SCR Overtemp Motor PTC Open Bypass A Open Bypass B Open Bypass C No Load A No Load B No Load C Line Imbalance Overvoltage Undervoltage Overload Code 1 2 3 4 5 6 7 8 9 4 4 4 4 4 4 4 4 0 1 2 3 4 15 6 7 8 9 4 20 21 22 Not applicable in MV applications Fault Underload Jam Stall Phase Reversal Coms Loss P2 Coms Loss P3 Coms Loss P5 Network P2 Network P3 Network P5 Ground Fault Excess Starts Hour Power Loss A Power Loss B Power Loss C Hall ID NVS Error No Load Line Loss A Line Loss B Line Loss C Code 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 The auxiliary contact is located at terminals 29 and 30 Note that the state this contact takes up
138. nt impedance should be connected in series with the capacitor bank to limit the inrush current A method of limiting the surge current is to add inductance in the capacitor conductors This can be accom plished by putting turns or coils of wire in the power connections to the capacitors 6 inch diameter coil six loops For more information refer to NEMA standard ICS 2 Part 2 Capacitor Applications Care should be used in mounting the coils so that they are not stacked directly on top of each other or they will have a cancelling effect Also the coils should be mounted on insulated supports away from metal parts so they will not act like induction heaters ATTENTION Any covers or barriers removed during installation must be replaced and securely fastened before energizing N equipment Failure to do so may result in severe burns injury or death Installation 2 15 Power Bus Isolation S witch Isolation Switch Fuse Fuse Contactor E Isolation Contactor di dt Inductor di dt Inductor Capacitor 1 PFCC Contactor T Power Factor X Correction Capacitor Bypass Contactor mY Motor Figure 2 7 Typical One Line Diagram Showing 2 Different Styles of Power Factor Capacitor Connections 23 BR gt 0 2 16 Installation Surge Arrestor Protection Devices 23 BR 2 2
139. ntrol Enable on page 2 16 for instructions 2 The control terminals must be wired according to Figure 3 10 on page 3 10 and Figure 3 16 on page 3 16 Option Action Operation Standard The green start button when pressed will Soft Stop commence motor acceleration to full speed Current Limit The red stop button when pressed will Full Voltage provide a coast stop and or reset fault Linear Speed Jog The jog button when pressed will initiate the programmed maneuver a The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will Preset f Slow Speed provide a coast stop The jog button is not active for Preset Slow Jog Speed Slow Speed cannot be operated via the HIM 1560E UM050B EN P June 2013 6 2 Optio Human Interface Module Option Action Operation cont Pump Control Pump Control The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button when pressed will initiate a pump stop maneuver lt Braking Control Smart Motor Braking The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button wh
140. o perform this start mode The start time is selectable from 0 to 30 seconds and determines the time the motor will ramp from 0 speed to full speed Kickstart is available with this option 100 Motor Speed Start r Run amp Stop gt Time seconds Figure 1 7 Linear Speed Acceleration Linear deceleration does not need to be used even if linear acceleration is used The stop time can be programmed for 0 to 60 seconds Linear deceleration cannot brake the motor load and reduce the stop time Note Consult factory if settings over 30 seconds are required The base rating of the MV SMC Flex is two starts or one start stop combination per hour thirty seconds maximum for each operation A stopping operation counts as a start for purposes of thermal capacity calculations ATTENTION 2 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 123 BAR 2 BKMTG 0 1 8 Product Overview 23 B R 2 BK MTGkl1 OI 23 B RJ 2 BK MTGkiH1 O Starting Modes cont 23 B RJ 2 BK MTG Kd 0 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 60 seconds and is adjusted
141. oad Blocked ventilation Duty cycle Allow motor to cool and reduce load Remove blockage and ensure motor is being adequately cooled Preset Slow Speed and Accu Stop options Extended operation at slow speeds reduces motor cooling efficiency Consult motor manufacturer for motor limitations Smart Motor Braking option Check duty cycle Consult motor manufacturer for motor limitations Motor short circuit Winding fault Identify fault and correct Check for shorted SCR replace if necessary Ensure power terminals are secure NOTE For Pump Stop issues please refer to Pump Application Considerations on page 1 20 123 B RJ 2 gt 9 6 Troubleshootin Control Module Removal The control module is not intended for field repair The entire module must be replaced in the event of failure The following procedure must be followed before unplugging the control module 1 Remove all power from the equipment To avoid shock hazard ensure the main power has been disconnected before working on the controller A motor or control devices Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in burns injury or death 2 Make sure that the wires are properly marked and that the program parameters are recorded 3 Disconnect all control wires to control module 4 Loosen the four control module sc
142. oduct is subjected to a sustained fire from some other source some of the polymer materials will produce toxic gases As with any fire individuals involved in extinguishing the fire or anyone in close proximity should wear a self contained breathing apparatus to protect against any inhalation of toxic gases Disposal When disposing of the product it should be disassembled and separated into groups of recyclable material as much as possible 1 e steel copper plastic wire etc These materials should then be sent to local recycling facilities In addition all disposal precautions mentioned above must also be taken for those particular materials Appendix A 1560E 1562E SMC Flex Specifications Table A 1 Specifications Electrical Ratings UL CSA NEMA IEC Power Circuit Method of Connection Motor in delta or star SCRs between windings and supply Number of Poles Equipment designed for three phase loads only 2400 V AC 15 10 3300 V AC 15 10 3 6 kV Rated volgo Ur 4200 V AC 15 1096 72K 6900 V AC 15 10 2500 V Rated Insulation Voltage Ui 5000 V 77 M 7200 V 3 6 kV 40 kV Rated Impulse Voltage Uimp 60 kV 7 2 kV 60 KV 2500 V 7 625 VAC Dielectric Withstand 5000 V 13 250 V AC 7200 V 18 200 V AC Repetitive Peak Inverse Voltage Rating 2500 V max 6 500 V 2 SCRs per phase 5000 V max 13 000 V 4 SCRs per phase 7200 V max 19 500 V
143. on of S CR Pry heatsinks to close gap ensuring that SCR is seated properly in both its locating pins Rotate SCR so thatall leads have same direction Proceed to replace SCR s matched pair SCR2 Note You must replace both SCRs of a matched set SCR4 Shorting Bar Hardware Shorting Bar Hardware Heatsink 5 Heatsink 2 Figure 9 10 Removal of SCR2 and SCR4 3300 to 4160 V 180 360 23 2 0 Troubleshootin 9 22 S 5 wo e wo _ Load Connection 7 7 D iri wn c ea g 5500 6900 V 180 360 one phase Figure 9 11 Power Module Assembly e Load Connection ERE hi 2 5 D 2 ENS 90 gt NE d A 0 j t A CAN I KA 94 ARE ANS NE y EI a with Gate Driver Boards Removed 5500 6900 V 180 360 Figure 9 12 Power Module Assembly one phase 23 BR 2 BKOMTG ko 0 Troubleshootin 9 23 Module retaining hardware locations 4
144. on power up normally open or normally closed can be programmed These parameters can be found in either Basic Setup or the Linear List groups when modifying parameters in the Set Up mode 1560E UM050B EN P June 2013 7 4 Diagnostics Fault Definitions Table 7 B shows the fault definition for the SMC Flex Table 7 B Fault Definitions Fault Description Line Loss The SMC Flex can determine if a line connection has been lost and will indicate this accordingly Shorted SCR Shorted SCRs will be detected and starting will be prohibited by the SMC Flex Open gate indicates that an abnormal condition that causes faulty firing 0 open SCR gate or faulty gate Open Gate driver has been sensed during the start sequence The SMC Flex controller will attempt to start the motor a total of three times before the controller shuts down The power pole temperature in each phase is monitored If the temperature rises above the predetermined Power Pole PTC level the unit will fault to protect the power pole reset can be performed once the temperature falls below Overtemperature this level This fault may also represent loss of gate driver power during gating Motor PTC A motor PTC can be connected to terminals 23 and 24 If the PTC parameter is enabled and the PTC trips the SMC Flex will trip and indicate a Motor PTC fault Onan Bypass Power Pole bypass contacts are monitored for proper operation In
145. ons Red LED to initiate test pulses Figure 3 3 Interface PCB 15602 5 June 2013 3 8 Commissioning Procedures Power Supply Tests cont 1560E UMO50B EN P June 2013 NOTE Systems with optional Pump Control or Soft Stop include continuous gate drive power supplies IGDPS therefore step 5 does not apply 5 Plug in test power supply TB1 Plug in test power supply TB1 6 Since the gate driver circuits normally receive power from the snubber circuits when the SMC is operating an alternate source must be used for testing Locate the Portable Test Power Supply that was included with the equipment and verify that the rating corresponds to the available power system i e 110 120 VAC or 220 240 VAC Plug the unit into the power source and plug the green connector into TB1 on each of the gate driver sections See Figure 3 4 Yellow LED 7 7 Gate TP1 Com TP2 lt Fa L IIzTTPT Gate 1 NC Oe TP2 Figure 3 4 Test Power Application on Gate Driver Board EE The yellow LED on the upper right hand side
146. op Braking Current 35 FLC 0 400 0 Slow Speed Sel 39 SS High Preset SS Accu Stop Slow Speed Dir 40 SS FWD Slow Speed Cur 41 FLC 0 450 0 Slow Running Cur 42 FLC 0 450 0 Accu Stop Stopping Current 43 FLC 0 400 0 Disable Class 10 Overload Class 44 Class 15 Disable i Class 20 Cassi Service Factor 45 0 01 1 99 1 15 Motor FLC 46 A 1 0 1000 0 1 0 Overload Reset 47 Manual Manual Overload Overload A Lvl 50 96 MTU 0 100 0 Underload F Lvl 51 FLC 0 99 0 Underload Underload F Dly 52 SEC 0 99 0 Underload A Lvl 53 96 FLC 0 99 0 Underload A Dly 54 SEC 0 99 0 Undervolt F Lvl 55 9o V 0 99 0 Undervolt F Dly 56 SEC 0 99 0 Undervolt A Lvl 57 V 0 99 0 Undervolt A Dly 58 SEC 0 99 0 Overvolt F Lvl 59 V 0 199 0 Overvolt F Dly 60 SEC 0 99 0 Ovenvoltaga Overvolt A Lvl 61 V 0 199 0 Overvolt A Dly 62 SEC 0 99 0 Unbalance F Lvl 63 0 25 0 Unbalance F Dly 64 SEC 0 99 0 Unbalance Unbalance A Lvl 65 0 25 0 Unbalance Dly 66 SEC 0 99 0 Jam F Lvl 67 FLC 0 1000 0 Jami Jam F Dly 68 SEC 0 99 0 Jam A Lvl 69 96 FLC 0 1000 0 Jam A Dly 70 SEC 0 99 0 Stall Stall Delay 71 SEC 0 0 10 0 0 1560E UMO50B EN P June 2013 Table B 1 Parameter List cont Parameter Information B 3 Group Parameter Description Units Min Max Seti Gnd Fit Enable 72 Aus Disable Enable Gn
147. opening the connection to terminal 17 It is more important in this configuration to integrate the control circuit of the 1560E with the existing controller for better control of the Stop option The start signal for this scheme cannot be a slave of the main contactor since it must remain closed to accomplish the option stop maneuver The SMC Flex module can be used to control the main contactor such that it will close when a start is initiated and remain closed until it has sensed the motor has stopped following an option stop maneuver Product Overview 1 31 Bulletin 1560E DPI Control Controlled Start only The control scheme shown in Figure 1 27 allows the MV SMC Flex to be controlled using DPI This special usage of DPI includes provisions for a Hand mode of control as well With the Hand Auto selector switch in the Auto position and closure of the existing starter main contactor terminal 18 is energized allowing a start command to be executed via DPI AUX2 serves as an interlock with the main contactor or breaker in the existing starter As with the other control schemes the SMC Flex module closes energizing B IV as the motor approaches rated speed Hand control is enabled with the selector switch in the Hand position Closure of the Start relay from the existing starter allows the unit to initiate motor soft starting 123 2 BKMTG 0 1 32 Produ
148. or s full load current rating and the delay time up to 99 0 seconds for application flexibility 60096 Full Load T Percent x Current i amp Programmed StarttTime Stall gt Time seconds Figure 1 11 Stall Protection Product Overview 1 1 Percent User Programmed Full Load Trip Level Current 600 Running gt lt Jam gt Time seconds Figure 1 12 Jam Detection Detection is disabled during slow speed and braking operation Ground Fault In isolated or high impedance grounded systems core balanced current sensors are typically used to detect low level ground faults caused by insulation breakdowns or entry of foreign objects Detection of such ground faults can be used to interrupt the system to prevent further damage or to alert the appropriate personnel to perform timely maintenance The MV SMC Flex s ground fault detection capabilities consist of using a core balance current transformer for 1 to 5A core balanced ground fault protection with the option of enabling Ground Fault Trip Ground Fault Alarm or both a core balance CT is provided with 1562E units Ground Fault Trip The MV SMC Flex will trip with a ground fault indication if e 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
149. ose 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 22 BR 2 BKMTG 0 1 2 Product Overview Description cont 23 2 BK MTG Kd 0 23 BR 2 BICMTG 1123 BR 2 BICMTG 0 1560E Retrofit Controller A medium voltage solid state controller designed to work in conjunction with an existing customer supplied starter It includes Tin plated copper horizontal power bus optional A continuous bare copper ground bus Power electronics A bypass vacuum contactor Three 3 current transformers A low voltage control panel complete with microprocessor based control module Top and bottom plates to accommodate power cables Note See Interlocking page 2 8 1562E Combination Controller A medium voltage solid state controller that provides isolation and protection for new installations It includes Tin plated copper horizontal power bus optional A continuous bare copper ground bus Power electronics A main non load break isolating switch and operating handle An isolation vacuum contactor A bypass vacuum contactor Three 3 current limiting power fuses for NEMA Class E2 operation Three 3 current transformers A control power transformer optional
150. ow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt P 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 Page Preface Service Procedure Moat nts P 1 Product Overview Chapter 1 Manual Objective ss etie e e E Et et 1 1 teet 1 1 D Scription tope aula eee HERE 1 1 1503E OEM Controller 1 1 1560E Retrofit Controller 1 2 1562E Combination Controller ss 1 2 SMC Flex Control Module 1 2 Starting Modes oed eere uet 1 3 SOLS Gee oer tra me 1 3 Selectable Kickstart i eee cete to 1 4 Current Limit Start ia iecit rete 1 4 Dual Ramp nisse e reet pte Perge 1 5 EullVoltage Statt eite Ee rm pe certe aee 1 5 Pres t Slow Speed dt dene Egi hagas 1 6 Linear Speed Acceleration and Deceleration 1 7 SOLS Op xe eere reden ini 1 8 Protection and Diagnostics 1 9 Ovyerload xo us taq e ete en tee ER IURE RES Red 1 9 Underload iz n ert
151. planning to implement some of the advanced features i e Dual Ramp Unbalance Level etc then the Linear List programming group should be selected It provides all the Basic Setup parameter set plus the advanced set Parameter Option SMC Option Displays the type of controller This is factory set and not adjustable Standard Motor Connection Displays the motor type the device is being connected to Line or Delta Line Voltage Displays the system line voltage the unit is connected to MV Ratio Scales the output from the Voltage Sensing Board to display correct line voltage 1 to 10000 See Table 3 B Input Voltage Ranges Starting Mode Allows the user to program the SMC Flex controller for the type of starting that best fits the application Soft Start Current Limit Full Voltage Linear Speed Ramp Time This sets the time period during which the controller will ramp the output voltage 0 to 30s Initial Torque The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter 0 to 90 locked rotor torque Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter 1560E UMO50B EN P June 2013 4 12 Programming Basic Setup cont 1560E UMO50B EN P June 2013 Parameter Option Current Limit Level The current limit level that is applied for the Ramp time s
152. r closed for about 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits 15602 5 June 2013 C 2 1560E and 1560E Relay Control Functional Description cont 1560E UMO50B EN P June 2013 Bulletin 1562E Basic Control With Controlled Stop When wired as shown in Figure C 2 the controller operates in much the same manner as in Figure C 1 Terminal 16 on the SMC Flex module now controls the start and stop maneuvers Terminal 16 must remain energized for the module to run When the Stop button is pressed and opens the SMC Flex module will initiate the option stop An uncontrolled or coast stop is achieved by opening the connection to terminal 17 This contact should remain open to ensure all hold in contacts clear to prevent a re start If the motor has started the unit is in the bypass mode and a trip occurs within the SMC Flex module or from an external protection relay Aux 2 will open the line contactor immediately AUX1 will remain closed for 10 seconds A trip due to an overload or fault condition will result in a coast stop Bulletin 1562E DPI Control Controlled Start only Refer to Figure C 3 and description on page 1 29 1560 1560E Relay Control C 3 Bulletin 1560E Basic Control Controlled Start Only The Bulletin 1560E is intended for addition to an existing motor controller which provides circuit isol
153. r with the system voltage or with the voltage sensing board Note that the load side voltages Load A Load B Load C will be very low since the SCRs are not turned on and only a low leakage current flows to the motor If the motor will start and run the line and load voltages should be the same when the bypass contactor is closed 123 B RJ 2 BKMTG Ktj 0 9 8 Troubleshootin Voltage Sensing Board j Replacement Ensure there is no power to the equipment To prevent electrical shock ensure the main power has oa Mounting Hardware Mounting Hardware been disconnected before working on the sensing board A Verify that all circuits are voltage free using a hot stick or appropriate high voltage measuring defice Failure to do so may result in injury or death Mark the position of the ribbon cable and wires Remove the screws and lift the ring lugs from the terminals to remove the wires Release the locking mechanism located on each side of the ribbon cable connector and pull the ribbon cable straight out to prevent bending the pins Remove the 4 nuts that secure the assembly to the side panel Replace with the new assembly securing with all 4 nuts and washers See diagram below Replace ring lugs on terminals Plug in ribbon cable making sure that it is positioned properly and fitting is secure locking mechanism is engaged For personnel and equipment safety ensu
154. ractices of NFPA 70 Electrical Safety Requirements for Employee Workplaces must be followed if it is necessary to work in the vicinity of energized equipment 1 Apply rated control voltage to the control circuit 2 Using the control schematic apply control signals to cause relays and contactors to energize to verify operation 3 Remove any jumpers used in the test and restore all circuits to normal when finished 1560E UMO50B EN P June 2013 Commissioning Procedures 3 11 Resistance Checks To ensure that resistors and connections have not been damaged during shipment and installation the following resistance tests should be performed before energizing the starter 1 Remove all power from the equipment Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment 2 Measure DC resistance per the following chart Table 3 A Power Circuit Resistance Measurements Location of Probes 1000V 1300V 1500V 2300V 3300V 4160V 5500V 6900 V Cathode to Cathode KOhms 22 30 23 31 21 29 24 32 Cathode to Cathode KOhms 17 23 19 25 20 27 21 29 40 53 43 57 60 80 64 84 Cathode to Gate Ohms 10 40 10 40 10 40 10 40 10 40 10 40 10 40 10 40 Measured between terminals Cathode on SPGD Boards upper t
155. ram the desired number of starts per hour up to 99 This helps eliminate motor stress caused by repeated starting over a short time period Note The base rating of the MV SMC Flex is two starts thirty seconds each max per hour Applications requiring more frequent starts or longer duration starts should be reviewed with the factory to avoid equipment damage Overtemperature The power module temperature is monitored during starting and stopping maneuvers by thermistors The thermistor is connected to the gate driver board where it is processed and the status is transmitted by fibre optic cable through the interface board to the control module When an overtemperature condition exists gt 85 C the control module trips and indicates Power Pole fault An overtemperature condition could indicate high ambient temperature overloading or excessive cycling After the power module temperature is reduced to allowable levels the fault can be cleared see page 9 1 for instructions Meterin Power monitoring parameters include gp Three phase current Three phase voltage Power in MW Power usage in MWh Power factor Motor thermal capacity usage Elapsed time Motor speed 100 with use of optional tachometer input Notes 1 Voltage measurement is not available during the braking operation of the SMB Smart Motor Braking Accu Stop and Slow Speed with Braking control options 2 The elap
156. re both grounding connections are reconnected to the sensing board Mounting Hardware Mounting Hardware Figure 9 2 Sensing Board with mounting hardware placement 23 BR 2 25 0 Troubleshooting 9 9 IGDPS Boards MV SMC units provided with optional stop capabilities soft stop linear deceleration or pump control utilize isolated gate drive power supply IGDPS boards These boards provide a continuous source of power to the gate drive boards The IGDPS boards are fed from a 50 V DC power supply provided with the MV SMC The circuitry for the IGDPS is encapsulated in epoxy As a result the board can not be field repaired and there are no internal test points or adjustments available If one of the six 6 isolated 20 V DC outputs fails the entire board must be replaced Detail a e Input Connection Terminal Channel Number Labels Output Test Point Detail B Figure 9 3 IGDPS Board 23 2 0 9 10 Troubleshooting IGDPS Board LEDs 23 BR 2 25 0 A green LED is provided inside each of the six 6 output module boxes channels to indicate the presence of a healthy output voltage 20 V DC LED ON Output Healthy LED OFF Output Voltage is below 18 V DC If the IGDPS is healthy then all six 6 LEDs will be illuminated If this is not true this may indicate eith
157. re that branch circuit protection of the AC line input to the controller be provided by a circuit breaker or motor starter This function is included with a Bulletin 1562E Important The control and signal wires should be positioned at least six 6 inches 150 mm from power cables Additional noise suppression practices including separate steel conduits for signal leads etc are recommended Bulletin 1503E For 1503E refer to applicable documentation from OEM for installation grounding interlocking and wiring This manual should be utilized in conjunction with the OEM supplied documentation and is suitable for commissioning programming calibration metering serial communica tions diagnostics troubleshooting and maintenance of a standard solid state controller 23 2 BKMTG 0 2 12 Installation Power Wiring Interlocking 23 BR 2 BKMTG 0 The wire sizes must be selected individually observing all applicable safety and CEC or NEC regulations The minimum permissible wire size does not necessarily result in the best operating economy The minimum recommended size for the wires between the controller and the motor is the same as that used if a main voltage source connection to the motor was used The distance between the controller and motor may affect the size of the conductors used Consult the wiring diagrams and appropriate CEC or NEC regulations to determine
158. release 3 006 or later Chapter 9 Troubleshooting General Notes and Warnings For safety of maintenance personnel as well as others who might be exposed to electrical hazards associated with maintenance activities follow the local safety related work practices for example the NFPA 70E Part II in the United States Maintenance personnel must be trained in the safety practices procedures and requirements that pertain to their respective job assignments Hazardous voltage is present in the motor circuit even when the SMC Flex controller is off To avoid shock hazard disconnect main power before working on the controller motor or control devices such as Start Stop push buttons Procedures that require parts of the equipment to be energized during troubleshooting testing etc must be performed by properly qualified personnel using appropriate local safety work practices and precautionary measures Disconnect the controller from the motor before measuring insulation resistance IR of the motor windings Voltages used for insulation resistance testing can cause SCR failure Do not make any measurements on the controller with an IR tester megger Note The time it takes for the motor to come up to speed may be more or less than the time programmed depending on the frictional load and inertial characteristics of the connected load Note Depending on the application the Braking options SMB Motor Braking Accu Stop and Slow
159. rews 5 Carefully rotate the module to the left and unplug the five ribbon cables from the interface board ATTENTION When removing the control module make sure to hold the module in place as the screws are removed to avoid strain on the ribbon cables To install control module follow the reverse order for removal Note The MV SMC Flex must use firmware release 3 006 or later 23 BR 2 25 0 Troubleshooting 9 7 Voltage Feedback Circuit Tests The most straightforward means of checking the feedback circuits is to perform the snubber and resistor testing procedure found on page 9 27 Another possible test involves measuring the feedback voltages at the interface board see Figure 3 2 This can only be done with line voltage applied If the motor does not start it may be necessary to temporarily modify the control circuit to close the line contactor without applying a start signal to the SMC Flex module In this case the three line voltages Line A Line B Line C measured with respect to ground should be as follows check all three phases Table 9 F Voltage Feedback Measurements Feedback Voltage 1000 19 21 1300 24 2 6 1500 2 8 3 0 2400 18 2 0 3300 12 14 System Voltage Feedback Voltage Vu 4160 15 17 4800 10 12 5500 11 13 6600 14 15 6900 15 16 If any voltage is well outside this range there may be a problem eithe
160. rm a three phase AC line controller configuration Each power module includes a snubber circuit to limit the rate of rise in voltage across each SCR pair The module also includes patented gate driver circuits which derive their power from the snubber circuit Voltage sharing resistors are connected across each SCR pair to provide static voltage balance for series connected SCRs These resistors are tapped to provide a reference for overvoltage protection circuitry on the gate driver board A voltage sensing board is used to reduce the line side and load side voltages to lower levels that can be measured by the SMC Flex control module Self Powered Silicon Controlled Rectifier Gate Driver Board This board provides the turn on capability for SCR devices The board also provides optical fibre isolation between itself and the gating source logic It is powered by recovering energy from the snubber circuit so it is fully isolated from the control and logic circuits it is self economizing when the unit is not running or is in bypass mode Note If pump control or stop control are used the gate driver boards are powered continuously using separate power supply boards Refer to Chapter 8 for additional details The MV SMC Flex has three heatsinks fitted with a thermistor to monitor temperature rise The circuitry on the gate driver board accepts the thermistor and drives a fibre optic cable if the temperature is below the setpoint 85 C
161. rogram the Normal state of the second auxiliary contact This contact is located at terminals 33 and 34 N O N C Parameter Mgmt The newly programmed parameters values can be saved to memory or the factory default parameter values can be recalled Ready User Store User Recall Load Default Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter Thenew programmed parameter values will not be stored to the EEPROM without the user s direction in Parameter Management User Store When programmed for Emergency Run and the Option 2 input is energized a Start command will first close the bypass contactor then the line contactor for an across the line start of the motor A Stop command will open the line contactor first and allow the motor to coast regardless of the programmed Stop Mode For Pump Option modules the Option 2 input defaults to Emergency Run for MV applications Programming 4 13 Motor Protection While the Basic Set Up group allows the user to get started with a minimum number of parameters to modify the Motor Protection group allows full access to the SMC Flex controller s powerful parameter set Following is a listing of the additional setup parameters provided Note The majority of parameters have a Fault and an Alarm setting Parameter Option Overload Trip Class Service Factor Allows the u
162. rs below provide application flexibility and easy setup Parameter Range Overload Class Off 10 15 20 30 Overload Reset Manual Auto Motor FLC 1 0 1000 0 amps Service Factor 0 01 1 99 Important During slow speed operations current waveforms exhibit non sinusoidal characteristics These non sinusoidal characteristics inhibit the controller s current measurement capability To compensate for additional motor heating that may result the controller uses motor thermal modeling which increments motor thermal usage This compen sation takes place when the Preset Slow Speed option is used Notes 1 The factory default setting for Overload Class which is OFF disables overload protection An overload trip class and the motor s full load current rating must be programmed to enable overload protection 2 Ifthe MV SMC Flex is used to control a multi speed motor or more than one motor the Overload Class parameter must be programmed to OFF and separate overload relays must be supplied for each speed motor 3 Automatic reset of an overload fault requires the start input to be cycled in a 2 wire control scheme 4 The trip rating is 117 of the programmed FLC Figures 1 9 and 1 10 provide the overload trip curves for the available trip classes 123 B RJ 2 gt 1 10 Product Overview Protection and Diagnostics cont Class 10 1000 0 10000 0 100 0
163. s 30 1560E UMO50B EN P June 2013 8 10 Communications Configuring DataLinks Updating Firmware 1560E UM050B EN P June 2013 DataLinks are supported in the SMC Flex A DataLink is a mechanism used by most drives to transfer data to and from the controller without using an Explicit Message The SMC Flex supports 16 bit DataLinks therefore the device can be configured to return up to four additional pieces of information without the need for an explicit message Rules for Using DataLinks Each set of DataLink parameters in an SMC Flex can be used by only one adapter If more than one adapter is connected multiple adapters must not try to use the same DataLink Parameter settings in the SMC determine the data passed through the DataLink mechanism When you use DataLink to change a value the value is not written to the Non Volatile Storage NVS The value is stored in volatile memory and lost when the drive loses power Parameters 88 to 103 are used to configure the DataLinks For additional information regarding DataLinks refer to the user manual for the communication interface being used Note Node addressing of the DPI communication card can be programmed via software or a hand held DPI HIM The on board HIM cannot be used to address the communication card The latest version of firmware and instructions for the SMC Flex can be obtained from www ab com Note The MV SMC Flex must use firmware
164. s in the Set Up mode the new values are stored in RAM When power is applied to the controller parameter values stored in the EEPROM are copied to RAM RAM is volatile and the values stored in this area are lost when the controller is powered down Read only Memory ROM The SMC Flex controller comes with factory default parameter values These settings are stored in nonvolatile ROM and are displayed the first time you enter the Program mode Electrically Erasable Programmable Read only Memory EEPROM The SMC Flex controller provides a nonvolatile area for storing user modified parameter values in the EEPROM Programmin 4 7 Using Parameter Management Description Action Display Saving to EEPROM To ensure that the newly modified parameters are not lost if control power is removed from the controller store the values into EEPROM Save EEPROM Recall EEPROM Recalling from EEPROM Parameters stored in EEPROM can lt q Recall EEPROM be manually brought to RAM by directing the controller to recall the values in its EEPROM Recalling Defaults After parameter values have been em lt q Reset to Defaults modified and saved to EEPROM Save EEPROM factory default settings can still be re initialized 1560E UMO50B EN P June 2013 4 8 Programmin Parameter Modification All parameters are modified using the same method The basic steps to performing parameter modification
165. s on either side of the clamp bars They must remain as they are to maintain squareness See Figures 9 6 9 9 and 9 15 2 Loosen the clamp by rotating the centre nut below the indicator washer at the top end of the clamp Refer to Figures 9 6 9 9 and 9 15 As the centre nut is rotated the entire spring assembly is retracted from the top heatsink Continue to retract until there is a gap of approximately 6 mm 0 25 in The heatsinks may now be spread apart to allow removal of the SCRs Apply a thin film of Electrical Joint Compound supplied to both faces of the new SCRs Place the new SCRs in position starting from the top and pushing the heat sinks together as you proceed down the stack Make sure the SCRs are positioned and oriented properly Refer to Figures 9 7 9 10 and 9 16 Ensure that the SCRs are properly seated on the locating pins in the heatsinks and rotate each SCR so that the leads are oriented toward the front right side of the assembly Advance the centre nut until the spring assembly engages the top heatsink Make sure the clamp is properly seated on the locating pins in the top and bottom heatsinks before beginning to tighten Tighten the centre nut until the indicator washer becomes loose with some friction The clamp is now at the proper force and must not be clamped any tighter If the indicator washer becomes too loose no friction back the centre nut off slowly until the washer is loose with some frict
166. se two people to remove and handle the assembly Place the heatsink on a cart to aid in its transport 8 Place the module on a flat surface see Fig 9 7 9 10 and 9 14 When tilting the module ensure that wires are not damaged B Replace SCRs Note For 600 A units it is mandatory that the entire stack be replaced The high clamping force requires the factory to tighten the clamp hardware See Appendix D Spare Parts section for part numbers Proceed to step C Note Refer to Figures 9 5 to 9 16 SCR positions are numbered in succession from the top down The SCR cathode is at the end with the wide flange The SCRs must be oriented correctly with the cathode end either up or down depending on the specific assem bly Note the orientation before removing the SCRs and refer to the detail in the appropriate figure in this chapter 1 Remove the shorting bar Measure the resistance between adjacent heatsinks to determine which SCR s is are shorted Assemblies with four or six SCRs must use matched sets See Figures 9 8 and 9 14 for the position of the matched sets If an SCR from each set is shorted all of the SCRs in the module must be replaced A properly functionning SCR will measure in excess of 100 kilohms from anode to cathode and 10 40 ohms from gate to cathode 23 BR 2 BKOMTG 0 Troubleshooting 9 15 SCR Replacement Procedure cont Important DO NOT loosen any of the nuts on the fiber rod
167. sed 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 10096 23 B RJ 2 BEMTG KH 0 1 18 Product Overview Communication A serial interface port DPI is provided as standard which allows connection to the Bulletin 20 HIM LCD human interface modules DPI amp Figure 1 14 DPI Location ATTENTION Two peripheral devices can be connected to the DPI The maximum output current through the DPI is 280 mA Prog ramming 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 Port5 DPI Communications Port 2 Ports 2 and 3 when two 5 are connected with a splitter Figure 1 15 Built in Keypad and LCD 23 2 BK MTG Kd 0 Status Indication Control Options Product Overview 1 19 Four programmable hard contact outputs are provided as standard The Auxiliary 1 Contact is It is always programmed for Up to speed to control the bypass contactor in MV applications The fault Contact is for fault indication and is programmable for N O N C The alarm Contact is for alarm indication and is programmable for N O N C The Auxiliary 2 Contact is for
168. ser to select the operation of the Motor FLC Overload Reset overload Overload Alarm Level Underload Underload Fault Level Determines the trip level as a percentage of the motor s FLA and the delay period Underload Fault Delay Underload Alarm Level Underload Alarm Delay Undervoltage Determines the trip level as a percentage of line voltage and delay period Undervoltage Fault Level Undervoltage Fault Delay Undervoltage Alarm Level Undervoltage Alarm Delay Overvoltage Determines the trip level as a percentage of line voltage and delay period Overvoltage Fault Level Overvoltage Fault Delay Overvoltage Alarm Level Overvoltage Alarm Delay Unbalance Allows the user to set the current unbalance trip level and delay period Unbalance Fault Level Unbalance Fault Delay Unbalance Alarm Level Unbalance Alarm Delay Jam Determines the trip level as a percentage of motor full load current and delay period Jam Fault Level Jam Fault Delay Jam Alarm Level Jam Alarm Delay Stall Allows the user to set the stall delay time Stall Delay Ground Fault Allows the user to enable the ground fault level in amps delay time and inhibit time A separate 825 CBCT is required Ground Fault Enable Ground Fault Level Ground Fault Delay Ground Fault Inhibit Time Ground Fault Alarm Enable Ground Fault Alarm Level Ground Fault Alarm Delay PTC Allows the user to conne
169. supporting the options described below are shown later in this chapter Option Parameter Range Standard Soft Stop SMC Option This parameter identifies the type of control present and is not user programmable Standard Soft Stop Time Allows the user to set the time period for the soft stopping function 0 120 8 Preset Slow Speed SMC Option This parameter identifies the type of control present and is not user programmable Standard Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 Forward 10 Reverse High 15 Forward 20 Reverse Slow Speed Direction This parameter programs the slow speed motor rotational direction Forward Reverse Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting 0 450 of full load current Pump Control Pump Control SMC Option Pump Control This parameter identifies the type of control present and is not user programmable Pump Stop Time 0 1205 Allows the user to set the time period for the pump stopping function Starting Mode Allows the user to program the SMC Flex controller for the type of starting that best fits the appl
170. switch to providing full voltage to the motor If the controller senses that the motor has reached full speed before completing the Soft Start it To apply a fixed reduced output voltage to the motor the following parameters are provided for user adjustment Parameter Option Starting Mode Current Limit This must be programmed for Current Limit Ramp Time 0 to 30s This programs the time period that the controller will hold the fixed reduced output voltage before switching to full voltage Current Limit Level This parameter provides adjustability for the reduced output voltage level provided to the motor 50 to 600 full load current Kickstart Time A boost of current is provided to the motor for the programmed time period 0 0 to 2 0 s Kickstart Level Adjusts the amount of current applied to the motor during the kickstart time 0 to 90 locked rotor torque If the controller senses that the motor has reached full speed before completing the Current Limit Start it will automatically switch to providing full voltage to the motor 1560E UMO50B EN P June 2013 4 10 Programming Dual Ramp Start 1560E UMO50B EN P June 2013 The SMC Flex controller provides the user with the ability to select between two Start settings The parameters below are available in the Set Up programming mode To obtain Dual Ramp control Ramp 1 is located in the Basic Set Up and Ramp 2 is located in th
171. t button initiates the start sequence Relay CR closes and applies control power to terminal 17 of the SMC Flex module The auxiliary contact 2 Normal closes energizing M IV and MC which completes the hold in circuit on the start button and closes the main contactor The SMC Flex module examines the line voltage looks for fault conditions checks phase rotation calculates zero crossing information and begins gating the SCRs to start the motor When the motor approaches rated speed the SMC Flex module closes the AUXI up to speed auxiliary contacts energizing B IV which closes the bypass contactor The motor then runs at full line voltage When the Stop button is pressed the CR relay opens terminal 17 on the SMC Flex module The Normal contact opens dropping out the main contactor allowing the motor to stop The AUXI contact is held closed for a short time by the control module This holds the bypass contactor closed for about 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits Product Overview 1 29 Bulletin 1562E Basic Control With Controlled Stop When wired as shown in Figure 1 23 the controller operates in much the same manner as in Figure 1 22 Terminal 16 on the SMC Flex module now controls the start and stop maneuvers Terminal 16 must remain energized for the module to run When the Stop button is pressed and CR opens th
172. t can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Before proceeding ensure that all sources of power are isolated and locked out Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Any covers or barriers removed during this procedure must be replaced and securely fastened before energizing equipment Where appropriate the case of test equipment should be connected to ground Isolate incoming power Open the door s providing access to the SCR heatsink assemblies You will be touching components which are connected to the high voltage power circuit so be sure to isolate power as stated above Apply rated control voltage to the control circuits from a separate control source or by plugging into the test source connector and selecting the TEST position of the control switch Locate the SMC Flex Interface board in the control section See Figures 3 2 and 3 3 This circuit board has the control module mounted on it Locate the switch labeled SW2 at the upper left corner of the board Close the switch by sliding the toggle up This starts a pulse generator to supply simulated gate pulse signals via fibre optic cables to the gate driver boards A red LED beside the switch and the three yellow LEDs on the left side of the Interface board should be lit Note They may appear dim depending on ambient light conditi
173. t in the desired position Care must be exercised when using either a forklift or the pipe rolling technique for positioning purposes to ensure that the equipment is not scratched dented or damaged in any manner Always exercise care to stabilize the controller during handling to guard against tipping and injury to personnel 23 2 BEMTG kd 0 Installation Site Installation 2 3 Consider the following when selecting the installation site A The operating ambient temperature should be between 0 C and 40 C 32 F and 104 F for NEMA Type 1 or 12 enclosures For higher ambient conditions please consult Rockwell Automation factory B The relative humidity must not exceed 95 non condensing Excessive humidity can cause electrical problems from corrosion or excessive dirt build up a The equipment must be kept clean Dust build up inside the enclosure inhibits proper cooling and decreases the system reliability The equipment should not be located where liquid or solid contaminants can drop onto it Controllers with ventilated enclosures in particular those with fans must be in a room free of airborne contaminants D Only persons familiar with the function of the controller should have access to it E The losses in the controller produce a definite heat dissipation depending on the unit size that tends to warm the air in the room Attention must be given to the room ventilation and cooling require
174. t setup 0 to 30s Dual Ramp Initial Torque 2 The initial reduced output voltage level for the second Start setup is established and adjusted with this parameter 0 to 90 locked rotor torque The Dual Ramp feature is available on the standard controller Kickstart can be programmed for both start modes Programming 4 11 Full Voltage Start Linear Speed Basic Setup The SMC Flex controller may be programmed to provide a full voltage start output voltage to the motor reaches full voltage within 1 4 second with the following programming Parameter Option Starting Mode This must be programmed for Full Voltage Full Voltage The SMC Flex provides the user the ability to control the motor speed during starting and stopping maneuvers A tach input is required as specified in Linear Speed Acceleration on page 1 7 Parameter Option Starting Mode Linear Speed This must be programmed for Linear Speed Ramp Time 0 to 30s This programs the time period that the controller will ramp from 0 speed to full voltage Kickstart Time 0 002 25 A boost of current is provided to the motor for the programmed time period Kickstart Level Adjusts the amount of current applied to the motor during the kickstart time 0 to 90 locked rotor torque The Basic Setup programming group provides a limited parameter set allowing quick start up with minimal adjustments If the user is
175. tart 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 Percent Voltage 100 ol Initial Torque Start Run Time seconds Figure 1 1 Soft Start 123 BAR 2 gt 0 1 4 Product Overview Starting Modes cont 23 BR 2 0 Selectable Kickstart Selectable kickstart provides a power boost at start up that is user adjustable from 0 to 90 of locked rotor torque The additional power helps motors generate higher torque to overcome the resistive mechanical forces of some applications when they are started The selectable kickstart time is user adjustable from 0 0 to 2 0 seconds Kickstart 100 Initial Torque E Stat gt lt Run Time seconds Figure 1 2 Selectable Kickstart Current Limit Start e This starting mode provides a true current limit start that is used when limiting the maxim
176. tart 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 100 Percent Voltage Time seconds Figure 1 5 Full Voltage Start 23 BAR 2 BKMTG 0 1 6 Product Overview Starting Modes cont 23 BR 2 BKMTG 0 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 2046 of base speed high settings Forward 15 High N B Time seconds Stat AU gt gt 10 Low 20 High Reverse Figure 1 6 Preset Slow Speed Option Important Slow speed running is not intended for continuous operation due to reduced motor cooling The two starts per hour limitation also applies to slow speed operation This option employs a cycle skipping scheme which produces limited torque Applications should be checked with the factory Product Overview 1 7 Linear Speed Acceleration and Deceleration The SMC Flex has the ability to control the motor speed during starting and stopping maneuvers A tachometer signal 0 to 5V DC is required t
177. teet tenere etie 4 13 Motor Information ss 4 15 1560E UMO50B EN P June 2013 iv Table of Contents MV Dialog Plus Medium Voltage Controller User Manual Metering Chapter 5 Page OVERVIEW Q Su S kuqa Suka cater ees 5 1 Motor Data Entry eere Ree RAP te 5 1 Options Chapter 6 OVERVIEWS te ese has HU Rat 6 1 Human Interface Module sess 6 1 Programming Parameters essere rennen 6 3 Control Warn ee eee tte eee eene 6 5 Diagnostics Chapter 7 OVeEVIQWaa e 7 1 Fault Display nes ua tedden e 7 1 cain ec eere e egeta 7 2 ase a 7 2 Ta e eere 7 3 Fault Definitions eco ete epo hee T quas sS 7 4 Communications Chapter 8 sieh eee dett e E pini Sopa Gp 8 1 Communication Ports sus 8 1 Human Interface Module a 8 1 Keypad Des rIDtIODn esee pee eie ge taies 8 2 Connecting the Human Interface Module to the Controller 8 4 Control Enable i ete ote otto Er n 8 4 Control Enable ih eod eas 8 6 Loss of Communication and Network Faults 8 6 SMC Flex Specific Information a 8 6 Default Input Output Configuration esee 8 7 Variable Input Output Con
178. ter identifies the type of control present and is not user programmable Braking Control Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 High 15 Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting 0 450 of full load current Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 400 of full load current Al braking stopping current settings in the range of 1 100 will provi de 100 braking current to the motor Braking Control is not offered for standard use in MV applications Please consult factory for further assistance Options 6 5 Control Wiring Refer to Chapter 1 Product Overview for typical control wiring examples used with various control schemes 1560E UMO50B EN P June 2013 6 6 Options 1560E UM050B EN P June 2013 Overview Fault Display Chapter 7 Diagnostics This chapter describes the fault diagnostics of the MV SMC Flex controller Further this section describes the conditions that cause various faults to occur Protection Programming Many of the protective features available with the SMC Flex controller can be enabled and adj
179. the event of a contact failure the SMC Flex will indicate an Open Bypass fault No Load The SMC Flex can determine if a load connection has been lost and No Load fault will be indicated Line Unbalance Voltage unbalance is detected by monitoring the three phase supply voltages The formula used to calculate the percentage voltage unbalance is as follows Vu 100 Va Va Vu Percent voltage unbalance Va Maximum voltage deviation from the average voltage Average voltage The controller will shut down when the calculated voltage unbalance reaches the user programmed trip percentages Overvoltage and Undervoltage Protection Overvoltage and undervoltage protection are user defined as a percentage of the programmed line voltage The SMC Flex controller continuously monitors the three supply phases The calculated average is then compared to the programmed trip level Underload Underload protection is available for undercurrent monitoring The controller will shut down when the motor current drops below the trip level This trip level a percentage of the motor s full load current rating can be programmed Overload Protection Overload protection is enabled in the Motor Protection group by programming the Overload class Overload reset Motor FLC Service factor Refer to Chapter 5 for more information on Motor Protection Phase Reversal Phase reversal is indicated when th
180. ting or stopping current to flow for extended periods Pump Start Run P ump Stop gt Time seconds Figure 1 17 Pump Control Option Product Overview 1 21 Pump stopping is not intended to be used as an emergency stop Refer to the applicable standard for emergency stop requirements Pump stopping may cause motor heating depending on the mechanical dynamics of the pumping system Therefore select the lowest stopping time setting that will satisfactorily stop the pump Braking Control Option The Braking Control option Smart Motor Braking Accu Stop and Slow Speed with Braking are not offered for standard use in MV applications Please consult factory for further assistance 23 B RJ 2 BKMTG Ktj 1 22 Product Overview Hardware Description 23 BR 2 0 The following sections contain descriptions of system components and system operation Each section will be described to give the user an understanding of the MV SMC Flex to facilitate operation and maintenance of the system Refer to Figures 1 18 through 1 21 Typical MV SMC Flex Power System Power Module The controller consists of three power modules one for each phase Each power module consists of incoming and outgoing terminals for cables SCRs heatsink and clamp assembly The SCRs are connected in inverse parallel and in series for 12 or 18 SCR assemblies to fo
181. tor Connection Service Factor Jam F Dly Parameter Mgt Parameter Mgt Parameter Mgt Volts Phase C A Line Voltage Motor FLC Jam A Lvl Current Phase A MV Ratio Overload Reset Jam A Dly Data Links Motor Data Current Phase B Starting Mode Overload A Lvl Parameter Mgt Current Phase C Ramp Time Parameter Mgt Data In 1 Motor Watt Meter Initial Torque Stall Data In A2 Motor ID Megawatt Hours Cur Limit Lvl Data In B1 CT Ratio Elapsed Time Kickstart Time Stall Dly Data In B2 MV Ratio Meter Reset Kickstart Lvl Underload F Lvl Parameter Mgt Data In C1 Parameter Mgt O Power Factor Option 2 Input Underload F Dly Data In C2 Mtr Therm Usage Stop Mode Underload A Lvl Ground Fault Data In D1 Stop Time Underload A Dly Data In D2 Braking Current Parameter Mgt Gnd Fit Enable Data Out A1 Overload Class Gnd Fit Lvl Data Out A2 Service Factor Gnd Fit DI Data Out B1 Motor FLC Gnd Fit nh Time Data Out B2 CT Ratio Undervolt F Lv Gnd Fit A Enable Data Out C1 Overload Reset Undervolt F Dly Gnd Fit A Lvl Data Out C2 Aux1 Config Undervolt A Lvl Gnd FIt A Dly Data Out D1 Fault Contact Undervolt A Dly Parameter Mgt Data Out D2 Depending upon SMC option selected some parameters may not appear in product display Steps back one level For further information on parameters see Appendix For further information on parameter management see page 4 7 Figure 4 2 Menu Structure Hierarchy 1560E UMO50B EN P June 2
182. ual 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 The following Rockwell Automation publications provide pertinent information for the MV SMC Flex and components 5 0 General Handling Procedures for MV Controllers e 1500 7 055 Medium Voltage Controller Two High Cabinet 200A 400A User Manual e 1502 UMOSOC EN P 400A Vacuum Contactor Series D User Manual e 1502 UM052B EN P 400A Vacuum Contactor Series E User Manual e 1502 UMOSIC EN P 800A Vacuum Contactor Series D and E User Manual 1560E SRO22A EN P Medium Voltage SMC Flex Controllers General Specifications The MV SMC Flex is a solid state three phase AC line controller It is designed to provide microprocessor controlled starting and stopping of standard three phase squirrel cage induction motors using the same control module as the Allen Bradley Bulletin 150 SMC Flex 1503E OEM Controller A chassis mount medium voltage solid state controller designed to mount in an OEM or customer supplied structure and designed to work in conjunction with an existing or OEM customer supplied starter It is comprised of several modular components including Frame mounted or lo
183. um 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 600 Percent Full Load Current 50 gt Time seconds Figure 1 3 Current Limit Start Kickstartis also available with Current Limit Start Dual Ramp Start and Linear Acceleration TheCurrent Limit Start mode design is based on a motor with a locked rotor current rating that is 600 of the full load current rating Product Overview 1 5 Dual Ramp Start This starting mode is useful for applications that have varying loads and therefore varying starting torque requirements Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings Percent Ramp 2 Voltage 100 Tp Ofer I Initial Torque 2 Le Initial Torque 1 i 2am i Stat FH Runt Start 2 s gt Time seconds Figure 1 4 Dual Ramp Start DualRamp Start is available only with the standard controller Full Voltage S
184. um to operate properly and to interrupt current Visually inspect the wear of the main contacts with the contacts closed When any part of the wear indicator located on the front side of the hex shaft moves up into the bearing replace all three vacuum bottles see Vacuum Contactor User Manual The vacuum level should be tested periodically by applying high voltage alternating current across the open bottle using a vacuum tester or Hi Pot equipment see Vacuum Contactor User Manual Terminals Loose connections can cause overheating that can lead to equipment malfunction or failure Check the tightness of all terminals and bus bar connections and securely tighten any loose connections Replace any parts or wiring damaged by overheating Coils If a coil exhibits evidence of overheating cracked melted or burned insulation it must be replaced In that event check for and correct overvoltage or undervoltage conditions which can cause coil failure Be sure to clean any residues of melted coil insulation from other parts of the device or replace such parts Maintenance 10 3 Solid State Devices Solid state devices require little more than a periodic visual inspection Printed circuit boards should be inspected to determine whether all cables are properly seated in their connectors Board locking tabs should also be in place Necessary replacements should be made only at the PC board or plug in component level Solvents should not be
185. used on printed circuit boards Where blowers are used air filters if supplied should be cleaned or changed periodically depending on the specific environmental conditions encountered For additional information see NEMA Standards Publication No ICS 1 1 1987 entitled Safety Guidelines for the Application Installation and Maintenance of Solid State Control Use of other than factory recommended test equipment for solid state controls may result in damage to the control or test equipment or unintended actuation of the controlled equipment Static Sensitive Items While performing maintenance on the MV SMC special precautions must be observed in handling or touching certain static sensitive components in the cabinet Most circuit cards and SCRs can be damaged by Electro Static Discharge ESD If personnel will make contact with an ESD sensitive component during maintenance they must be grounded Grounding should be accomplished with a wrist strap which is connected to an approved ground Overload Maintenance After a Fault Condition See NEMA Standards Publication No ICS 2 Appendix A entitled Maintenance of Motor controllers after a fault condition Final Check Out After maintenance or repair of industrial controls always test the control system for proper functioning under controlled conditions that avoid hazards in the event of a control malfunction 1560E UMO50B EN P June 2013 10 4 Maintenance Periodic Inspection
186. ush button must be clear and unobstructed B The following test equipment is to be prepared for use Test power supply supplied with each controller Multimeters Hi Pot Tester recommended or Megger Oscilloscope with memory optional C Complete drawing package and parts list D Specification of project 15602 5 June 2013 3 2 Commissioning Procedures1 System Characteristics Job Name Job Number Rated Voltage 1 Rated Current S F Actual Motor Load Load Type Fan Pump Conveyor Compressor Mixer Other Constant Torque or Variable Torque Actual Motor Data Motor HP Motor Rated Speed Motor F L A Motor S F Motor L R A Frequency Phases 1560E UMO50B EN P June 2013 Commissioning Procedures 3 3 Preliminary Check Programming Ensure that all sources of power are isolated and locked out before working on installed equipment Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in severe burns injury or death A Verify correct power cable phase sequencing and that connections are tight B Verify power fuse ratings and condition C Verify control fuse ratings and condition D Check that power cable installation has not damaged components and that electrical spacings have not been reduced Check that fibre optic cables are fully seated in their connectors
187. usted through the programming parameters provided For further details on programming refer to the Motor Protection section in Chapter 4 Programming The SMC Flex controller comes equipped with a built in three line 16 character LCD The LCD displays the fault message on the first line the fault code on the second line and the fault description on the third line FAULTED FAULT 27 COMS LOSS P2 Figure 7 1 Fault Display Note The fault display will remain active as long as control power is applied If control power is cycled the fault will be cleared the controller will re initialize and the display will show a status of Stopped Important Resetting a fault will not correct the cause of the fault condition Corrective action must be taken before resetting the fault 1560E UMO50B EN P June 2013 7 2 Diagnostics Clear Fault Fault Buffer 1560E UM050B EN P June 2013 You can clear a fault using any of several methods Program the SMC Flex controller for a Clear Fault which can be found in Main Menu Diagnostics Faults If a human interface module is connected to the controller press the Stop button Note The stop signal will not clear a fault if Logic Mask is disabled Logic Mask parameter 87 equals 0 Cycle control power to the SMC Flex controller Important overload fault cannot be reset until the Motor Thermal Usage parameter 12 value is below 75 See Protection and Diag
188. with line 144 X 319 Combined with line 568 X 12 55 5 68 X 12 55 Hm 4 64 All 144 X 319 Combined with line 144 X 319 Combined with line 5 68 X 5 68 5 68 X 9 00 5 68 X 9 00 5 68 X 9 00 FO 144 144 144 X 229 144 X 229 144 X 229 4 5 68 X 9 00 68 X 9 00 5 68 X 5 68 68 X 9 00 due 92004 144 X 229 144 X 229 144 X 144 144 X 229 5 68 X 9 00 5 68 X 9 00 5 68 X 9 00 5 68 X 9 00 144 220 144 220 144 220 144 X 229 um T 5 68 X 9 00 7 25 X 15 88 5 68 X 9 00 7 25 X 15 88 144 220 184 403 144 220 184 403 Dimensions in inches mm 1560E UMO50B EN P June 2013 A 4 Specifications Table Cable Quantity and Size Bulletin 200 400A 200 400A 600A 200 400A 600A 200 400A 14 60 14 62 14 64 14 70 14 72 14 74 4 76 Structure Max No amp Size of Code Incoming cables no bus Max No amp Size of Incoming Cables w bus 1 500 26 W X91 H 1 500 660 X 2311 2 250mcm phase 2 250mcm phase 36 W X 91 H 914 X 2311 2 250mcm phase 44WX91H 1 500 1118 X 2311 2 250mcm phase 36 W X 91H 914 X 2311 2 250mcm phase 62WX91H 1575 X 2311 1 Restrictions based upon single conductor cable 2 Please contact factory for multiple conductors shielded or other specialized cables 3 Please contact factory if the maximum number size needs to be exceeded We can accommodate special
189. wo or bottom two within a phase Measured between terminals Cathode on SPGD Boards top to bottom within a phase Measured between line and load terminals within a phase Voltage Sensing Module 3 If abnormal readings are obtained refer to Power Circuit Trouble shooting on page 9 12 The voltage sensing module consists of a voltage sensing board and mounting plate refer to Figure 9 2 The voltage sensing board has six independent channels which convert voltages up to 10800 V 7 2 kV 1 5 pu down to low voltage levels which can be used by the SMC Flex control logic Table 3 B shows the input voltage ranges for each of the input terminals on the voltage sensing module This module has been designed to operate at a nominal input voltage of up to 7200 V with a continuous 4096 overvoltage The output voltages are scaled to provide close to 10 V peak for a 140 input voltage at the high end of each of the voltage ranges Each of the channels has four taps to provide a range of input voltages and software will be used to scale the output to show the correct value on the SMC Flex front panel display See Parameter 106 MV Ratio 15602 5 June 2013 3 12 Commissioning Procedures Start Up 1560E UMO50B EN P June 2013 Table 3 B Input Voltage Ranges Tap Voltage Range MV Ratio D 800 1449 V 1020 C 1450 2499 V 390 B 2500 4799 V 165 A 4800 7200 V 105 The M
190. x 100 mm 1 4 x 4 in 3000 A Qty 2 9 5 x 127 mm 3 8 x 5 in 1200 65 mm 1 0 in2 total Cross Sectional Area per Phase 2000 A 129 mm 2 0 in total 3000 242 mm 3 75 in total Insulating Material Between Phases and Ground Air Standard Type Sleeve heat shrink Material Polyolefin Optional Insulation Material for Main Horizontal Bus Thickness 1 4 mm 0 055 Anti hygroscopic 0 5 to 1 Electrical Strength 900 V mil Vertical Power Bus Bus Bar Material Tin plated copper Continuous Current Rating at 40 C 104 F 400 600 and 800 A Fault Withstand Current Rating 72 cycle 5 Sleeve heat shrink Material Polyolefin Insulation Material for Vertical Bus Thickness 1 14 mm 0 045 in Anti hygroscopic 0 5 to 1 Electrical Strength 900 V mil Ground Bus Ground Bus Material Bare copper Optional Ground Bus Material Tin plated copper Continuous Current Rating at 40 C 104 F 600 A Dimensions per Phase 600 6 x 51 mm 1 4 x 2 in Cross Sectional Area 600A 32 mm 0 5 in total 1560E UMO50B EN P June 2013 Specifications A 7 Table A 7 Power Fuses and Losses Description Specifications Power Fuses and Fuse Holders This section details the power fuse and fuse holder technical information that each medium voltage product conforms to It includes information on R rated fuses as well as mounting dimensions

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