Home

Medium Voltage OneGear SMC Flex Motor Controller

Contents

1. d BYPASS CONTROLLER QB BC1 2 m BC2 BC3 POWER CONVERTER START CONTROLLER QB BC1 BC2 gt 4 U 2 gt 4 B mS a x es m e ba S ms RX1 me e RX1 me RX1 TX1 G RX1 oe YT 224 1 e pot p 2 2 em INCOMING ot LINEUNIT eee NL 2 SMC FLEX CT INPUTS FO4 15 FO16 27 FO28 39 3 PHASE PHASE PHASEC i GATE TRANSMITTERS Xn TBI FROM LEGEND m Lai gum WIRE CONNECTIONS FOR PHASE A y Bec s WIRE CONNECTIONS FOR PHASE B CONNECTIONS SHOWN FOR PHASE BEEN CURRENT LOOP CONDUCTORS PASS THROUGH THE C T S ON THE CURRENT LOOP ASSEMBLY REMOTE EQUIPMENT LACE GND1 GND2 6 VOLTAGE POWERBRICKS n S4 mas Jac TB6 C NS mee room CURRENT TRANSFORMER VOLTAGE SENSING BOARD eg gt CONTROL CURRENT LOOP GATE DRIVER BOARD sore gt SMC FLEX FIBRE OPTIC BOARD SMC FLEX INTERFACE BOARD E 0 CIRCUIT BREAKER oo
2. gts e o e o o o o Ro ro Isl Line Terminal Load Terminal Flex braid lt lt Power pole 15 With the gate pulses on check the voltage again on each gate driver board as described in step 13 above The voltage should be 4 5V DC 16 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 120V AC or 220 240V AC Plug the unit into the power source and plug the green connector into J1 on each of the gate driver boards see Figure 28 17 The yellow LED on the upper right hand side of the energized gate driver circuit should be lit it may appear dim depending on ambient light conditions While the gate pulses are still on check the voltage on each gate driver board as described in step 13 above The voltage should be 10 12V DC If the voltage is less than 5V then you have a bad gate driver board Do not leave the Portable Test Power Supply connected to a bad gate driver board The power supply adapter will overheat if the gate driver board is shorted 18 A more detailed check is performed by verifying the actual gate pulses by connecting an oscilloscope between TP1 and TP3 Figure 28 To check gate pulses the pulse generator must be enab
3. Current feedback test points Ribbon connector to Voltage Sensing Board Current loop power supply sensor input TB5 Current transformer connections TP18 19 20 Power supply test points x ed T L N G LN Serial Control Power Power Out Number 110 240V AC to SMC Flex Rockwell Automation Publication 7760 UM001E EN P December 2014 Notes 1 COMis the common connection for Gate and Pulse test points 2 VCOM is the common connection for Current and Voltage feedback test points Do not connect J2 VCOM to earth ground do not connect ICOM and VCOM together either directly or through test probes meter or scope common L Replacement Part Number Current loop CT Plug in test power supply Commissioning Procedure Chapter 2 Figure 28 Connection for Gate Driver Board Gate signal Temperature signal fibre optic fibre optic transmitter receiver Yellow LED 5V test point Thermistor connector connector a Snubber
4. 15 7762 Combination Controller Vacuum Contactor 16 7763 Combination Controller Vacuum Breaker 17 Power Factor Correction elec ee dd ee e Rer ng 18 Proposal for Implementation of Power Factor Correction Capacitors 20 SMC Flex Control Module 21 22 SOLE Stat UT SOT cs dees 22 Selectable Kickstart ead T EY RUE een 23 Current Limit Start e Lokal Ne DER ERE ees 23 Dua Ramp start ahs eie SP p e Ue E IS TR ER 24 Full Voltage Start bom 24 Preset Slow Speed i i necs set 25 Linear Speed Acceleration and 26 Sart ieu A 27 Protection and Diagnostics 28 28 Undetload 5 dca emot e ae Sonet LE rir 30 eee Even ces a dau 30 esee oua ed haee ECCE oS d aa 30 31 Stall Protection and Jam Detection 31 32 Thermistor PTC 33 PEG 34 Open 34 35 Excessive Starts Hour sees 35 MP 35 Metering er oe oa oe ooo ne ee 36 TO pec tT P 36 Commun
5. 0 100 1000 Percent Full Load Current Setting Rockwell Automation Publication 7760 UM001E EN P December 2014 29 Chapter 1 30 Product Overview 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 99 of the programmed motor full load current rating Trip delay time can be adjusted from 0 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 99 of the programmed motor voltage Trip delay time can be adjusted from 0 99 seconds Note For medium voltage applications undervoltage protection should be set at or above 80 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 ove
6. 59 Chapter 3 D Ia eeiahe ese Gee role ear oatetn men merase 61 Keypad Description e E eee 61 Programming Menu DUNS 61 Pe eh RENI MA HURTS 65 Parameter Management amon os 66 Random Access Memory RAM 66 Read only Memory ROM I UP oe a 66 Electrically Erasable Programmable Read only Memory EEPROM 66 Parameter Modification 0922222 chai 67 Sale Start eq voa eeu qua tub edad Ede d utar 68 Curt nr Limit Start ate ear Sox 68 Dyal Ramp Start uber ter ed Ead oo 69 Full Voltage Stare ee werd vows rotulo 70 Lincar Speed awit e is ede reti a d tese vni 70 Stop RR 70 Preset Slow Speed ausu ih se lay 71 Basic be E ED E 71 M tor Protection tre taa ot a tiene 72 Example Settings tiny voids e re pun eR 73 73 Overvoltage aac ea toe vee E dn 73 teed inn are RU is t 73 Rockwell Automation Publication 7760 UM001E EN P December 2014 Table of Contents deg cna arid 73 Motor Information a Mot a teorie uals Gores 74 Motor Data coco Ee eu ia Ee Ete dex se PEE EE cated 74 Chapter 4 Metering
7. Existing Controller Optional PFCC Cable Connection Point Power Converter Bypass Controller Optional PFCC ERES i RST RST RST RST RST aan d 1 i SMCFlex i Control Module Breaker Fused Contactor i i Optional Earthing Switch o n 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 i i i i i l PFCC 1 i i 1 i 1 E fetes SS Sea Se epee ec 1 i 1 i 1 i L 1 i 1 i 1 i i i i i bomo eee ep bee 18 Rockwell Automation Publication 7760 UM001E EN P December 2014 Start Controller Start Controller R ST Product Overview Chapter 1 Figure 6 Typical OneGear Single Line Diagram Bulletin 7762 10 12 kV Power Converter Bypass Controller Optional PFCC A Fused i i i i i i i i i Contactor i Contactor i i i i i i i i i i i i i i i i Optional Earthing Switch Figure 7 Typical OneGear Single Line Diagram with Optional Power Factor Correction Capacitor Bulletin 7763 10 14 4 kV Power Converter Bypass Controller Optional PFCC Control Module d P Breaker Contactor Optional E
8. Option Action Operation The green start button when pressed will commence motor acceleration to full speed Pump Control The red stop button when pressed will provide a coast stop and or reset a fault m The jog button when pressed will initiate a pump stop maneuver Braking Control GE The green start button when pressed will commence motor acceleration to full speed Smart Motor Braking E The red stop button when pressed will provide a coast stop and or reset a fault ia The jog button when pressed will initiate a pump stop maneuver Gm 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 Accu Stop With a stopped status the jog button when pressed will initiate slow speed motor operation From an at Jog 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 Em 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 Slow Speed with Braking Jog The jog button will initiate a brake stop Note Slow Speed cannot be operated via the HIM 1 Braking Control is not offered for standard use in MV applications Please consult factor
9. Unit Bus Bus Bar Material Bare copper Optional Unit Bus Plating Tin or Silver Continuous Current Rating at 40 C 104 F 630A Fault Withstand Current Rating 31 5 kA 100 msec Insulation Material where required Type Sleeve heat shrink Material Polyolefin Thickness 3 0 mm 0 12 in 120 mils Anti hygroscopic 0 25 Electrical Strength 500V mil 20 kV mm Ground Bus Ground Bus Material Bare copper Optional Ground Bus Material Tin plated copper Continuous Current Rating at 40 C 104 F 600A Dimensions 600A 8x 50 mm 5 16 x2 in Cross Sectional Area 600A 400 mm 0 625 in total Fault Withstand Current Rating 3 seconds 31 5 124 Rockwell Automation Publication 7760 UM001E EN P December 2014 7760 7761 7762 and 7763 SMC Flex Specifications Appendix A Table 45 Medium Voltage Spring Actuated Vacuum Circuit Breaker 10 12 kV Description Specification Voltage Ratings Maximum Rated Voltage 12 kV Basic Impulse Level 1 1 Withstand Phase to Ground Phase to Phase kV 75 Rated Insulation Voltage 12 kV Withstand Voltage at 50 Hz 28 kV Frequency Ratings 50 60 Hz Current Ratings Rated Normal current 40 C 630A Rated Breaking Capacity kA rated short circuit breaking current symmetrical 16 20 25 31 5 Rated short time withstand current 3s kA 16 20 25
10. Pump Start Rn Pump Stop Time seconds ATTENTION Pump stopping is not intended to be used as an emergency stop Refer to the applicable standard for emergency stop requirements mechanical dynamics of the pumping system Therefore select the lowest ATTENTION Pump stopping may cause motor heating depending on the stopping time setting that will satisfactorily stop the pump Braking Control Options The Braking Control options Smart Motor Braking Accu Stop and Slow Speed with Braking require attention to specific application considerations and therefore are not offered for standard use in MV applications Please consult factory for further assistance Hardware Description The following sections contain descriptions of system components and system operation Each section will be described to give the user an understanding of the MV SMC Flex to facilitate operation and maintenance of the system Refer to Figure 23 and Figure 24 Typical MV SMC Flex Power System 40 Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 Power Module The three phase AC line controller consists of three removable power modules one for each phase Each power module includes series connected PowerBricks 5 for 12 kV and 6 for 13 8 kV applications an isolated current loop power system a set of fiber optic cables for SCR control and line and load
11. EARTHING SWITCH OPTIONAL EQUIPMENT SMC FLEX POWERBRICK ASSEMBLY IK Laaydey MIIMA DnpoJg Figure 24 Typical OneGear SMC Flex Power System Bulletin 7760 71001999294 d NI JLOOWN 09ZZ uone i qng IMH tv 25 BYPASS CONTROLLER u QB L2 13 A POWER CONVERTER 2 EXISTING CONTROLLER CABLE CONNECTION UNIT p lt e y gt 12 A 4 gt 803 13 d AXE ae S S rz a C ovt ov2 ovt Tl s IBS CS al la si 5 gy a AT 797510 Aore TEST TEST TEST TEST S GP1 D GP2 D GP2 D GP1 Om B a ELO LL SRG Sco 4 gt 2 gt 74 aS TO SMC FLEX CT INPUTS FO4 15 FO16 27 FO28 39 PHASEA PHA
12. SMC Flex Control Module T i i S T Rockwell Automation Publication 7760 UM001E EN P December 2014 l 1 1 1 l 1 l 1 1 1 optional MPS To SMCFlex Control Module 1 l 1 1 Optional Earthing Switch 17 Chapter1 Product Overview Power Factor Correction Capacitors OneGear SMCs can be installed on a system with power factor correction capacitors These capacitors must be installed on the line side of the Power Converter to prevent damage to the SMC Flex Controller silicon controlled rectifiers SCR A separate switching contactor or breaker is required for the power factor correction capacitors This switching device closes only after the bypass contactor has closed The power factor correction capacitors must also be opened before the bypass contactor is opened to perform a stop function TIP Consult the factory is there are capacitors on the same branch circuit as the OneGear SMC WARNING Do not connect power factor correction capacitors in the circuit when OneGear SMC SCRs are gating Acceptable optional PFCC connection methods for Bulletin 7760 7762 and 7763 are shown in Figure 5 Figure 6 and Figure 7 The same concept applies to Bulletin 7761 Figure 5 Typical OneGear Single Line Diagram Bulletin 7760 10 14 4 kV with two optional Power Factor Correction Capacitor positions Vacuum Breaker
13. Bypass Contactor Enabled Bypass 0 Bypass Contactor Disabled 1 Ready Ready 0 Not Ready X X Option 1 1 Input Active Input 0 Input Inactive X X Option 2 1 Input Active Input 0 Input Inactive 92 Rockwell Automation Publication 7760 UM001E EN P December 2014 Bits 12 to 15 Not Used Table 33 Logic Status Word Control Communications Chapter 7 Bit Status Description 15 14 13 12 11 10 7 6 5 4 3 2 1 0 1 Stop Inhibit 0 No Action 1 Start en 0 No Action Option 1 Maneuver Inhibit Option Input 0 No Action 1 Clear Faults X Clear Faults 0 X Option 2 1 Perform Option 2 function Input 0 No Action Bits 5 10 Not Used 1 Use Aux 1 to Aux 4 A 0 Ignore Aux 1 to Aux 4 1 Aux 1 Active A nux 0 Aux 1 Inactive 1 Aux 2 Active Puce 0 Aux 2 Inactive 1 Aux 3 Active A s 0 Aux 3 Inactive 1 Aux 4 Active X ans 0 Aux 4 Inactive Reference Feed back The SMC Flex does not offer the analog Reference feature The analog Feedback Parameter Information feature is supported and will provide Parameter Current in Phase automatically as the feedback word A complete listing of the SMC Flex parameters is located in Appendix B Rockwell Automation Publication 776
14. Fiber Optic Interface Board Rockwell Automation Publication 7760 UM001E EN P December 2014 13 Chapter1 Product Overview 7760 Retrofit Controller A medium voltage solid state controller designed to work in conjunction with an existing customer supplied start controller It includes e Tin plated insulated copper horizontal power bus optional e A continuous bare copper ground bus 8 x 50 mm e Removable PowerBrick SCR assemblies Drawout bypass vacuum contactor breaker e Voltage sensing board low voltage control panel complete with microprocessor based control module e Fiber optic connection from SMC Flex control module to gate driver board on PowerBricks e Provision for bottom fed line and load connections Earthing switch optional Figure 1 Typical OneGear Single Line Diagram Bulletin 7760 10 14 4 kV Vacuum Breaker Existing Controller Cable Connection Unit Power Converter Bypass Controller peor I ret ne m emma Sn sn SS ims 4 _ 4 R S T 5 SMC Flex Control Module To Optional Farthing Bulletin Switch 7760 proof 14 Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 7761 Combination Controller A medium voltage solid state controller designed to work in conjunction with OEM customer supplied start and bypass con
15. Gnd Fit A Dly 78 Secs 0 250 10 Allows the user the ability to prevent some nuisance Alarms by entering a delay period that provides a window that the ground fault condition must persist within for the controller to Alarm PTC PTC Enable 79 Disable Enable Disable Enables PTC based over temperature protection when used with external PTC sensors Phase Reversal Phase Reversal 80 Disable Enable Disable Allows the user to prevent starting if the incoming line phase sequence is not correct The incoming power lines are expected to be in an ABC sequence The controller will fault if power lines are out of the ABC sequence Restart Starts Per Hour 81 Limits the number of starts that can occur in a one hour period This feature includes a sliding window for the one hour time period 2 recomMended Restart 136 Restart Attempts 82 Allows the user to enable the SMC Flex to auto restart for up to 5 attempts other than an SCR overtemp or motor overload fault The start signal must remain active for a restart to occur Rockwell Automation Publication 7760 UM001E EN P December 2014 SMC Flex Module Parameter Information Appendix B Group Parameter Parameter Units Min Max DefaultSettings Parameter Description User Settings Name Number Restar
16. High Eff Brake SMB Parameter Number 38 Units of Stopping Time Min Max 0 99 Default Settings Parameter Description This parameter is used to extend the SMB braking time by a percentage of the typical stopping time The need to adjust this parameter can occur when braking is applied to high efficiency motors and relates to the counter EMF produced by these motors This setting should never really exceed 50 Nuisance overload faults will likely occur if set incorrectly User Settings Preset SS Accu Stop Slow Speed Sel 39 SS Low 55 High SS High When this option is used this parameter provides the userthe ability to select between the Low and High settings for both the Preset Slow Speed and Accu Stop control options Preset SS Accu Stop Slow Speed Dir 40 SS FWD SS REV SSFWD Provides the user the ability to program the motor s direction of rotation Note that with the Preset Slow Speed option the controller has the capability to operate the motor in the reverse direction during slow speed operation without the use of a reversing contactor Preset SS Accu Stop Slow Accel Cur 4 96FLC 0 450 Provides the user the ability to program the current to slow speed operation for both the Preset Slow Speed and Accu Stop control options This setting is typically load dependent Preset SS Accu Stop Slow Running Cur 42 FLC 0 450
17. rovides the user with the ability to define the Basic Set Up Option Input 1 132 Option Fault Stop Option function of option Input 1 Fault NC Network Coast Stop Provides the user with the ability to define the Baste Set Up Stop Input Option Coast function of the stop input This is an additional Elapsed Time Meter that cannot Linear List Elapsed Time 2 134 Hours 0 0 3000 0 be reset by the user It increments exactly as the 1 Pump option modules default to Pump Stop 2 Brake option modules only 140 Elapsed Time but cannot be reset Rockwell Automation Publication 7760 UM001E EN P December 2014 Spare Parts Appendix C PowerBricks Table 51 PowerBrick Replacements Part Number Description PowerBrick Current Rating Match Designator 81020 230 51 R Complete PowerBrick W 81020 752 51 R excluding gate driver board U ae pas Complete Rollout Assembly 10 12 kV 160A 81020 761 52 R with PowerBricks gate driver boards and CT loop i HOER Complete Rollout Assembly 12 4 14 4 kV 81020 295 52 R with PowerBricks gate driver boards and CT loop i 81020 230 57 R Complete PowerBrick Y 81020 230 58 R excluding gate driver board 7 T Complete Rollout Assembly 10 12 kV 340A 81020 761 57 R with PowerBricks gate driver boards and CT loop Y Complete Rollout Assembly 12 4 14 4 kV 81020 295 57 R with PowerBricks gate driver boards
18. C2 0 2 7 LL E OO ad Sa L Connection to H3 7 a B T Os Overvoltage Sense Connection 6 Ifthe resistance values are out of range the PowerBrick must be removed from the power pole cart assembly Refer to PowerBrick removal procedure in the Installation Manual publication 7760 IN001_ EN P Rockwell Automation Publication 7760 UM001E EN P December 2014 109 Chapter 8 110 Troubleshooting 7 Refer to Figure 47 PowerBrick Component Locations Top View Once the PowerBrick has been removed remove the HS2 wire from the top of the center heatsink to isolate the SCRs from the snubber and sharing resistors Unplug the SCR gate connectors from the gate driver boards Measure the DC resistance between the center and either end heatsink The value should be greater than 100 If so and the gate cathode resistance is between 4 40 the SCRs do not need to be changed If the resistance is very low lt 4 an SCR has failed and must be replaced Note the Match Band character from the front of the PowerBrick and refer to Appendix C for replacement parts Figure 47 PowerBrick Component Locations Top View Gate Driver Board 8 Ifthe SCRs are healthy measure the DC resistance from S1 on the upper gate driver board to CS as shown in Figure 47 same as above The connection to CS is made at the hex socket head screw that protrudes through the round plastic feature
19. Provides the user the ability to program the operating current of slow speed operation for both the Preset Slow Speed and Accu Stop control options This setting is typically load dependent Accu Stop Stopping Current 43 FLC 0 400 Provides adjustment capability for the braking intensity from slow speed operation to the stopped condition for the Accu Stop control option Basic Set Up Overload Overload Class 44 Disable Class 10 Class 15 Class 20 Class 30 Class 10 Allows the user to select the time to trip for the built in overload This selection is based on the type of motor being used and the application it is being applied to Basic Set Up Overload Service Factor 45 0 01 1 99 1 15 This motor nameplate value is used to determine the ultimate overload trip current Basic Set Up Overload Motor FLC 46 1 0 2200 0 1 0 Sets the base current for use with all the current based protection features jam over under load motor overload The motor nameplate FLA is to be used Basic Set Up Overload Overload Reset 47 Manual Auto Manual Allows the user to select between an auto and manual reset mode for all Overload faults Linear List OL Shunt Time 48 Sec 0 999 This parameter prevents the overload from accumulating or incrementing the Motor Thermal Usage MTU during the programmed shunt time This function is all
20. Unbalanced feedback Overvoltage 20 e Supply voltage is greater than user e Check power system and correct if necessary programmed value Correct the user programmed value Undervoltage 21 Supply voltage is less than user e Check power system and correct if necessary programmed value e Correct the user programmed value The delay time is too short for the Extend the delay time to match the application requirements application Overload 22 Motor overloaded Check motor overload condition e Overload parameters are not matched Check programmed values for overload class and motor FLC to the motor Underload 23 Broken motor shaft e Repair or replace motor Broken belts toolbits etc e Check machine Pump cavitation Check pump system Jam 24 Motor current has exceeded the user e Correct source of jam programmed jam level Check programmed time value Stall 25 Motor has not reached full speed bythe Correct source of stall end ofthe programmed ramp time plus Stall delay time Phase Reversal 26 Incoming supply voltage is not in the Check power wiring expected ABC sequence Disable protection if not needed Comm Loss 27 28 29 Communication disconnection at the Check for a communication cable disconnection to the SMC Flex serial port controller Network 30 31 32 DPI network loss Reconnect for each DPI connected device Ground Fault 33 Ground fault current level has exceeded Check power syste
21. and CT loop Y g 81020 752 85 R Complete PowerBrick DM 81020 752 86 R excluding gate driver board DN T Complete Rollout Assembly 10 12 kV 580A 81020 761 85 R with PowerBricks gate driver boards and CT loop DM 81020 295 85 R Complete Rollout Assembly 12 4 14 4 kV DM with PowerBricks gate driver boards and CT loop Rockwell Automation Publication 7760 UM001E EN P December 2014 141 AppendixC Parts Table 52 Common Parts Part Number Description Quantity 80190 520 02 R Current loop self powered gate driver board CLGD 1 per SCR 81020 237 52 R 10 12kV Voltage Sensing Board VSB 1 per controller 81020 237 53 R 12 1 15 kV 80190 440 03 R Interface Board 1 per controller 80190 680 01 R Fiber Optic Board 1 per controller 80026 762 51 R Fiber Optic Cable Kit 1 per power pole 81023 213 09 R Fiber Optic Cable Kit Low Voltage Panel 1 per controller 80187 051 51 R 120V AC for North America Test Power Supply 1 per controller 80187 245 51 R Universal 80022 133 02 R Current loop power transformer 100VA 115 230 1 5V 1 per controller 80018 246 57 R Current loop cable 9 6 m 15 ft 1 per power pole 81023 036 61 R Current loop mounting bracket assembly includes hardware 1 per PowerBrick 6 81023 213 01 R Current loop flange 1 per SCR 6 81023 095 51 R Current loop current transformer 1 per SCR 80022 163 01 R Current loop sense
22. delay time and inhibit time A separate core Ground Fault Enable Ground Fault Level balance current transformer is required Ground Fault Delay Ground Fault Inhibit Time Ground Fault Alarm Enable Ground Fault Alarm Level Ground Fault Alarm Delay PTC Allows the user to connect 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 Phase Reversal sequence a fault will be indicated Restarts Allows the user to determine the maximum number of restarts per hour the unit can experience and Restarts Per Hour Restart Attempts delay time between consecutive starts Restart Delay 1 The delay time must be set to a value greater than zero when Undervoltage Overvoltage and Unbalance are enabled 2 For Jam and Underload detection to function the Motor FLC must be programmed in the Motor Protection group See page 63 Example Settings Undervoltage 1 With Line Voltage programmed for 11 000V and the Undervoltage level programmed for 8096 the trip value is 8800V Overvoltage With Line Voltage programmed for 13 800V and the Overvoltage level programmed for 11596 the trip value is 15 870V Jam With Motor FLC programmed for 150 A and the Jam level programmed for 400 the trip value is 600 A Underload With Motor FLC programmed for 90 A and the Underload level programmed for 6096 the trip value is
23. e Control voltage e Check control voltage Failed control module Replace control module Starting Two or three power phases are missing e Check power system Check voltage sensing module and connections Table 37 Motor Rotates but does not accelerate to full speed Display Possible Causes Possible Solutions Fault displayed See fault description See Table 35 addressing fault conditions Starting e Mechanical problems e Check for binding or external loading and correct e Inadequate Current Limit setting Check motor Failed control module e Adjust the Current Limit Level to a higher setting Replace control module 100 Rockwell Automation Publication 7760 UM001E EN P December 2014 Display Fault displayed Table 38 Motor Stops While Running Possible Causes See fault description Troubleshooting Chapter 8 Possible Solutions See Table 35 addressing fault conditions Display is blank Control voltage is absent Failed control module Check control wiring and correct if necessary Replace control module Stopped 0 0 A e Pilot devices e Check control wiring and correct if necessary Failed control module Replace control module Starting Two or three power phases are missing e Check power system Failed control module Check voltage sensing module and connections Replace control module Table 39 Irregular Starts Symptom Possible Causes Possible Solutions Bypass contact
24. 003 or later Rockwell Automation Publication 7760 UM001E EN P December 2014 95 Chapter7 Communications Notes 96 Rockwell Automation Publication 7760 UM001E EN P December 2014 General Notes and Warnings Chapter 8 Troubleshooting 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 in the United States Maintenance personnel must be trained in the safety practices procedures and requirements that pertain to their respective job assignments 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 ATTENTION Hazardous voltage is present in the motor circuit even when the 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 ATTENTION Disconnect the controller from the motor before measuring Note The time it takes for the motor to come up to speed may be more or less than the time p
25. 47 Commissioning Checks 49 Commissioning Procedure Start Up 59 Communications overview 37 85 Control Components Electronic Maintenance 118 Control Function Tests 58 Control Module Removal 102 Control Module Removal 102 Control Options Braking Control overview 40 overview 39 Pump Application Considerations 39 Pump Control overview 39 Control Wiring Options 80 controllers 7703 OEM 13 7760 Retrofit 14 7761 Combination 15 7762 Combination 16 7763 Combination 17 Current Limit Start Programming 68 Current Limit Start starting mode overview 23 Index Current Loop Gate Driver CLGD Board overview 41 Current Loop Power Supply 106 D Daignostics Fault Display 81 Diagnostics Clear Fault clearing a fault 81 Fault Buffer 82 codes 82 Fault Definitions 83 overview 81 Dual Ramp Start Programming 69 Dual Ramp Start starting mode overview 24 parameters 24 Excessive Starts Hour Protection and Diagnostics overview 35 Fans Maintenance 118 Fault Buffer 82 codes 82 Fault Definitions 83 Fault Display 81 clearing 81 Explanation 98 Full Voltage Start Programming 70 Full Voltage Start starting mode overview 24 Functional Description overview 44 G Ground Fault Alarm 33 Protection and Diagnostics overview 32 Trip 32 Ground Fault Alarm 33 Ground Fault Trip 32 Hardware Current Loop Gate Driver CLGD Board Rockwell Automation Publication 7760 UM001E EN P Decem
26. 60 63 13 201 16 500 1 Current deratings shown are the minimum levels Additional derating may be required due to power fuse limitations Please consult factory for additional details 2 Altitude correction factors for insulation withstand voltages derived from IEC 62271 1 Power Cell Current Rating at Ambient Temperature 40 C 50 C 160A 130A 340A 270A 580A 460A Rockwell Automation Publication 7760 UM001E EN P December 2014 123 AppendixA 7760 7761 7762 and 7763 SMC Flex Specifications Description Main Power Bus Table 44 Power Bus Specifications Specifications Bus Bar Material Tin plated insulated copper Optional Power Bus Plating Silver Continuous Current Rating at 40 C 104 F 1250 2000 A Maximum Full Load Temperature Rise 65 C 149 F Maximum Full Load Temperature 105 C 221 F 40 C ambient Fault Withstand Current Rating 3 seconds 31 5 kA RMS SYM Type of Bus Bracing Epoxy cast glass polyester Dimensions per Phase 1250A Qty 1 10 x 80 mm 3 8 x 3 in 2000 A Qty 2 10 x 80 mm 3 8 x 3 in Cross Sectional Area per Phase 1250A 800 mm 1 125 in total 2000A 1600 mm 2 25 2 total Type Sleeve heat shrink Material Polyolefin Insulating Material Between Phases and Ground Thickness 3 0 mm 0 12 in 120 mils Anti hygroscopic 0 2596 Electrical Strength 500V mil 20 kV mm
27. Automation Publication 7760 UM001E EN P December 2014 GP File Set Up 75 Chapter4 Metering Description Action Display 5 Press the Enter key to access the Monitoring group 6 Press the Enter key to access the Metering group Greur Metering 7 Scroll through the Metering parameters with the Up Down keys to access the desired FG BH information Press the Enter key to view that parameter Vu Volts Phase Volt Volts Phase i Volt Volts Phase i Volt F 4 Current Phase A Amps Pi Current Phase B 4 Amps Gg PEG Current Phase C Amps PHT Watt Meter KW Gig Kilowatt Hours KWH 9 Elapsed Time 4 Hour Gig P 10 Meter Reset No 11 Power Factor dnb P 12 Mtr Therm Usage MTU Refer to Metering on page 36 or Figure 34 on page 63 for details on the metering functions The metering values that are displayed on the SMC Flex can be modified to show you desired values by accessing Main Menu Preferences 76 Rockwell Automation Publication 7760 UM001E EN P December 2014 Overview Human Interface Module Chapter 5 Options The SMC Flex controller offers a variety of unique control programming and communication options t
28. Board POWER IN N Legend i Current Loop Conductors pass through the CT s on the current loop assembly BC4 Current Loop Current Sensor FB Miniature Circuit Breaker or Control Fuse KG Start Stop Signal Control Relay KG2 Bypass Controller Pilot Control Relay KG3 Start Controller Pilot Control Relay TT1 Current Loop Transformer Rockwell Automation Publication 7760 UM001E EN P December 2014 45 Chapter1 Product Overview Figure 26 Typical OneGear SMC Flex Control Circuit without Stop Control Bulletin 7760 Control Power 0 230V x o o FB HS wu OR FB 115V uo HBP wu e eV 1 0 To SMC Flex Interface M R BCA Board 6 N 5 f 6 Start Stop Signal from 7 V existing controller o Start Stop Signal Control Relay KG1 Controller Pilot From SMC Flex KG2 Control Rela Interface Board y DARS 5 SMC Flex to be SMC Flex control 2 by AUXA the customer terminals EXTERNAL BYPASS before start up DPI AUX2 AUX3 AUXA FAULT ALARM NORMAL PTC TACH GROUND INPUT INPUT FAULT I 23 24 25 26 27 28 29 30 31 32 33 34 SMC Flex Interface Board POWE
29. C Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 The Aux 4 contact is always configured as Normal N O to control the line circuit breaker contactor Network inputs can be obtained through proper programming of Option Input 1 and Option Input 2 Refer to Appendix B for available options Control Options The MV SMC Flex controller offers the control options described below IMPORTANT options listed in this section are mutually exclusive and must be specified when ordering An existing controller may be upgraded to another control option by replacing the control module and possibly other components Consult your nearest Rockwell Automation sales office Pump Control Option This option reduces surges during the starting and stopping of a centrifugal pump by smoothly accelerating and decelerating the motor The microprocessor analyzes the motor variables and generates commands that control the motor and reduce the possibility of surges occurring in the system The motor current will vary during the acceleration period and may be near the motor rated starting current The pump algorithm does not limit starting current since full voltage is needed to reach full speed with a loaded motor The starting time is programmable from 0 30 seconds and the stopping time is programmable from 0 120 seconds Kickstart is available with this option Pump Application Considerati
30. CT 1 per controller 80026 146 56 R Ribbon cable from VSB to Interface Board 1 per controller 80174 201 01 R Ribbon cable from control module to Interface 6 pin 2 per controller 80174 201 02 R board 8 pin 3 per controller Table 53 Accessories Part Number Description Quantity 41391 454 01 S1FX Control Module Standard 1 41391 454 01 B1FX Control Module Pump Control 80026 427 01 R Frequency to voltage converter to Tachometer 2 10 kHz 1 80026 427 02 R feedback 0 100kHz 80026 433 01 R 1 Optional equipment 12 Power Supply for frequency to voltage converter 7703E For OEM products refer to OEM supplied documentation for specific spare parts list Rockwell Automation Publication 7760 UM001E EN P December 2014 Accessories Appendix D Table of Accessories Table 54 Accessories Catalog Number Description Description Used With 20 HIM C3 HIM Remote Door Mounted P66 Type 4 12 Programmer Only 20 COMM R Remote 1 0 20 COMM S RS 485 DF 1 20 COMM D DeviceNet 20 COMM C ControlNet 20 COMM E EtherNet IP Communication Modules ae 20 COMM I InterBus 20 COMM L LonWorks 20 COMM Q ControlNet Fiber 20 COMM H RS485 HVAC Rockwell Automation Publication 7760 UM001E EN P December 2014 143 AppendixD Accessories Notes 144 Rockwell Automation Publication 7760 UM001E EN P December 2014 7760 U
31. Start 112 0 Disable 1 Enable Disable This parameter can be used to force the starting profile to complete its entire time period and ignore an early up to speed detection The default is set to Disabled so that the SMC can determine when the motor is at speed Rockwell Automation Publication 7760 UM001E EN P December 2014 See parameter 114 before adjusting this parameter Group Linear List Parameter Name Shut Off Parameter Number 113 Units current Min Max 0 37 Default Settings SMC Flex Module Parameter Information Parameter Description This parameter adjusts the level of current at which the SMC determines that the SCR has turned off Since this parameter has the potential to modify the SCR control scheme it is important that adjustments be made with the help of Technical Support Appendix B User Settings Do not change without factory assistance Linear List UTS Level 114 up to speed 75 The SMC has the ability to automatically determine ifthe motor is up to speed If there is a problem with detecting the up to speed condition this parameter can be modified to compensate Rule of thumb is this number should be increased on high efficiency motors experiencing problems Ifthe SMC is detecting the up to speed condition too late or not at all this number should be decreased on very low efficiency motors Note Be careful wh
32. Test 50 e The rear 3 grey connectors in the medium voltage cell connect to the blue receivers on the fiber optic board and the front 3 blue connectors receive the temperature feedback cables from the power pole harnesses one per power pole Verify that circuit board plug connectors are installed and fully inserted in their sockets e Verify that the cooling fan if supplied is secured and the rotor is not obstructed Complete device resistance checks per user manual Refer to Installation Instructions publication 7760 IN001_ EN P Complete Power Supply Tests Refer to Installation Instructions publication 7760 IN001_ EN P e Program the module with correct parameter settings Start the unit and record if available scope waveforms line voltage motor voltage and motor current MV SMC Flex Module Refer to Chapter 3 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 module should be programmed with an understanding of how the SMC functions and the characteristics of the motor and driven load Inappropriate settings may elicit unexpected results such as lack of acceleration torque or full voltage starting For Pump Control applications refer to Pump Application Considerations on page 39 If the factor
33. Testin Remove the ribbon connector from J1 by pressing down on the locking g tabs then gently pulling the connector out Measure the resistance between each tap and the ground connection and compare to the values in Figure 49 If the equipment includes an earthing switch the board will be effectively short circuited to ground In this case remove the ground wires before taking measurements Figure 49 Voltage Sensing Board To Interface Board Ground Connections em qr i i x a al Tz a g i 3 8 3 9 a a aj Li Rated Tap 1 3 5 2 4 6 Voltage to GND1 to GND1 12kV 17 4 25 z 6 222M0 338 0 Pu iL a 0 1 1 L2 T2 L3 T3 Measure across R2 R4 R6 R10 R12 R14 R18 R20 and R22 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 112 Rockwell Automation Publication 7760 UM001E EN P December 2014 Troubleshooting Chapter 8 If
34. UM001E EN P December 2014 Diagnostics Chapter 6 Fault Code Fault Code Motor PTC 12 Power Loss B 36 Open Bypass A 13 Power Loss 37 Open Bypass B 14 Hall ID 38 Open Bypass C 15 NVS Error 39 No Load A 16 No Load 40 No Load B 17 Line Loss 41 No Load 18 Line Loss B 42 Line Imbalance 19 Line Loss C 43 Overvoltage 20 V24 Loss 45 Undervoltage 21 V Control Loss 46 Overload 22 Input 1 48 Underload 23 Input 2 49 Jam 24 System Faults 128 209 1 Not applicable in MV applications Fault and Alarm Auxilia ry Auxiliary contacts can be programmed for Fault or Alarm N O or N C indication Parameter setup can be found in the Parameter Motor Protection Indication group when modifying parameters in the Program Mode Fault Definitions Note Additional details regarding fault definitions can be found in Chapter 1 Product Overview Table 25 Fault Definitions for the SMC Flex Fault Description Line Loss F1 F2 F3 The SMCFlex 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 Open gate indicates that an abnormal condition that causes faulty firing e g open SCR gate or faulty 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 P
35. are programmable to the function found on page 71 If programmed to Network or Network NC they can be controlled over a Network Please see Table 33 which defines the Logic Command Word Control Note For MV applications some of the I O are assigned to specific functions Please refer to Note on page 38 for additional details Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 Communication A serial interface port DPI is provided as standard which allows connection to the Bulletin 20 HIM LCD human interface modules Figure 19 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 Figure 20 Built in Keypad and LCD Port 5 DPI Communications Port 2 Ports 2 and 3 when two HIMs are connected with a splitter Rockwell Automation Publication 7760 UM001E EN P December 2014 37 Chapter1 Product Overview Status Indication 38 All auxiliary contacts can be programmed as NO or NC for the following states except External Bypass which can only be programmed as NO Normal Normal NC The contact state changes when the unit receives a Start Stop signal Up to Speed Up to Speed NC The c
36. displayed voltage and visa versa Remove any temporary jumpers or grounding devices used during commissioning 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 Check that all barriers or covers removed during installation or commissioning have been securely mounted Close and secure all doors and verify function of all interlocks that prevent access to medium voltage compartments when the unit is energized If an earthing switch is provided it must be opened before the apparatus can be inserted to the service position The controller is ready to power the motor Rockwell Automation Publication 7760 UM001E EN P December 2014 59 Chapter2 Commissioning Procedure Notes 60 Rockwell Automation Publication 7760 UM001E EN P December 2014 Overview Keypad Description Chapter 3 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 Note This User Manual pertains to the OneGear 10 15 kV SMC Flex control modules with version 6 003 firmware or later The keys found on the front of the SMC Flex controller are described below Table 7 SMC Flex Controller Keys Key Action Description Escape Esc Exit a menu cancel a change to parameter
37. period which the controller will ramp the voltage during a stopping maneuver 0 0 120 CT Ratio Scales the CT input to actual motor current 5 amp secondary assumed 1 1500 Example CT Ratio 150 5 program 150 Rockwell Automation Publication 7760 UM001E EN P December 2014 71 Chapter3 Programming Parameter Description Option Aux Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 19and Normal Normal NC Up to Speed Up 20 Aux Contacts 1 allows the user to configure the operation ofthe contacts to Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Aux2 Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 29 and Normal Normal NC Up to Speed Up 30 Aux Contacts 2 allows the user to configure the operation ofthe contacts to Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Aux3 Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 31 and Normal Normal NC Up to Speed Up 32 Aux Contacts 3 allows the user to configure the operation of the contacts to Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Aux4 Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 33 and Normal Normal NC Up t
38. ramp time initial torque are selected When input signal is high ramp time 2 initial torque 2 are selected Once the Option 2 input has been set to Dual Ramp you must ESC back to the Parameter File menu Re enter into the Set Up menu to show both Basic Set Up and Dual Ramp Basic Set Up Start Mode This selects the start mode for option 1 um Basic Set up Ramp Time This programs the time period during which the controller will ramp the output voltage up to full voltage 0 30 s for the first Start set up Basic Set up Initial Torque This parameter establishes and adjusts the initial reduced output voltage level for the first Soft Start set up 0 90 locked rotor torque Dual Ramp Start Mode 20 This selects the start motor for option 2 Dual Ramp Ramp Time 2 This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Start set up 0 30 8 Dual Ramp Initial Torque 2 The initial reduced output voltage level for the second Start set up is established and adjusted with this parameter 1 The Dual Ramp feature is available on the standard controller 2 Kickstart can be programmed for both start modes 0 90 locked rotor torque 3 For ramp times greater than 30 s set Ramp Time 2 to zero and program Start Time 2E parameter 130 for the new time Do not exceed the thermal capacity of the controller Rockwell Automatio
39. to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence 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 ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal P
40. 0 UM001E EN P December 2014 93 Chapter7 Communications Scale Factors for PLC Communication Display Text Unit Equivalents 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 RSNetworx When receiving or sending information from a PLC each text description has a numerical equivalent Table 34 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 34 Display Text Unit Equivalents Text Descriptor Numerical Equivalent Disabled 0 Class 10 1 Class 15 2 Class 20 3 Class 30 4 94 Rockwell Automation Publication 7760 UM001E EN P December 2014 Con
41. 01E EN P December 2014 63 Chapter 3 Programming Table 8 Parameter Linear List Parameter Description Parameter Description Parameter Description 1 Volts Phase A B 46 Motor FLC 91 Data In B2 2 Volts Phase B C 47 Overload Reset 92 Data In C1 3 Volts Phase C A 48 OL Shunt Time 93 Data In C 4 Current Phase A 49 OL Trip Enable 94 Data In D1 5 Current Phase B 50 Overload A 95 Data In D2 6 Current Phase C 51 Underload F Lvl 96 Data Out A1 7 Watt Meter 52 Underload F Dly 97 Data Out A2 8 Kilowatt Hours 53 Underload A 98 Data Out B1 9 Elapsed Time 54 Underload A Dly 99 Data Out B2 10 Meter Reset 55 Undervolt F Lvl 100 Data Out C1 11 Power Factor 56 Undervolt F Dly 101 Data Out C 12 Mtr Therm Usage 57 Undervolt A Lvl 102 Data Out D1 13 Motor Speed 58 Undervolt A Dly 103 Data Out D1 14 SMC Option 59 Overvolt F Lvl 104 Motor ID 15 Motor Connection 60 Overvolt F Dly 105 CT Ratio 16 Line Voltage 61 Overvolt A Lvl 106 MV Ratio 17 Starting Mode 62 Overvolt A Dly 107 Aux Config 18 Ramp Time 63 Unbalance F Lvl 108 Aux3 Config 19 Initial Torque 64 Unbalance F 01 109 Aux4 Config 20 Cur Limit Level 65 Unbalance A Lvl 110 Aux2 Config 21 Reserved 66 Unbalance A Dly 111 Language 2 Kickstart Time 67 Jam F Lvl 112 Timed Start 23 Kickstart Level 68 Jam F Dly 113 Shutoff Level 24 Option 2 Inp
42. 31 5 Making Capacity kA 40 50 63 80 Pole Distance mm 150 Opening Time ms 33 60 Arcing Time ms 10 15 Total Breaking Time ms 43 75 Closing Time ms 60 80 Operating Temperature C 5 50 with derating 1 The voltage and current ratings listed are valid up to 1000 m 3300 ft Please refer to Controller Derating chart for ratings above this altitude Rockwell Automation Publication 7760 UM001E EN P December 2014 125 AppendixA 7760 7761 7762 and 7763 SMC Flex Specifications Table 46 Medium Voltage Spring Actuated Vacuum Circuit Breaker 12 5 15 kV Description Specification Voltage Ratings Maximum Rated Voltage 17 5 kV Basic Impulse Level 1 1 Withstand Phase to Ground Phase to Phase kV 95 Rated Insulation Voltage 17 5 KV Withstand Voltage at 50 Hz 38 kV Frequency Ratings 50 60 Hz Current Ratings Rated Normal current 40 C 630A Rated Breaking Capacity rated short circuit breaking current symmetrical 16 20 25 31 5 Rated short time withstand current 3s kA 16 20 25 31 5 Making Capacity kA 40 50 63 80 Pole Distance mm 150 Opening Time ms 33 60 Arcing Time ms 10 15 Total Breaking Time ms 43 75 Closing Time ms 60 80 Operating Temperature C 5 50 with derating 1 The voltage and current ratings listed are valid up to 1 000 m 3 300 feet Please refer to Controller Deratin
43. 54 A 1 The average value of the three phase to phase voltages is utilized 2 The largest value of the three phase currents is utilized Rockwell Automation Publication 7760 UM001E EN P December 2014 73 Chapter3 Programming 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 Table 21 Motor Data Entry Options Parameter Description Option Display Overload Class 0 The factor default setting disables overload protection To enable Disable 10 15 20 30 it enter the desired trip class in this parameter Overload Class Service Factor 2 Enter the value from the motor s nameplate 0 01 1 99 Fa Service Factor tts MAB Motor FLC Enter the value from the motor s nameplate 1 0 2200 A PEA Motor FLC Amps Overload 90 Allows the user to select either manual or auto reset after an Manual Auto FG overload Overload Reset Manual Motor Connection 4 Enter the location of the SMC in relation to the motor windings Line Delta Fou Motor Con
44. 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 Displacement Power Factor Yes 122 Rockwell Automation Publication 7760 UM001E EN P December 2014 Electrical Ratings Tachometer Input Control Module IEC 7760 7761 7762 and 7763 SMC Flex Specifications Appendix A Voltage 0 5V DC 4 5V DC 10096 speed Current 1 Excludes power electronics 1 0mA 2 For stop maneuvers the gate driver boards are pre charged with a current loop power supply 75 VA Environmental Ratings Operating Temperature Range Table 42 Environmental Ratings IEC 0 50 C 32 122 F with derating above 40 C Storage and Transportation Temperature Range 20 75 4 167 F Altitude 0 1000 meters 3300 feet without derating Humidity 5 95 non condensing Pollution Degree 2 Table 43 Controller Deratings Power Cell Rating Reduce B I L and power Altitude Range 160A 340A 580A frequency Withstand Rating By Reduce Max Continuous Current Rating i 1000 2000 m 5A 10A 15A 13 3300 6600 ft 2001 3000 10A 20 A 30 28 6601 9900 ft 3001 4000 15 30 45A 4496 9901 13 200 ft 4001 5000 m 20A 40A
45. 760 UM001E EN P December 2014 Important Commissioning Checks Commissioning Procedure Chapter 2 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 ATTENTION Ensure that all sources of power are isolated and locked out before important checks are completed For more details follow the commissioning guidelines that follow this page ATTENTION When commissioning a MV SMC Flex it is critical that following Inspect the equipment for any signs of physical damage Verify SMC Flex physical installation is complete This includes physical attachment to adjacent cabinets bus bar power cable and control cable interconnections with Line and Bypass control gear and power cables to the motor Verify that any apparatus covers and barriers that were removed during installation have been replaced and secured Verify the integrity and operation of all safety interlocks Verify that motor mechanical installation is complete Verify that Incoming Power wiring to the equipment is complete and all connections are tight Verify that Motor cabling to the equipment is complete and that all connections are tight Verify that Control wiring between units of the equipment is complete Check for any damaged components and verify that electrical clearances have not been reduced while installing powe
46. 7760 UMO001C EN P September 2014 Lots oae a i d etu 145 7760 UM001B EN P MENTRE ON 145 Rockwell Automation Publication 7760 UM001E EN P December 2014 9 Table of Contents Notes 10 Rockwell Automation Publication 7760 UM001E EN P December 2014 Preface Service Procedure For your convenience the Rockwell Customer Support and Maintenance CSM provides an efficient and convenient method of servicing medium voltage products Contact your local area support office to make arrangements to have a qualified service representative come to your facility A complete listing of Area Support Offices may be obtained by calling your local Rockwell Automation Distributor or Sales Office For MV SMC Flex technical support on start up or existing installations contact your Rockwell Automation representative You can also call 1 519 740 4790 for assistance Monday through Friday from 9 00 a m to 5 00 p m Eastern time zone Rockwell Automation Publication 7760 UM001E EN P December 2014 11 Preface Notes 12 Rockwell Automation Publication 7760 UM001E EN P December 2014 Manual Objectives Documentation Description Chapter 1 Product Overview This manual is intended for use by personnel familiar with Medium Voltage and solid state power equipment The manual contains material which will allow the user to operate maintain and troubleshoot the OneGear MV SMC Flex family of controllers The family
47. A1 Stop Time Gnd Fit Lvl Data Out A2 Braking Current Undervoltage Gnd Fit Dly Data Out B1 Overload Class Gnd Fit Inh Time Data Out B2 Service Factor Underload F Lvl Gnd Enable Data Out C1 Motor FLC Underload F Dly Gnd Fit A Lvl Data Out 2 CT Ratio Underload A Lvl Gnd Fit A Data Out D1 Overload Reset Underload A Dly Parameter Mgt Data Out D2 Aux Config Parameter Mgt Parameter Mgt Aux2 Config PTC Aux3 Config Overvoltage Aux4 Config PTC Enable Backspin Timer Underload F Lvl Parameter Mgt Parameter Mgt Underload F Dly Underload A Lvl Phase Reversal DualRamp Option2 Underload A 01 Input Dual Ramp ParameterMgt Phase Reversal Parameter Mgt Starting Mode 2 Unbalance Ramp Time 2 Restart Initial Torque 2 Underload F Lvl Cur Limit Lvl 2 Underload F Dly E ts Kickstart Time 2 Underload A Lvl Restart DI Kickstart Lvl 2 Underload A Dly Eine cf to Parameter Mgt Parameter Mgt 9 Preset SS Option 2 Input Preset SS Slow Speed Sel Slow Speed Dir Slow Speed Acc Slow Running Cur Parameter Mgt 9 oe Depending upon SMC option selected some parameters may not appear in product display Steps back one level Braking Current For further information on parameters see Appendix B Slow Speed Sel For further information on parameter management see page 66 Slow Speed Dir Slow Accel Cur Slow Running Cur Stopping Current Parameter Mgt Rockwell Automation Publication 7760 UM0
48. Extensive protection features e Metering Communication capability e I O Innovative control option provides enhanced performance e Pump Control Start and Stop Control modes These modes features and options are further described in this chapter 1 Requires motor tachometer 2 This option utilizes gating patterns which result in motor and line currents that produce noise and vibration in the motor and or distribution transformer This must be considered before applying this option Rockwell Automation Publication 7760 UM001E EN P December 2014 21 Chapter1 Product Overview Starting Modes 22 Soft Start This mode has the most general application The motor is given an initial torque setting which is user adjustable from 0 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 30 seconds Once the MV SMC Flex controller senses that the motor has reached the up to speed condition during the voltage ramp operation the output voltage automatically switches to full voltage and the bypass contactor is closed Figure 8 Soft Start Percent Voltage 100 Initial Torque Start Time Seconds Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 Selectable Kickstart Selectable kickstart provides a power boos
49. ICE 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 117 Chapter9 Maintenance Environmental Considerations 118 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 barriers are in place and securely fastened 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 wa
50. Ifa RESET push button is present the N O push button auxiliary contact can be connected to Option Input 2 terminal 15 Option Input 2 must be programmed for Clear Fault Cycle control power to the SMC Flex controller IMPORTANT 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 details An overload fault cannot be reset until the Motor Thermal Usage parameter 12 value is below 75 See Protection and Diagnostics on page 28 for further descriptions A fault code cross reference is provided in Table 6 A Note Complete MV SMC Flex controllers are factory tested to prove fault trip functions so the Fault Buffer may already have fault codes in the queue Fault Codes Table 6 A provides a complete cross reference of the available fault codes and corresponding fault descriptions Table 24 Fault Code Cross Reference Fault Code Fault Code Line Loss A 1 Stall 25 Line Loss B 2 Phase Reversal 26 Line Loss C 3 Coms Loss P2 27 Shorted SCR A 4 Coms Loss P3 28 Shorted SCR B 5 Coms Loss P5 29 Shorted SCR C 6 Network P2 30 Open Gate A 7 Network P3 31 Open Gate B 8 Network P5 32 Open Gate C 9 Ground Fault 33 PTC Pwr Pole 10 Excess Starts Hour 34 SCR Overtemp 11 Power Loss A 35 Rockwell Automation Publication 7760
51. M001D EN P October 2014 7760 UM001C EN P September 2014 7760 UM001B EN P June 2013 Appendix E History of Changes This appendix summarizes the revisions to this manual Reference this appendix to determine what changes have been made across multiple revisions Change Inserted Power Factor Correction connection method information Added Proposal for Implementation of Power Factor Correction Capacitors Inserted History of Changes appendix Topic Migrated manual to FrameMaker Added 580 A to rated current in Electrical Ratings Updated Output Rating kW Hp Added 580 A power cell ratings in Control Deratings Added 580 A power cell current ratings to Control Deratings Added 580 A PowerBrick current ratings to PowerBrick Replacements Added Index Change Replaced inside front cover Rockwell Automation Publication 7760 UM001E EN P December 2014 145 AppendixE History of Changes Notes 146 Rockwell Automation Publication 7760 UM001E EN P December 2014 Numerics 7703 OEM Controller description 13 7760 Retrofit Controller description 14 7761 Combination Controller description 15 7762 Combination Controller Vacuum Contactor description 16 7763 Combination Controller Vacuum Breaker description 17 Barriers Maintenance 118 BasicSet Up Programming 71 C Circuit Board Replacement 107 Coils Maintenance 116 Commisioning Procedure Preliminary Set Up
52. Maximum Number of Sensors 6 Maximum Cold Resistance of PTC Sensor Chain 15000 Response Time 800 ms Rockwell Automation Publication 7760 UM001E EN P December 2014 33 Chapter1 Product Overview The following figure illustrates the required PTC sensor characteristics per IEC 34 11 2 Figure 18 PTC Sensor Characteristics per IEC 34 11 2 4000 1330 550 250 100 20 10 T 20 C TNF20K TNF 15K 0 5 1 L TNF 5K i TNF PTC Trip The MV SMC Flex will trip with a PTC indication if e No other fault currently exists PTC protection is enabled The resistance across terminals 23 and 24 is either greater than the relay s response resistance or less than the short circuit trip resistance Open Gate An open gate fault indicates that improper SCR firing typically caused by an open SCR gate or driver system has been detected on one of the power poles Before the controller shuts down it will attempt to start the motor a total of three times or as programmed in Parameter 82 An open gate is detected when the module sends a gate signal to the SCRs but does not detect that they turned on SCR turn on is detected when the voltage across the leg L T collapses The Open Gate detection is active during starting or stopping only 34 Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 Line Faults The MV SMC Flex controll
53. Ms are enabled on ports 2 and 3 Rockwell Automation Publication 7760 UM001E EN P December 2014 89 Chapter7 Communications Control Enable Loss of Communication and Network Faults SMC Flex Specific Information 90 Mask Code Description 32 Only the DPI communication card on port 5 is enabled 36 One HIM on port 2 and the DPI communication card on port 5 are enabled 44 Two HIMs on ports 2 and 3 and the DPI communication card on port 5 are enabled 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 a communication 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 IMPORTANT 5 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 faul
54. Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Default Settings Normal Parameter Description Allows the user the ability to configure each Auxiliary relay contact for a specific operation Note Normal SMC in RUN User Settings External Bypass or Up to Speed see Chap 1 Basic Set Up Aux3 Config 108 Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Alarm Allows the user the ability to configure each Auxiliary relay contact for a specific operation Note Normal SMC in RUN Basic Set Up Aux4 Config 109 Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Normal Allows the user the ability to configure each Auxiliary relay contact for a specific operation Note Normal SMC in RUN Basic Set Up Aux2 Config 110 Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Fault Allows the user the ability to configure each Auxiliary relay contact for a specific operation Note Normal SMC in RUN Language Language 111 English French Spanish German Portuguese Mandarin English Allows the user to change the text display to one of the available options Linear List 138 Timed
55. R IN L2 SMC Flex Fiber Optic Board POWER IN N Legend Current Loop Conductors pass through the 5 on the current loop assembly BC4 Current Loop Current Sensor FB Miniature Circuit Breaker or Control Fuse KG1 Start Stop Signal Control Relay KG2 Bypass Controller Pilot Control Relay TT4 Current Loop Transformer 46 Rockwell Automation Publication 7760 UM001E EN P December 2014 Chapter 2 Commissioning Procedure Prelimin ary Set Up A Ensure the work area is clean and tidy Pathways to main disconnect and emergency stop push button must be clear and unobstructed B The following test equipment is to be prepared for use e Test power supply supplied with each controller e Multimeters Hi Pot Tester recommended or Megger Oscilloscope with memory optional C Complete drawing package and parts list D Specification of project Rockwell Automation Publication 7760 UM001E EN P December 2014 47 Chapter2 Commissioning Procedure System Characteristics Job Name Job Number Rated Voltage Rated Current Actual Motor Load Load Type Fan Pump Compresor Mixer S F Other Constant Torque or Variable Torque Actual Motor Data Motor HP Motor Rated Speed Motor EL A Motor S F Motor L R A Frequency Phases 48 Rockwell Automation Publication 7
56. SEB PHASEC GATE TRANSMITTERS LEGEND T FROM A WIRE CONNECTIONS FOR PHASE A For g LU omn WIRE CONNECTIONS FOR PHASE B ms cj CONNECTIONS SHOWN FOR PHASE C CURRENT LOOP CONDUCTORS PASS THROUGH THE 1 5 xm av ON THE CURRENT LOOP ASSEMBLY mE E a REMOTE EQUIPMENT 2 m VOLTAGE NUMBER OF n POWERBRICKS n d o VICA 5 e mw FRO CURRENT SHORT CIRCUIT PROTECTIVE DEVICE MAY BE A CIRCUIT ops BREAKER OR FUSED CONTACTOR WITH DISCONNECT UH BC CURRENT TRANSFORMER OSMA BV VOLTAGE SENSING BOARD 38 2 GP CURRENT LOOP GATE DRIVER BOARD i ae d TES KF1 SMCFLEX FIBRE OPTIC BOARD wol KF2 SMC FLEX INTERFACE BOARD FROM 0 5 A MOTOR PHASE QB CIRCUIT BREAKER CONTROL cS aal 18 5 CURRENT FEEDBACK FROM QE EARTHING SWITCH OPTIONAL EQUIPMENT QUT e EXISTING CONTROLLER RS SMCFLEX POWERBRICK ASSEMBLY MalAJIAQ 11939 4 Chapter1 Product Overview Functional Description Bulletin 7763 Basic Control Controlled Start only When wired as shown in Figure 25 on page 45 the controller operates as follows Pressing the Start button initiates the start sequence Relay KG1 closes and applies control power to terminal 17 of the SMC Flex module The auxiliary contact 4 set for closes picking up which completes the hold in circu
57. User Manual Allen Bradley Medium Voltage OneGear SMC Flex Motor Controller 10 15 kV Publication 7760 UMO01E EN P Allen Bradley Rockwell Software 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
58. ab com mvb 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 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 7760 December 2014 Supersedes Publication 7760 UM001D EN P October 2014 Copyright 2014 Rockwell Automation Inc All rights reserved Printed in Canada
59. act 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 or breaker directly In this case the control circuit would look like and function similar to the descriptions above for the Bulletin 7763 Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 Figure 25 Typical OneGear SMC Flex Control Circuit without Stop Control Bulletin 7763 Control Power FB 115V To SMC Flex c Interface Board TB6 f i f i WP A B C START STOP ry Jn Start Stop Signal T Xo kei Control Relay KG3 RS Bypass Controller Pilot KG2 Control Relay From SMC Flex Interface Board bes SMC Flex to be 11 12 13 14 15 16 17 18 19 20 21 22 programmed by SMC Flex control C the customer i AUX 1 terminals URTOSSP ED before start up DPI AUX2 AUX 3 AUXA ne aor ROUND FAULT ALARM NORMAL INPUT INPUT FAULT lt d r a a 25 2 2 28 29 3 32 34 j Start Controller Pilot nee Control Relay SMC Flex Interface Board POWER IN LON SMC Flex Fiber Optic
60. akage current may be recorded for future comparison testing and must be less than 40 mA Ifa 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 5k megohms or greater It is recommended that the Main and Bypass switches be in the open position and that the input and output cables be disconnected for each phase Ifan earthing switch is provided it must be open This will ensure the unit is isolated from the line earth and the motor The line and the motor may be tested separately to locate problem areas 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 51 Chapter2 Commissioning Procedure SW2 When ON up provides test pulses to gate driver circuits Note Must be OFF down for normal operation Phase A Fibre Optic Transmitters send gate signals to driver boards Phase B Fibre Optic Transmitters Figure 27 Connection and Test Information for Interface Board LED Red ON when test p
61. al reduced output voltage level for the voltage ramp to the motor is established and adjusted with 0 90 locked rotor torque this parameter Kickstart Time A boost of current is provided to the motor for the programmed time period 0 0 2 0 Kickstart Level Adjusts the amount of current applied to the motor during the kickstart time 0 90 locked rotor torque 1 Ifthe controller senses that he motor has reached full speed before completing the Soft Start it will automatically switch to providing full voltage to the motor 2 For ramp times greater than 30 s set Ramp Time to zero and program Ramp Time E parameter 129 to the new time Do not exceed the thermal capacity of the controller Current Limit Start To apply a fixed reduced output voltage to the motor the following parameters are provided for user adjustment Table 13 Current Limit Start Parameters and Options Parameter Description Option Starting Mode This must be programmed for Soft Start Current Limit Ramp Time Programs the time period that the controller will ramp the output voltage to full voltage from the initial 0 30 59 Torque level programmed Current Limit Level This parameter provides adjustability for the reduced output voltage level provided to the motor 50 60 load current Kickstart Time A boost of current is provided to the motor for the programmed time period 0 0 2 0 s Kickstart Level Adjusts the amount of current
62. ame positions and secure them with cable ties at the ends of the wire guide channels g Re install the insulation shrouds with nylon screws torque to 0 3 Nem 2 7 Ibein breakdowns due to surge voltages Failure to replace all six covers with nylon hardware before energizing may result in personal injury property damage or economic loss ATTENTION The insulation shrouds are required to prevent insulation 104 Rockwell Automation Publication 7760 UM001E EN P December 2014 Troubleshooting Chapter 8 Figure 43 14 4 kV Sensing Board Insulation Shrouds Insulation Shroud A Nylon Screw goes here f VSB channel 6 Replace with the new assembly securing with all 4 fasteners See diagram below a Reconnect the high voltage wire to the bus bars and plastic stand off clips ATTENTION The high voltage wires must not touch earthed metal or bare conductors 7 Plugin ribbon cable making sure that it is positioned properly and fitting is secure locking mechanism is engaged Re connect both ground wires and shield connection for the ribbon cable 8 For personnel and equipment safety ensure both grounding connections are reconnected to the sensing board Rockwell Automation Publication 7760 UM001E EN P December 2014 105 Chapter8 Troubleshooting Figure 44 Sensing Board with mounting hardware placement Mounting Hardwar Mounting Hardware Mounting Har
63. ample Settings Jam 73 Overvoltage 73 Underload 73 Undervoltage 73 Full Voltage Start 70 Keypad description 61 Linear Speed 70 Menu 61 structure hierarchy 62 Motor Data Entry 74 Motor Information 74 Motor Protection 72 MV SMC Flex Module 50 overview 37 61 parameter list 64 parameter management 66 Electrically Erasable Programmable Read only Memory EEPROM 66 Random Access Memory RAM 66 Index Read Only Memory ROM 66 Parameter Menu structure hierarchy 63 parameter modification 67 Parameters Options 79 Password 65 modification procedure 65 Preset Slow Speed 71 Soft Start 68 Stop Control 70 Protection and Diagnostics 28 Excessive Starts Hour overview 35 Ground Fault overview 32 Jam Detection overview 31 Line Faults overview 35 Open Gate overview 34 Overload overview 28 Overtemperature overview 35 Overvoltage overview 30 PTC Protection overview 33 Stall Protection overview 31 Thermistor overview 33 Unbalance overview 31 Underload overview 30 Undervoltage overview 30 PTC Protection Protection and Diagnostics overview 33 Trip 34 PTC Trip 34 Pump Application 39 Resistance Checks and Power Supply Tests 53 5 Selectable Kickstart starting mode overview 23 SMC Flex Control Module description 21 SMC Flex Module Parameters 131 List 131 Rockwell Automation Publication 7760 UM001E EN P December 2014 149 SMC Flex Specifications Controller Deratings 123 Electrical R
64. an restore defaults by accessing the memory storage menu Table 10 SMC Flex Controller ROM Reset Procedure Display Memory Storage Reset to Defaults Electrically Erasable Programmable Read only Memory EEPROM The SMC Flex controller provides a non volatile area for storing user modified parameter values in the EEPROM Rockwell Automation Publication 7760 UM001E EN P December 2014 Programming Chapter3 Parameter Modification All parameters are modified using the same method The basic steps to performing parameter modification are described below Notes 1 Parameter values modified while the motor is operating are not valid until the next start sequence begins 2 Ifthe password is set parameters cannot be adjusted without logging in 3 Use the Sel key to highlight a single digit Table 11 Parameter Modification Procedure Description Action Display D Amps vot MTU 1 Press the ESC key to go from the status display to the Main menu E 2 Scroll with the Up Down keys until the Preferences option is highlighted Main Menu Memory Storage 3 Pressthe Enter key to access the Parameter menu Fe Monitoring 4 Scroll with the Up Down keys until the option you want to use Monitoring Motor HGB Fe Protection etc is highlighted For this example Set Up will be used Set Up Motor Protection 5 Press Enter to select the Set Up gr
65. applied to the motor during the kickstart time 0 90 locked rotor torque 1 Ifthe controller senses that he motor has reached full speed before completing the Soft Start it will automatically switch to providing full voltage to the motor 2 For ramp times greater than 30 s set Ramp Time to zero and program Ramp Time E parameter 129 to the new time Do not exceed the thermal capacity of the controller 68 Rockwell Automation Publication 7760 UM001E EN P December 2014 Dual Ramp Start Programming _ 3 The SMC Flex controller provides the user with the ability to select between two Start settings The parameters below are available in the Set Up programming mode To obtain Dual Ramp control Ramp 1 is located in the Basic Set Up and Ramp 2 is located in the Option 2 Input Dual Ramp Table 14 Dual Ramp Parameters and Options Parameter Description Option Set Up The user must select the Set up programming mode to obtain access to the Dual Ramp parameters Basic Set up Starting Mode Set up as stated in previous pages Option Input 2 Dual Ramp This allows the user the option to choose between two Soft Start profiles defined by 1 Start Mode Ramp Time Initial Torque and 2 Start Mode 2 Ramp Time 2 Initial Torque 2 When this feature is turned on the ramp time initial torque combination is determined by hard contact input to terminal 15 When this input signal is low
66. arthing Switch Rockwell Automation Publication 7760 UM001E EN P December 2014 19 Chapter1 Product Overview Proposal for Implementation of Power Factor Correction Capacitors Control Relay Permissives Bypass Control B Start Control M Capacitor Control CC KG4 1 Normal start rung KG1 initiates start through the SMC Flex module at Term 16 2 M closes motor accelerates the Up to Speed contact within the SMC Flex module between terminal 19 and 20 closes B closes 3 KG3 and then close to apply PFCC 4 Ifoption stop KG1 opens KG4 immediately to drop out PFCC and command SMC to stop 5 CC holds in until CC drops out then permits to open option stop continues 6 Ifa coast stop is initiated the Flex will open the contact between 20 and 34 KG3 will open M and command KG 4 to open CC CC will hold B until CC drops out 20 Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 SMC Flex Control Module The MV SMC Flex controller offers a full range of starting and stopping modes as standard e Soft Start with Selectable Kickstart Soft Stop e Current Limit Start with Selectable Kickstart e Linear Acceleration with Selectable Kickstart e Linear Deceleration Dual Ramp Start e Preset Slow Speed e Full Voltage Start Other features that offer further user benefit include
67. at the top of the snubber capacitor This resistance should be 60 6 Ifa capacitance meter is available connect from CS to 52 on the lower gate driver board The snubber capacitor should be 0 68 04yF Ifa capacitance meter is not available an ohmmeter may be used and should ramp up to gt 2 MO over several seconds This method does not ensure that the capacitor is healthy but will show if it is shorted or open If the snubber components are suspect repair or replace the PowerBrick Refer to Appendix C for replacements parts Rockwell Automation Publication 7760 UM001E EN P December 2014 9 10 11 Troubleshooting Chapter 8 Measure DC resistance between C1 and C2 at the gate driver boards The value should be 32 5 1 7 k If this point is open the sharing resistors are damaged or wire connections are open Repair or replace the PowerBrick refer to Appendix C If the PowerBrick is replaced ensure that all components are securely connected per Figure 48 Check DC resistance values per step 5 above Replace the PowerBrick in the power pole assembly Figure 48 PowerBrick Component Wiring Diagram Thermistor Sharing Resistors Snubber G2 Rockwell Automation Publication 7760 UM001E EN P December 2014 111 Chapter8 Troubleshooting Volta ge Sensing Board 1 Check the resistance of the voltage sensing module refer to Figure 49
68. atings Bullet 7761 121 Environmental Ratings 123 Medium Voltage Magnetically Actuated Vacuum Circuit Breaker 10 to 12 kV 127 12 5 to 15 kV 128 Medium Voltage Spring Actuated Vacuum Circuit Breaker 10 to 12 kV 125 12 5 to 15 kV 126 Medium Voltage Vacuum Contactor 10 to 12 kV 129 Power Bus Specifications 124 Soft Start Programming 68 Soft Start starting mode overview 22 Soft Stop starting mode overview 27 Solid State Devices Maintenance 116 Spare Parts PowerBrick Accessories 142 Common Parts 142 Replacements 141 Stall Protection Protection and Diagnostics overview 31 Starting Modes Current Limit Start overview 23 Dual Ramp Start overview 24 parameters 24 Full Voltage Start overview 24 Linear Speed Acceleration and Deceleration overview 26 overview 22 Preset Slow Speed overview 25 Selectable Kickstart overview 23 Soft Start overview 22 Soft Stop overview 27 Static Sensitive Items Maintenance 117 Status Indication overview 38 Stop Control Programming 70 T Terminals Maintenance 116 tests Control Function 58 Hi Pot and Megger 50 Resistance and Power Supply 53 Thermistor Protection and Diagnostics overview 33 Troubleshooting Circuit Board Replacement 107 Current Loop Power Supply 106 Fault Display Explanation 98 Flowchart 98 Irregular Starts 101 Miscellaneous Situation 101 Motor Rotates but does not accelerate to full speed 100 Motor Stops While Running 101 Motor Will Not Start 100 Power Resisto
69. ault and an Alarm setting Table 20 Motor Protection Parameters and Options Description Allows the user to select the operation of the overload Option Trip Class Service Factor Motor FLC Overload Reset Overload Alarm Level Underload 90 Determines the trip level as a percentage of the motor s FLA and the delay period Underload Fault Level 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 1 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 1 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 2 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 72 Rockwell Automation Publication 7760 0 December 2014 Programming Chapter 3 Parameter Description Option Ground Fault Allows the user to enable the ground fault level in amps
70. aults 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 Line Loss F41 F42 F43 During expected SCR gate periods the power pole voltage and currents are monitored If the SCR conduction is not continuous a fault is indicated 1 Phase loss overvoltage and undervoltage protection are disabled during braking operation 2 detection and underload protection are disabled during slow speed and braking operation 84 Rockwell Automation Publication 7760 UM001E EN P December 2014 Overview Communication Ports Chapter 7 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 commun
71. be configured to return additional information The I O message size depends on how many Configuration DataLinks are enabled The following table summarizes the I O data sizes Table 31 Variable Input Output Configuration Data Links Rx Size Tx Size Logical Status Command 16 b Reference Feedback 16 b z 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 X X X X To configure DataLinks refer to Configuring DataL inks on page 95 Rockwell Automation Publication 7760 UM001E EN P December 2014 91 Chapter 7 Communications SMC Flex Bit Identification Table 32 Logic Status Word Bit Status Description 15 14 13 12 11 10 8 7 6 5 4 3 2 1 0 1 Control Power Applied 5 Enabled 0 No Control Power 1 Power Applied to Motor Running 0 Power not Applied to Motor 1 ABC Phasing Phasing 0 CBA Phasing X Phasing 1 3 phase is valid Active 0 No valid 3 phase is detected X Starting 1 Performing a Start Maneuver Accel 0 Not performing a Start Maneuver X Stopping 1 Performing a Start Maneuver Decel 0 Not performing a Start Maneuver 1 Alarm Present 2 Bom 0 No Alarm Present 1 Fault Condition Exists Fault 0 No Fault Condition 1 Full Voltage Applied 0 Not Full Voltage Applied Start 1 Start Isolation Contactor Enabled Isolation 0 Start Isolation Contactor Disabled 1
72. beft 27 Nem Take care not to drop any hardware during the process of re connecting the links Rockwell Automation Publication 7760 UM001E EN P December 2014 57 Chapter2 Commissioning Procedure Control Function Tests Voltage Sensing Module 58 Ensure that the following are carried out before the control function test 1 The Medium Voltage to the Incoming Line Unit is locked and tagged out 2 Theearthing switch on the Bypass Unit is closed 3 The SCR Power Trucks are racked in and mechanically bolted in position The Power connections to SCR Power Truck are made and torqued to 14 Ne m 11 Ibeft The fibre optic connections on the fibre optic board are plugged in and the current loop wires are terminated 5 The Soft Starter Unit doors are closed in the required sequence as per interlock sequence 6 The connector for control wiring of the Bypass and Main Circuit breakers or contactors are plugged in 7 The Bypass and Main circuit breakers or contactors are racked to the Test position for the control function test The following control function test shall be carried out 8 Apply rated control voltage to the control circuit 9 Using the control schematic apply control signals to cause relays circuit breakers or contactors to energize to verify operation 10 Remove any jumpers used in the test and restore all circuits to normal when finished The voltage sensing module consists of a voltage sensing boa
73. ber 2014 147 Index 148 overview 41 description 40 Interface Board overview 41 Power Module description 41 Hi Pot and Megger Test 50 Human Interface Module HIM overview 77 1 0 overview 36 Interface Board overview 41 Interlocks Maintenance 118 J Jam Detection Protection and Diagnostics overview 31 K Keypad Programming description 61 L Line Faults Protection and Diagnostics overview 35 Linear Speed Programming 70 Linear Speed Acceleration and Deceleration starting mode overview 26 M Maintenance Barriers 118 Coils 116 Contamination 115 Control Components Electronic 118 Environmental Considerations 118 Disposal 119 Hazardous materials 118 Fans 118 Interlocks 118 Periodic Inspection 115 Power Components 117 Safety and Preventative 115 Solid State Devices 116 Static Sensitive Items 117 Terminals 116 Vacuum Bottles 116 Metering overview 36 75 viewing data 75 modules SMC Flex Control 21 Motor Protection Programming 72 MV SMC Flex Module Programming 50 0 Open Gate Protection and Diagnostics overview 34 Options Control Wiring 80 overview 77 Programming Parameters 79 Overload Protection and Diagnostics overview 28 Overtemperature Protection and Diagnostics overview 35 overview Communications 37 85 Control Options 39 Braking Control 40 Pump Control 39 Diagnostics 81 Functional Description 44 Hardware Current Loop Gate Driver CLGD Board 41 Inte
74. ce 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 FLEX 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 1 2 Disconnect the HIM and allow to power down Reconnect the HIM On Initializing screen the bottom right corner of LCD shows Port X Note this port number 88 Rockwell Automation Publication 7760 UM001E EN P December 2014 Communications Chapter 7 Figure 39 Port Number Displayed 3 Go to Logic Mask found as follows Main Menu Parameter Communications Comm Mask Logic Mask Figure 40 Logic Mask Displayed 4 Set 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 If enabling control from the built in SMC Flex programmer the Logic Mask must be set as follows Table 29 Logic Mask Requirements Mask Code Description 0 No external DPI devices are enabled 4 Only one HIM on port 2 is enabled 12 Two HI
75. connections Each PowerBrick includes two inverse parallel connected SCRs plus snubbers and self powered gate driver circuits Each PowerBrick includes a snubber circuit to limit the rate of rise in voltage across each SCR pair The module also includes patented current loop gate driver circuits which derive their power primarily from the snubber circuit Voltage sharing resistors are connected across each SCR pair to provide static voltage balance for series connected SCRs These resistors are tapped to provide a reference for overvoltage protection circuitry on the gate driver board A voltage sensing board is used to reduce the line side and load side voltages to lower levels that can be measured by the SMC Flex control module Current Loop Gate Driver CLGD Board This board provides the turn on capability for SCR devices The board also provides optical fibre isolation between itself and the gating source logic It is primarily powered by recovering energy from the snubber circuit so it is fully isolated from the control and logic circuits The board also receives short term power from the current loop power supply The MV SMC Flex has three heatsinks fitted with a thermistor to monitor temperature rise The circuitry on the gate driver board accepts the thermistor and drives a fibre optic cable if the temperature is below the setpoint 85 C If the temperature rises above the setpoint the driver is turned off and the MV SMC Flex i
76. consists of the following Bulletin numbers 7760 7761 7762 and 7763 Note This user manual pertains to units with firmware release 6 003 or later The following Rockwell Automation publications provide pertinent information for the MV SMC Flex and components Table 1 Rockwell Automation MV SMC Flex publications MV 0QS050B EN P General Handling Procedures for MV Controllers 7760 TD001 EN P OneGear SMC Flex Solid State Motor Controller 10 15 kV Technical Data 7760 SRO01_ EN P OneGear SMC Flex Solid State Motor Controller 10 15 kV Specification Guide 1560E WP023 EN P How to Successfully Apply Medium Voltage Soft Starters 150 WP003 EN P SMC Flex Controller with Pump Control 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 1500 SMC Flex 7703 OEM Controller A medium voltage solid state controller designed to mount in a structure provided by an OEM and designed to work in conjunction with existing or OEM customer supplied start and bypass controllers It is comprised of several modular components including e PowerBrick SCR assemblies including gate driver boards Loose interface and voltage feedback boards Fiber optic cables for SCR firing e Microprocessor based control module
77. contact your nearest Rockwell Automation sales office You can also call Rockwell Automation Medium Voltage Product Support at 1 519 740 4790 for assistance Rockwell Automation Publication 7760 UM001E EN P December 2014 65 Chapter3 Programming Parameter Management Description Recalling Defaults After parameter values have been modified factory default settings can still be re initialized 66 Before you begin programming it is important to understand how the controller memory is e structured within the SMC Flex controller e used on power up and during normal operation Refer to Figure 35 and explanations below Figure 35 Memory Block Diagram EEPROM RAM ROM 23 23 35223 Random Access Memory RAM This is the work area of the controller after it is powered up The SMC Flex uses an Auto Store feature when programming parameters When parameters are modified in the program mode the new values are stored immediately in RAM and then in EEPROM once the enter key has been pressed If control power is lost prior to the enter key being pressed these values will be lost When the device first powers up the values from the EEPROM area of memory are copied into RAM Read only Memory ROM The SMC Flex controller comes with factory default parameter values These settings are stored in non volatile ROM and are displayed the first time you enter the Program mode At any time you c
78. d above there may be one or more shorted SCRs in the PowerBricks 3 Ifa short circuit is suspected the power pole cart must be removed from the equipment to facilitate further testing Refer to cart removal instructions in the Installation Instructions Manual publication 7760 14001 EN P 4 Remove the clear plastic guards from the front and rear of the power pole assembly by removing two screws from the top and bottom of each guard 5 Measure DC resistances as follows for each PowerBrick Refer to Figure 46 C1 to C2 21 29 Gate to Cathode 4 40 Figure 46 PowerBrick Current Loop Gate Driver Board Connections Test Power Supply Connector Current Loop CT Connector Gate Logic Fibre Optic Receiver Temperature Feedback Fibre Optic Transmitter Thermistor Connector J2 Snubber Resistor P U U 5 i Connection H E ii i 2 3 UE Match Band Character Therm J1 a CT Rx1 Tx1 Si 23 Cl Ovi G1 C1 OO Connection to H2 H Hn RIS lu 4 EI gt SCR Gate Lead Connectors 15 Snubber Capacitor m E Connection CT
79. d to the motor approx 0 90 for ramp profile 2 Basic Set Up Stop Mode m 32 Soft Stop Linear Speed sug Accu Stop Soft Stop Allows the user to select the type of stop provided with the installed controller Basic Set Up Stop Time 33 Secs 0 120 Allows the user to select the length of stopping time when a stopping mode is selected Linear List Pump Pedestal 34 Only available with Pump Control option Allows the ability to manually adjust the pump algorithm slightly for different applications The purpose of this parameter is to allow the pump stop algorithm to be more aggressive earlier in the ramp If experiencing overload trips during stopping either reduce the stopping time or try increasing this by units of 5 Try not to exceed a value of 40 Basic Set Up Accu Stop Braking Current 35 FLC 0 400 When the Smart Motor Braking option is installed this parameter allows the user the ability to adjust the braking current level applied to the motor Smart Motor Braking and Accu Stop has the capability to apply braking current to the motor from the at speed condition With Smart Motor Braking the braking maneuver continues until the motor comes to rest at which point the controller automatically ceases braking action Note that high braking currents can introduce excessive vibration to the motor couplings and or gearing and additional heating in the mo
80. ddenly when power is removed from the motor Fluid surges with pumps still occur with the Soft Stop option e 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 Motor overheats e Overload 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 e Winding fault Identify fault and correct Check for shorted SCR replace if necessary Ensure power terminals are secure Motor coasts when option stop is programmed Control Module Removal 102 Option not programmed e Current loop power supply not active e Incorrect control logic Verify the option parameter settings and correct if necessary Verify current loop power supply see Resistance Checks and Power Supply Tests Verify connections to module terminals 16 and 17 see Functional Description on page 44 Note For Pump Stop issues please refer to Pump Application Considerations on page 39 The control module is
81. de tec rx aa LP ER 93 Scale Factors for PLC 94 Read Example 94 Write Example mo DRUSI 94 Display Text Unit Equivalents s ioo ce erede ES EURO 94 Configuring 95 Rules for Using DataLinks rete sce ere ses 95 Updating Firmware oieee ce ha Mod 95 Rockwell Automation Publication 7760 UM001E EN P December 2014 7 Table of Contents Troubleshooting Maintenance 7760 7761 7762 and 7763 SMC Flex Specifications SMC Flex Module Parameter Information Spare Parts Chapter 8 General Notes eaves 97 Control Module Removal eee 102 Voltage Feedback Circuit Test 103 Voltage Sensing Board 103 12 kV Voltage Sensing Board 104 14 4 kV Voltage Sensing Board 104 Current hoop Power Supply 106 Circuit Board Replacement n wan Indiae d dS Sai 107 Power Lo onbehex daw v vee webs cet 108 PowerBrick SCR Testing ote ehe 108 Voltage Sensing Board Testing cet e Ha ee cepere 112 Power Resistor Replacement err Yee ehe 113 Chapter 9 Safety and Preventative rei ood ooa 115 Periodic Inspection sas b
82. disposal precautions should be taken Printed Circuit Boards Printed circuit boards may contain a very small amount of lead in components and materials Shipping and handling of these boards are typically not restricted by environmental 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 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 product 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 i 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 119 Chapter9 Maintenance Not
83. dware Mounting Hardware Wire Guide Channels Cable Ties lt High Voltage Wires Current Loop Power Supply The current loop gate driver CLGD boards mounted on each PowerBrick see Figure 46 receive power from two sources 1 The snubber circuit while the SCR power modules are active 2 The current loop power supply which maintains a pre charge level of power during periods when the SCR power modules are inactive this allows SCR gating while the snubber circuit is being charged 106 Rockwell Automation Publication 7760 UM001E EN P December 2014 Troubleshooting Chapter 8 Figure 45 Current Loop Power Supply Current Loop Current Transformer 1800 6 Watt Resistor Transformer E z w Transformer Guard Ground Wire The current loop power supply provides a current of 40 50 A AC to each SCR power module phase assembly If this current is not detected and fed back to the interface boards stop maneuvers will not function and an Alarm will be generated 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 destroyed by static charges generated by friction of materials made with synthetic fibres Use of damaged circuit boards may also damage related components A groundi
84. e overloading or excessive cycling After the power module temperature is reduced to allowable levels the fault can be cleared see Maintenance on page 115 for instructions Rockwell Automation Publication 7760 UM001E EN P December 2014 35 Chapter1 Product Overview Metering 1 0 36 Power monitoring parameters include Three phase current Three phase voltage Power in MW Power usage in MWh Power factor Motor thermal capacity usage Elapsed time Motor speed full speed with use of optional tachometer input Notes 1 Voltage measurement is not available during the braking operation of the SMB Smart Motor Braking Accu Stop and Slow Speed with Braking control options The elapsed time and MWh values are automatically saved to memory every 12 hours Motor thermal capacity usage is determined by the built in electronic thermal overload An overload fault occurs when this value reaches 100 The SMC Flex has the ability to accept up to two 2 inputs and four 4 outputs controlled over a network The two inputs are controlled at terminal 16 Option Input 1 and terminal 15 Option Input 2 For these two inputs see Chapter 3 for the parameter settings and see Chapter 7 for the bit identification By using these two terminals as inputs the Stop Input will need to be programmed to meet the desired stop functionality The four 4 outputs are Aux 1 Aux 2 Aux 3 and Aux 4 All auxiliary contacts
85. e phase to phase supply voltage Metering Volts Phase B C 2 V measurements at all times including bypass operation Provides the phase to phase supply voltage Metering Volts Phase C A 3 V measurements at all times including bypass operation Metering Current Phase A 4 A Provides the phase A motor current measurement Metering Current Phase B 5 A Provides the phase B motor current measurement Metering Current Phase C 6 A Provides the phase C motor current measurement Provides the power usage of the connected motor Metering Watt Meter 7 KW MW This value is calculated from the voltage current and power factor measurements KWH Provides the power usage over time of the Metering Kilowatt Hours 8 MWH connected motor Indicates the total time of motor operation in hours Metering Elapsed Time 9 Hours The accumulated ime is updated continuously during run time NO ETM Reset Provides the user the capability to reset the value Metering Meter Reset 10 NO stored in the elapsed time 9 and kilowatt hours 8 KWH Reset meters to zero Metering Ba wor Fator T 0 00 0 99 Provides the operational displacement power factor measurement of the connected motor Provides the theoretical model of motor heating as a percentage value At 100 MTU the controller Metering Mtr Therm Usage 12 AMTU 0 10 will fault on overload This model is based on the motor thermal overload calculation Indicates the operating percentage of motor base Metering Motor S
86. e user to set a percentage of line to line Voltages that will cause an Alarm when the voltage falls above this value A zero value is the off setting Rockwell Automation Publication 7760 UM001E EN P December 2014 135 Appendix B Group Unbalance SMC Flex Module Parameter Information Parameter Name Unbalance A Dly Parameter Number 66 Units Secs Min Max Default Settings Parameter Description Allows the userthe ability to prevent some nuisance Alarms by entering a delay period that provides a window that the voltage unbalance condition must persist within for the controller to Alarm User Settings Jam Jam F Lvl 67 FLC 0 1000 Allows the user to set an instantaneous over current level 96 of line FLC that will cause a fault A zero value is the off setting Jam Jam F Dly 68 Secs Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the motor over current condition must persist within for the controller to fault Jam Jam A Lvl 69 96FLC 0 1000 Allows the user to set an instantaneous over current level 96 of line FLC that will cause an Alarm A zero value is the off setting Jam Jam A 70 Secs Allows the userthe ability to prevent some nuisance Alarms by entering a delay period that provides a window that the motor over current condition must persist
87. ed 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 1 Braking Control is not offered for standard use in MV applications Please consult factory for further assistance 2 All braking stopping current settings in the range of 1 100 will provide 100 braking current to the motor Control Wiring 80 Note Options that control the stopping of the motor Soft Stop Pump Stop Linear Speed Braking require the self powered gate drivers to be pre charged by the current loop power supply If this supply is not present an alarm symbol will appear at the upper right corner of the control module display and the options will be inhibited When the motor is stopped it will coast If the supply is restored the alarm symbol will be cleared and the module will perform the programmed sequence Refer to Chapter 1 for typical control wiring examples used with various control schemes Rockwell Automation Publication 7760 UM001E EN P December 2014 Overview Fault Display Clear Fault Chapter 6 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 adjusted t
88. en adjusting this level Improper adjustment can cause the SMC to start at full voltage All Parameter Mgmt 115 Ready Load Default Ready Allows the user to load factory default values for all parameters Basic Set Up Backspin Timer 116 Secs 0 999 Only available with the Pump Control option Ensures that a specific amount of time passes between a stop and start sequence Linear List V Shut Off Level 117 V 25 This parameter provides the user with the ability to manually adjust the level for the controller s voltage shut off detection Since this parameter has the potential to modify the SCR control scheme it is important that adjustments be made with the help of Technical Support It is important that you do not disable both parameter 113 and this one at the same time otherwise SCR firing instability can occur Linear List OL Reset Level 118 75 Sets the level at which the motor overload is allowed to be reset Once the TCU has dropped below the program level the device can be reset manually or will auto reset if programmed for auto reset operation Linear List Ambient Temperature 119 50 Provides the ability to compensate for a lower or higher ambient temperature condition The ambient temperature programmed should be representative of the actual nominal temperature or worst case condition since improper programming can result in nuisance tri
89. er continually monitors line conditions for abnormal factors Pre start protection includes Line Fault with phase indication Line voltage loss Missing load connection Shorted SCR Running protection includes e Line Fault no phase indication Line voltage loss Missing load connection Phase reversal protection u can be toggled either ON or OFF Note Phase reversal protection is functional only at pre start Excessive Starts Hour The MV SMC Flex module allows the user to program the desired number of starts per hour up to 99 This helps eliminate motor stress caused by repeated starting over a short time period Note The base rating of the MV SMC Flex is two starts thirty seconds each max per hour Applications requiring more frequent starts or longer duration starts should be reviewed with the factory to avoid equipment damage Overtemperature The power module temperature is monitored during starting and stopping maneuvers by thermistors The thermistor is connected to the gate driver board where it is processed and the status is transmitted by fibre optic cable through the interface board to the control module When an overtemperature condition exists gt 85 C the control module trips and indicates PTC Power Pole fault This trip may also indicate a problem with the gate driver board fiber optic cable or interface board An overtemperature condition could indicate high ambient temperatur
90. es 120 Rockwell Automation Publication 7760 UM001E EN P December 2014 Specifications Tables Appendix A 7760 7761 7762 and 7763 SMC Flex Specifications Table 41 Electrical Ratings Bulletin 7761 Electrical Ratings 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 Rated Voltage Ur 12kV 15 kV Rated Insulation Voltage Ui 12kV 15 kV Rated Impulse Voltage Uimp 75 kV 95 kV Dielectric Withstand 28 kV 36 kV Repetitive Peak Inverse Voltage Rating 32500 39000 100 15 000 Hp Output Rating 75 11 000 kW Semi Conductor Isolation Fiber optic Operating Frequency 50 60 Hz dv dt Protection RC Snubber Network Transient Protection Integrated overvoltage trigger circuit 160A Rated Current 340A 580A dv dt 1000V us di dt 100 A us Voltage Drop Line to Output Terminals 2 5V per SCR without bypass Less than 1 0V with bypass total Overall Efficiency 99 9596 with bypass Initial Torque 0 90 of motor locked rotor torque 600 10 seconds Thermal Capacity 450 30 seconds Ramn Time 0 30 seconds P Consult Factory for Longer Time Kickstart 0 90 of motor locked rotor torque for 0 0 2 0 seconds Rockwell Automation Publication 7760 UM001E EN P December 2014 121 AppendixA 7760 7761 7762 and 7763 SMC Flex Specificat
91. fe UR lag Vath oleae JON al ol ote bith Made Bee Mel 75 Viewing Metering Dates ronis pupii D ghee sous ET You 75 Chapter 5 Options Xu n 77 Human Interface Module aoe ee 77 Programming Parameters doceo Id dead eue vie EE 79 Gonttel Wiring creo 80 Chapter 6 Diagnostics MEI nuo LN 81 Protection Programming eere Hs cH e VERE RS 81 Fault Display cime 81 Cleappaulps eus ell ote Cor vb itas pce D CO EA st c cM 81 Paul BUleE noise act 82 ro tete t etie Cart dare 82 Fault and Alarm Auxiliary Indication 0 eee eee eee eee 83 Definitions eo ese dottoh eens aditu eie pa at 83 Chapter 7 Communications PI et 85 Communication Ports 85 Human Interface Module eese e 86 Keypad Description sci koe paese 86 Connecting the Human Interface Module to the Controller 87 HIM Control Enable 88 Enable sei ree ee insite ie es DR REP DC ts 90 Loss of Communication and Network 90 SMC Flex Specific Information ooi 90 Default Input Output Configuration ere etr emet nds 91 Variable Input Output Configuration cleri ran ho ete etas 91 SMC Flex Bit 1 8 92 Peedbacleo voient qan a wo sd Sever ach oc dut 93 Parameter i esses ce
92. figuring DataLinks Updating Firmware Communications Chapter 7 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 16bit 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 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 e Parameter settings in the SMC determine the data passed through the DataLink mechanism e 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 88 103 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 release 6 003 or later This User Manual pertains to units with firmware release 6
93. for the duration of time programmed Fault buffer 1 allows display of the current fault Linear Fault 124 5 value of 0 indicates that there is no current fault Fault buffer 2 represents fault history of the device Linear List Fault 2 125 0 255 with fault 1 being the current fault and fault 5 being the oldest fault kept in memory Fault buffer 3 represents fault history of the device Linear List Fault 3 126 0 255 with fault 1 being the current fault and fault 5 being the oldest fault kept in memory Fault buffer 4 represents fault history of the device Linear List Fault 4 127 0 255 with fault 1 being the current fault and fault 5 being the oldest fault kept in memory Fault buffer 5 represents fault history of the device Linear List Fault 5 128 0 255 with fault 1 being the current fault and fault 5 being the oldest fault kept in memory This parameter provides the user with the ability to extend the ramp time beyond the initial range of 0 Linean List 3 o 0 999 0 30 seconds To use this parameter parameter 18 must be set to 0 Allows for the second ramp time to also be Linear List Ramp Time 2E 130 Sec 0 999 0 extended To use this parameter parameter 26 must be set to 0 Allows the stop time be extended beyond the limit Linear List Stop Time E 131 Sec 0 999 0 of 120 seconds Parameter 33 must be set to 0 for this parameter to be active Disable oe Provides the user with the ability to define th
94. g a core balance current transformer for 1 5A core balanced ground fault protection with the option of enabling Ground Fault Trip Ground Fault Alarm or both a core balance CT can be provided with 1562E units Ground Fault Trip The MV SMC Flex will trip with a ground fault indication if Notrip currently exists Ground fault protection is enabled GF Inhibit Time has expired GF Current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay Parameter 75 Gad Fit Inh Time allows the installer to inhibit a ground fault trip from occurring during the motor starting sequence and is adjustable from 0 250 seconds Parameter 74 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 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 5 0 A Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 IMPORTANT Theground 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 Fit Inh Time expires Ground Fault Alarm The MV SMC Fle
95. g chart for ratings above this altitude 126 Rockwell Automation Publication 7760 UM001E EN P December 2014 7760 7761 7762 and 7763 SMC Flex Specifications Appendix A Table 47 Medium Voltage Magnetically Actuated Vacuum Circuit Breaker 10 12 kV Description Specification Voltage Ratings Maximum Rated Voltage 12 kV Basic Impulse Level 1 1 Withstand Phase to Ground Phase to Phase kV 75 Rated Insulation Voltage 12 kV Withstand Voltage at 50 Hz 28 kV Frequency Ratings 50 60 Hz Current Ratings Rated Normal current 40 C 630A Rated Breaking Capacity kA rated short circuit breaking current symmetrical 16 20 25 31 5 Rated short time withstand current 3s kA 16 20 25 31 5 Making Capacity kA 40 50 63 80 Pole Distance mm 150 Opening Time ms 35 45 Arcing Time ms 10 15 Total Breaking Time ms 45 60 Closing Time ms 50 60 Operating Temperature C 25 50 with derating 1 The voltage and current ratings listed are valid up to 1000 m 3300 feet Please refer to Controller Derating chart for ratings above this altitude Rockwell Automation Publication 7760 UM001E EN P December 2014 127 AppendixA 7760 7761 7762 and 7763 SMC Flex Specifications Table 48 Medium Voltage Magnetically Actuated Vacuum Circuit Breaker 12 5 15 kV Description Specification Voltage Ratings Maximum Rated Voltage 17 5 kV Basic I
96. ge 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 e Service factor Refer to Chapter 5 for more information on Motor Protection Phase Reversal Phase reversal is indicated when the incoming power to the SMC Flex controller is in any sequence other than ABC This pre start protective feature can be disabled Coms Loss 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 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 Other settings could cause this fault see Table 8 D Network Network f
97. hat provide enhanced capabilities See Chapter 1 for brief descriptions of each option Note Only one option can reside in a controller The control buttons available with the Bulletin 20HIM Human interface modules are compatible with the SMC Flex controller s control options The following table details the functionality of each button with regards to each option Notes 1 The logic mask port must be enabled prior to initiating control commands to the SMC Flex controller Refer to Control Enable on page 90 for instructions 2 The control terminals must be wired according to Figure 25 on page 45 or Figure 26 on page 46 Table 23 Human Interface Module Operations Option Action Operation Standard The green start button when pressed will commence motor acceleration to full speed Soft Stop Current Limit The red stop button when pressed will provide a coast stop and or reset a fault Full Voltage Linear Speed The jog button when pressed will initiate the programmed maneuver Gg The green start button when pressed will commence motor acceleration to full speed Bes The red stop button when pressed will provide a coast stop Slow Speed The jog button is not active for Preset Slow Speed Jog Note Slow Speed cannot be operated via the HIM Pump Control Rockwell Automation Publication 7760 UM001E EN P December 2014 77 Chapter5 Options
98. he user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings Table 2 Dual Ramp Start Parameter Set Up The user must select the Set up programming mode to obtain access to the Dual Ramp parameters Option Basic Set up Starting Mode Set up as stated in previous pages Option Input 2 Dual Ramp qm This allows the user the option to choose between two Soft Start profiles defined by 1 Start Mode Ramp Time Initial Torque and 2 Start Mode 2 Ramp Time 2 Initial Torque 2 When this feature is turned on the ramp time initial torque combination is determined by a hard contact input to terminal 15 When this input signal is low ramp time initial torque are selected When input signal is high ramp time 2 initial torque 2 are selected Once the Option 2 input has been set to Dual Ramp you must ESC back to the Parameter File menu Re enter into the Set Up menu to show both Basic Set Up and Dual Ramp Basic Set Up Start Mode This selects the start mode for option 1 Basic Set up Ramp Time This programs the time period during which the controller will ramp the output voltage up to full voltage for the first Start set up 0 305 Basic Set up Initial Torque This parameter establishes and adjusts the initial reduced output voltage level for the first Soft Start set up 0 90 locked rotor torque Dual Ramp Start Mode 20 This selects the start mo
99. hrough the programming parameters provided For further details on programming refer to the Motor Protection section in Chapter 3 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 Figure 36 Fault Display Faulted Fault 27 COMS LOSS P2 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 Note You can hit ESC to get to another programming diagnostic list but the SMC Flex will still be in a faulted state IMPORTANT Resetting a fault will not correct the cause of the fault condition Corrective action must be taken before resetting the fault You can clear a fault using any of several methods Press and hold the front panel ESC key for 3 seconds Rockwell Automation Publication 7760 UM001E EN P December 2014 81 Chapter 6 Diagnostics Fault Buffer 82 Program the SMC Flex controller for a Clear Fault which can be found in Main Menu Diagnostics Faults Ifa human interface module is connected to the controller press the Stop button Note A stop signal from the HIM will always stop the motor and clear the fault regardless of Logic Mask configuration
100. icSetUp Ramp Time 18 Secs 0 30 L bypass and full voltage if the controller senses that the motor has reached full speed prior to the ramp time completion Also refer to Parameter 129 When using the soft start mode this parameter 25 3 allows the user to adjust the initial torque level BasicSetUp Initial Torque 19 ALRT 9 90 70 applied to the motor at the beginning of the start maneuver Cur Limit Start When using the current limit starting mode this Basic Set Up Level 20 FLC 50 600 350 parameter allows the user to adjust the current level applied to the motor during the start maneuver BasicSetUp Reserved 21 Reserved When programmed with a non zero value this parameter provides a torque pulse for the BasicSetUp Kickstart Time 22 Secs 0 0 2 0 0 0 programmed time period at the beginning of the starting maneuver 0 0 2 0 s When the Kickstart Time is programmed this parameter provides the user with the ability to set Basic Set Up Kickstart Level 23 ALRT 0 4 0 the level of the torque pulse applied to the motor approx 0 90 Disable Preset Slow Speed Dual Ramp Provides the user with the ability to define the Basic Set Up Option Input 2 24 Fault Fault NC Disable function of option Input 2 disable coast stop ault Fault option fault fault N C network Network Clear Fault Full Voltage Current Limit y Soft Start When the dual ramp mode is selected this Dual Ramp Starting Mode 2 25 Linear Soft Sta
101. ication he 37 Programming Shute 37 Satis Indication meias oaa at aee un acc ans 38 Control OPNS aad jes re Go Dy Oi a edt 39 Pump Control 39 Rockwell Automation Publication 7760 UM001E EN P December 2014 5 Table of Contents Commissioning Procedure Programming Pump Application 39 Braking Control Options balia ee Sua 40 Hardware Description curs vadat a HU Pott cal uc auae 40 lower 41 Current Loop Gate Driver CLGD 41 ovo quid idu dui dutem Va bits 41 Functional Descriptions sses 44 Bulletin 7763 Basic Control Controlled Start only 44 Bulletin 7760 Basic Control Controlled Start Only 44 Chapter 2 Preliminary See Up cessere erue 47 Bystein Characteristics 48 Actaal Motor Load sox 48 Important Commissioning Checks iu eus ene 49 50 MV SMG Flex 50 Hi Pot and Megger txt ees Ruta db dA Sane 50 Resistance Checks and Power Supply 53 Control Function Westerns a Curiae us pde 58 Voltage Sensing Module c eee cer eh ER EC DR 58 Sare
102. ication therefore all standard DPI communication interfaces used by other devices i e PowerFlex Drives can be used in the SMC Flex ScanPort devices are not supported by the SMC Flex Standard DPI communications cards are available for various protocols including DeviceNet ControINet 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 Figure 37 Communication Interfaces Protocol Type Cat No User Manual DeviceNet 20 COMM D 20COMM UM002 EN P ControlNet 20 COMM C 20COMM UM003 EN P Remote 1 0 20 COMM R 20COMM UM004 EN P Profibus 20 COMM P 20COMM UM006 EN P 5 485 20 COMM S 20COMM UM005 EN P InterBus 20 COMM I 20COMM UM007 EN P EtherNet IP 20 COMM E 20COMM UM010 EN P RS485 HVAC 20 COMM H 20COMM UM009 EN P LonWorks 20 COMM L 20COMM UM008 EN P ControlNet Fiber 20 COMM Q 20COMM UM003 EN P 1 The final letter in a publication number prior to the language indicator e g here EN for English denotes revision level of user manual Example Publication 2000MM UMOO2C 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 I
103. ion duty cycle Fan failure Replace fan Ambient temperature limit exceeded Wait for controller to cool or provide external cooling Failed thermistor Check connection or replace thermistor Failed control module Replace control module failed gate driver board Test or replace gate driver board Failed fiber optic cable Test or replace cable Failed interface board Test or replace interface board or fiber optic board check ribbon cables Motor PTC 12 Motor ventilation blocked Check for proper ventilation Motor duty cycle exceeded e Check application duty cycle e PTCopen Wait for motor to cool or provide external cooling e Check resistance of PTC Open Bypass 13 14 15 e Control voltage is low Check control voltage power supply Inoperable bypass contactor or breaker Check control circuit operation e Check control plug on contactor or breaker e Check that Aux 1 is set correctly External bypass or up to speed as required by the application See Status Indication on page 38 No load 16 17 18 40 Loss of load side power wiring e Check all load side power connections and motor windings Loss of feedback Check voltage sensing module Line Unbalance 19 e Supply unbalance is greater than the e Check power system and correct if necessary user programmed value e Extend the delay time to match the application requirements The delay time is too short for the e Check voltage sensing module application
104. ions Electrical Ratings Approvals IEC Safety 92 59 EEC Directive Ref BSEN 61010 1 1993 BSEN 60204 1 1997 IEC 62271 1 IEC 62271 200 IEC 60146 1 1 IEC 60947 4 2 Short Circuit Protection The power electronics unit must be protected by current limiting fuses or a fast acting circuit breaker The standard 12 kV combination controller includes appropriate fusing coordinated with motor Fault Level Withstand 31 5 kA 100 ms Control Circuit Rated Operation Voltage 120 240V AC 15 10 115 230V 15 10 Dielectric Withstand 1600V AC 2000V Operating Frequency 50 60 Hz Enclosure Enclosure Type IP4X IP41 and IP42 Overload Characteristics SMC Flex Control Module Type Solid state thermal overload with phase loss Current Range 1 0 1 000 A Trip Classes 10 15 20 and 30 Trip Current Rating 117 of Motor FLC Number of Poles 3 Power Requirements Control Module Self powered 75VA Gate Driver Boards 75VA total Vacuum Contactor Breaker Refer to Contactor Breaker Specifications Auxiliary Contacts Control Module Rated Operation Voltage Max 20 265V 5 30V DC resistive Rated Insulation Voltage 2774 Operating Frequency 50 60 Hz DC Conventional thermal current Ith 5A Utilization Category AC 15 DC 12 Mechanical Ratings Control Module Control Terminals Terminals M 3 5 x 0
105. ips 4 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 green ground wires 5 Remove the four fasteners that secure the assembly to the panel Remove assembly including high voltage wires from the equipment Rockwell Automation Publication 7760 UM001E EN P December 2014 103 Chapter8 Troubleshooting 12 kV Voltage Sensing Board VSB a Place the assembly on a flat surface table or bench and disconnect the wires from the six channels at the end of the VSB Cut the cable ties and remove the wires from the assembly b Install the wires on the new assembly in the same positions and secure them with cable ties at the ends of the wire guide channels Figure 42 Sensing Board High Voltage Wire Connections Mounting Hardware i Mounting Hardware Wire Guide Channels Cable Ties 4 High Voltage Wires 14 4 kV Voltage Sensing Board VSB c Place the assembly on a flat surface table or bench d Remove the nylon screws that secure the insulation shrouds from the ends of the VSB channels and remove the shrouds e Disconnect the wires from the six channels at the end of the VSB Cut the cable ties and remove the wires from the assembly f Install the wires on the new assembly in the s
106. it on the start button and closes the Start Breaker 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 2 which closes the bypass breaker The motor then runs at full line voltage When the Stop button is pressed the KGI relay opens terminal 17 on the SMC Flex module The AUX4 AUX1 contacts open which opens the start and bypass breakers allowing the motor to stop Bulletin 7760 Basic Control Controlled Start Only The Bulletin 7760 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 26 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 7760 to start also A KG1 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 KG1 relay The AUX1 contact External Bypass is held closed for 10 seconds to keep the bypass contactor closed for a short time The Fault cont
107. k to the Bus is by copper flexible link to the first and last SCR of the series connections of SCR in the SCR Power Truck Figure 30 shows the Mechanical connections to bolt the truck in position and the Electrical connections Refer to Installation Instructions Publication 7760 IN001B EN P for instructions on removing the SCR Power trucks Rockwell Automation Publication 7760 UM001E EN P December 2014 53 Chapter2 Commissioning Procedure The Fibre optic cables are removed at the fibre optic board end and gently coil the cable bundle on the power truck to be racked out The current loop cables are removed from the terminal blocks and kept free of any ties to be free while racking out the SCR Power Truck Once after racking out the SCR Power truck the truck should be positioned directly in front of and in parallel with the front of the enclosure The fibre optic cables are then plugged in to the fibre optic board using the fibre optic extension cable to carryout the Power supply and pulse checks The clear polycarbonate covers must be removed from the SCR Power Truck by removing two screws from the top and the bottom mounting brackets at the front and rear Figure 29 Interface PCB SW2 Close slide up to initiate test pulses Red LED ON when test pulses active D1 _ OK 2 i To ensure that resist
108. kwell Automation Publication 7760 UM001E EN P December 2014 27 Chapter1 Product Overview Protection and Diagnostics 28 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 3 Programming An Overload Fault will occur when this value reaches 100 The parameters below provide application flexibility and easy setup Table 4 Overload Parameters Parameter Range Overload Class Disable 10 15 20 30 Overload Reset Manual Auto Motor FLC 1 0 2200 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 compensation takes place when the Preset Slow Speed option is used Notes 1 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
109. l Video e Utility Reset User Display Linear List l GROUP MENU Parameter menu continued in Figure 34 TheSMCFlex controller does not support EEPROM Link Process or Start up modes Steps back one level Shown if password protection is configured 62 Rockwell Automation Publication 7760 UM001E EN P December 2014 Programming Chapter 3 Figure 34 Parameter Menu Structure Hierarchy Parameter e s Metering Basic Overload Jam Comm Masks Language Linear List Volts Phase SMC Option Overload Class Underload Lvl Logic Mask Language All Parameters Volts Phase B C Motor Connection Service Factor Underload F Dly Parameter Mgt o Parameter Mgt Parameter Mgt Volts Phase C A Line Voltage Motor FLC Underload A Current Phase A MV Ratio Overload Reset Underload 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 A1 Motor Flc Watt Meter Initial Torque Stall Data In A2 Motor ID Megawatt Hours Cur Limit Lvl Underload Data In B1 CT Ratio Elapsed Time Kickstart Time Stall Dly Data In B2 MV Ratio Meter Reset Kickstart Lvl Underload Lvl Parameter Mgt O Data In C1 Parameter Mgt Power Factor Stop Input Underload F Dly Data In C2 Mtr Therm Usage Option 1 Input Underload A Lvl Ground Fault Data In D1 Motor Speed Option 2 Input Underload A Dly Data In D2 Stop Mode Parameter Mgt SGnd Fit Enable Data Out
110. led i e SW2 toggled up and the Portable Test Power Supply should be connected to J1 The pulse should appear as shown in Figure 31 and Figure 32 Rockwell Automation Publication 7760 UM001E EN P December 2014 55 Chapter2 Commissioning Procedure Figure 31 Gate Pulse Detail Typical SCR ABB Volts wo s 0 00 200 4 00 000 10 20 30 40 500 600 700 Microseconds Figure 32 Gate Pulse Test Waveform 19 Ifno pulse is observed and the yellow LED is lit check for a shorted gate on the SCR by removing the green plug and connecting an ohm meter to the gate leads If the LED is still not lit and the circuit voltage is as specified in step 18 above pinch the tab on the blue fire optic connector and carefully pull it straight out of the receiver The end of the connector should glow red to indicate the presence of gate signal If it does not remove the other end of the cable from the interface or Fibre Optic board and check that the grey transmitter is emitting red light If it is the fibre optic cable must be replaced If it is not the interface board should be replaced or Fibre Optic board should be replaced IMPORTANT The fibre optic system used in this equipment utilizes LED transmitters classified as IEC 60825 1 AEL Class 1 which are considered eye safe However the light is concentrated in the fibre and it is recommended that users not look directly into the fibre and connectors Directing the light to a fi
111. ll protection is user adjustable from 0 0 10 0 seconds enabled only after the programmed start time expires It is recommended that it be set at 1 0 second e 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 motors full load current rating and the delay time up to 99 0 seconds for application flexibility Figure 16 Stall Protection 600 Percent Full Load Current a Programmed StartTime Stall gt Time seconds Rockwell Automation Publication 7760 UM001E EN P December 2014 31 Chapter 1 32 Product Overview Figure 17 Jam Detection Percent Full Load Current 100 Running gt lt Jam gt Time seconds Jam Detection is disabled during slow speed and braking operation Ground Fault In isolated or high impedance grounded systems core balanced current sensors are typically used to detect low level ground faults caused by insulation breakdowns or entry of foreign objects Detection of such ground faults can be used to interrupt the system to prevent further damage or to alert the appropriate personnel to perform timely maintenance The MV SMC Flex s ground fault detection capabilities consist of usin
112. m and motor correct if necessary programmed values Check programmed ground fault levels to match application requirements Excess Starts Hr 34 Number of starts ina one hour period Wait an appropriate amount of time to restart has exceeded the value programmed Consult factory if more than 2 starts per hour are required Power Loss with phase 35 36 37 Missing supply phase as indicated Check for open line i e blown line fuse indication Loss of feedback e Check CT connections replace Interface board HAL ID 38 Faulty interface e Check ribbon cable connections between interface board and control module Replace interface board Rockwell Automation Publication 7760 UM001E EN P December 2014 99 Chapter8 Troubleshooting Display Fault Code Possible Causes Possible Solutions NVS Error 39 Data entry error e Check user data and perform a User Store function Replace control module Line Loss 41 42 43 Line Distortion e Check supply voltage for capability to start stop motor High impedance connection Check for loose connections on line side or motor side power wires V24 Recovery 44 Internal power supply problem Cycle control power to reset the control module If Fault persists replace control module V24 Loss 45 Internal power supply problem Cycle control power to reset the control module If Fault persists replace control module V Control Loss 46 Internal se
113. mpulse Level 1 1 Withstand Phase to Ground Phase to Phase kV 95 Rated Insulation Voltage 17 5 KV Withstand Voltage at 50 Hz 38 kV Frequency Ratings 50 60 Hz Current Ratings Rated Normal current 40 C 630A Rated Breaking Capacity kA rated short circuit breaking current symmetrical 16 20 25 31 5 Rated short time withstand current 3s kA 16 20 25 31 5 Making Capacity kA 40 50 63 80 Pole Distance mm 150 Opening Time ms 35 45 Arcing Time ms 10 15 Total Breaking Time ms 45 60 Closing Time ms 50 60 Operating Temperature C 25 50 with derating 1 The voltage and current ratings listed are valid up to 1000 m 3300 feet Please refer to Controller Derating chart for ratings above this altitude 128 Rockwell Automation Publication 7760 UM001E EN P December 2014 7760 7761 7762 and 7763 SMC Flex Specifications Appendix A Table 49 Medium Voltage Vacuum Contactor 10 to 12 kV Description Specification Voltage Ratings Maximum Rated Voltage 12 kV Rated insulation voltage 12 kV Impulse withstand voltage 75 kV Withstand Voltage at 50 Hz 28 kV Frequency Ratings 50 60 Hz Current Ratings Rated service current A 400 Rated normal current A 400 Short time withstand current for 1 s A 6000 Rated Peak Current kA 15 Rated short circuit time 5 1 Maximum rated admissible overcu
114. n Publication 7760 UM001E EN P December 2014 69 Chapter3 Programming Full Voltage Start The SMC Flex controller may be programmed to provide a full voltage start output voltage to the motor reaches full voltage within 1 4 second with the following programming Table 15 Full Voltage Start Parameter and Options Parameter Description Option Starting Mode This must be programmed for Full Voltage Full Voltage Linear Speed The SMC Flex provides the user the ability to control the motor speed during starting and stopping maneuvers A tach input is required as specified in Linear Speed Acceleration and Deceleration on page 26 See also Table 53 on page 142 Table 16 Linear Speed Parameters and Options Parameter Description Option Starting Mode This must be programmed for Linear Speed Linear Speed Ramp Time Programs the time period that the controller will ramp from 0 speed to full voltage 0 30 s Kickstart Time A boost of current is provided to the motor for the programmed time period 0 0 2 2 Kickstart Level Adjusts the amount of current applied to the motor during the kickstart time 0 90 locked rotor torque 1 For ramp times greater than 30 s set Ramp Time to zero and program Ramp Time E parameter 129 to the new time Do not exceed the thermal capacity of the controller Stop Control The SMC Flex can be programmed to extend the motor stop time beyond the normal coast to res
115. nection Line Voltage 9 Enter the system voltage in this parameter This must be done to 1 15 000V PEE ensure optimum motor performance and correct operation of Line Voltage undervoltage and overvoltage protection LE Volt 1 Found in Overload programming group Only one location needs to be programmed 2 Found in Basic Set up programming group 3 Refer to the SMC Flex controller nameplate for maximum ratings Exceeding these could result in damage to the controller 4 This is not to indicate how the motor windings are configured Do not select Delta for MV applications 74 Rockwell Automation Publication 7760 UM001E EN P December 2014 Metering Chapter 4 Ove rview While the SMC Flex controller operates your motor it also monitors several different parameters providing a full function metering package Viewing Metering Data To access the metering information follow the procedure below Table 22 Viewing Metering Data Procedure Description Action Display META Amps EET Volt 1 Press any key to access the Main menu Main Menu Param ter 2 Scroll with the Up Down keys until the Parameter option is shown Main Menu Parameter Memory Storage 3 Press the Enter key to access the Parameter option 4 Scroll with the Up Down keys until the Monitoring option is displayed 4 4 Rockwell
116. ng wrist strap is recommended for handling sensitive circuit boards ATTENTION Some circuit boards may contain CMOS components which can be 1 Remove all power from the equipment 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 ATTENTION To avoid shock hazard ensure the main power has been 2 Carefully detach all wires cables and connectors noting their location and orientation For the interface board remove the control module Rockwell Automation Publication 7760 UM001E EN P December 2014 107 Chapter8 Troubleshooting Power Circuit 108 Some 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 ATTENTION The fibre optic cables be damaged if struck or bent sharply 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 see Table of Accessories on page 143 Install the new board by replacing the ha
117. ngertip or another object is sufficient to determine correct performance 56 Rockwell Automation Publication 7760 UM001E EN P December 2014 20 21 22 23 Commissioning Procedure Chapter 2 When each gate driver circuit has been checked disconnect the power supply and remove it from the cabinet Disconnect the current loop cable from the terminal blocks and lay it on the cart Open the switch SW2 on the interface board Figure 27 before returning the unit to service Ensure the red LED is off Remove the fibre optic cables from the fibre optic board and gently coil the cable bundle on the SCR Power truck to be racked in Replace the clear polycarbonate barriers on the SCR Power Truck and secure with two screws at the top and two screw at the bottom on both the front and the rear module and the enclosure and unit Bus at the rear They must be replaced ATTENTION The clear barriers provide insulation between the converter 24 25 before re installing the converter modules Failure to do so may result in arc faults which could result in burns injury or death Carefully rack in the SCR Power Truck connect all the fibre optic cables on the fibre optic board and the temperature fibre optic cable to the bulkhead connector Connect the current loop cables in the terminal blocks routing the cable through the ties provided Finally make the Power connections with the flexible links to the Bus and torque to 20 l
118. 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 SHOCK HAZARD To avoid shock hazard ensure the 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 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 screws 5 Carefully rotate the module to the left and unplug the five ribbon cables from the interface board Rockwell Automation Publication 7760 UM001E EN P December 2014 Voltage Feedback Circuit Test Voltage Sensing Board Replacement Troubleshooting Chapter 8 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 6 003 or later This User Manual pertains to units with firmware released 6 003 or later The most straightforward means of checking the feedback circuits is to perform the Voltage Sensing Board Replacement on page 103 Anothe
119. nse circuit problem Cycle control power to reset the control module If Fault persists replace control module Option Input 1 48 External Fault e Check programming of Parameter 132 e Check status of device connected to Input 1 Option Input 2 49 External Fault e Check programming of Parameter 24 e Check status of device connected to Input 2 System Faults 128 209 Control module internal fault Cycle control power to reset the control module Review control module wiring Ensure ground terminal is securely reconnected to earth ground Ensure RC snubber is connected to all inductive loads in the control circuit that are connected to the control module terminals If fault persists replace control module 1 Prestart fault indication Display Table 36 Motor Will Not Start No Output Voltage to the Motor Possible Causes Possible Solutions Fault displayed See fault description See Table 35 addressing fault conditions Display is blank Control voltage is absent Failed control module e Check control wiring and correct if necessary Cycle control power e Replace control module Stopped 0 0 e Pilot devices Check wiring SMC Enable input is open at terminal 13 Check wiring Terminal 16 is open Check wiring Start Stop control has not been enabled forthe human Follow the instructions on page 88 to page 90 enable interface module control capability
120. nterface 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 85 Chapter7 Communications Human Interface Module The SMC Flex controller can be programmed with the built in keypad and LCD display or with the optional Bulletin 20HIM LCD human interface modules Parameters are organized in a three level menu structure and divided into programming groups Note Node addressing of the DPI communication card can be programmed via software or a hand held DPI HIM The onboard HIM cannot be used to address the communication card Keypad Description The functions of each programming key are described below Table 26 Keypad Descriptions Key Name Description Escape Exit a menu cancel a change to a parameter value or acknowledge a fault alarm Ca Select Select a digit select a bit or enter edit mode in a parameter screen Vu Up Down Arrows Scroll through options increase decrease a value or toggle a bit Enter 86 Enter a menu enter edit mode in a parameter screen or save a change to a parameter value Note Ifa human interface module is disconnected from the SMC Flex controller while the Logic Mask is set to 1 Coms Loss will occur Note For ease of programming val
121. o Speed Up 34 Aux Contacts 4 allows the user to configure the operation ofthe contacts to Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Parameter Mgmt Recall of factory default parameter values Ready Load Default g y y 1 Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter 2 Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter 3 Refer to the 1 0 section on page 36 and Notes on page 38 for MV specific functionality 4 This is not to indicate how the motor windings are configured Do not select Delta for MV applications 5 When programmed for Emergency and the Option 2 input is energized Start command will first close the bypass contactor then the line contactor for an across the line start of the motor 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 Motor Protection Parameter Overload 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 F
122. odule only Consult factory 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 Table 9 Password Modification Procedure Description Action Display EY Amps Volt 1 Press the ESC key go from the status display to the Main menu eT eT Diagnostics 2 Scroll with the Up Down keys until the Preferences option is highlighted Main Menu Preferences Diagnostics 3 Press the Enter key to access the Preferences menu Preferences Change Password User Dspy lines 4 Scroll with the Up Down keys until the Change Password option is highlighted 5 Press the Enter key Preferences Change Password User Dspy lines 6 Press the Up Down keys to enter the desired number If you are modifying the password make a note of it as displayed 7 Verification of the new password is required Press the Enter key 8 Press the Enter key after you have completed modifying the password TELE 1 complete the programming process re enter the Main Menu mode to log out This will eliminate unauthorized access to the programming system Prefs Password New Code 83 Verify 83 Note If you lose or forget the password
123. of base speed high settings Figure 11 Preset Slow Speed Option 100 1 Motor Forward Speed 15 High Pi B ON Low Time seconds eH in 10 Low x 20 High Reverse 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 25 Chapter 1 26 Product Overview 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 5V DC is required to perform this start mode The start time is selectable from 0 30 seconds and determines the time the motor will ramp from 0 speed to full speed Kickstart is available with this option Figure 12 Linear Speed Acceleration 100 Motor Speed lt Run gt lt _ Stop Time seconds Linear deceleration does not need to be used even if linear acceleration is used The stop time can be programmed for 0 120 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
124. ogram the slow speed that best fits the application Programming Chapter3 This control mode may be configured to allow slow speed operation ofthe Option Low 796 Forward 1096 Reverse High 1596 Forward 2096 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 Basic Set up The Basic Set up programming group provides a limited parameter set allowing quick start up with minimal adjustments If the user is planning to implement some of the advanced features 1 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 Table 19 Basic Set up Parameters and Options Parameter Description Option SMC Option Displays the type of controller This is factory set and not adjustable Standard Motor Connection Displays the location of the SMC in relation to the motor windings 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 co
125. one start stop combination per hour 30 seconds maximum for each operation A stopping operation counts as a start for purposes of thermal capacity calculations IMPORTANT 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 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 0 120 seconds and is adjusted independently from the starting time The load will stop when the output voltage drops to a point where the load torque is greater than the developed motor torque Figure 13 Soft Stop Option Percent Voltage 100 Kickstart Coast to Rest Soft Stop Initial Torque lt Start gt lt Run gt lt Soft Stop Time Seconds 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 30 seconds maximum for each operation A stopping operation counts as a start for purposes of thermal capacity calculations IMPORTANT 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 Roc
126. ons 1 Consult factory if start time settings over 30 seconds are required The base rating of the MV SMC Flex is two starts or one start stop combination per hour thirty seconds maximum for each operation A stopping operation counts as start for purposes of thermal capacity calculations 2 The Pump Control option functions only for centrifugal pumps It is not suited for positive displacement piston or other types of pumps 3 The Pump Stop option functions only for a centrifugal pump running at greater than approximately 2 3 of the motor rated horsepower 4 Pump applications with input and or output valves that are closed during starting and or stopping may not benefit from the Pump Control option Consult the factory for applications with valves Rockwell Automation Publication 7760 UM001E EN P December 2014 39 Chapter1 Product Overview 5 For starting or stopping times longer than 15 seconds power fuse selection should be reviewed to ensure no element damage occurs The fuse minimum melting time current characteristic curve should be consulted to ensure that at 1 1 times the full voltage locked rotor current of the motor the actual starting or stopping time does not exceed 75 of the fuse melting time 6 Motor overload and or upstream breaker settings may have to be adjusted to allow the starting or stopping current to flow for extended periods Figure 22 Pump Control Option 100 Motor Speed
127. ontact state changes when the motor approaches rated speed and controls the Bypass switch for 7762 and 7763 configurations in Figure 3 and Figure 4 Alarm Alarm NC The contact state changes when an Alarm condition is detected Fault Fault NC The contact state changes when a Fault condition is detected Network Control Network Control NC The contact state is controlled over the network Refer to Table 33 on page 93 which describes logic command word to control auxiliary outputs External Bypass This contact controls the Bypass switch for MV applications with the 7760 configuration in Figure 1 Note The tag name without a suffix indicates a NO state e g Normal On the other hand tag name followed by NC indicates a normally close state e g Normal NC Figure 21 Control Terminals PIS Ed CIEE Opt Opt Stop Input Input Start Input 2 1 Input Aux 1 External Bypass Te Ts Te T TT T PTC TACH Ground Aux 2 Aux 3 Aux 4 Normal Input Input Fault Fault Alarm i Contract Contact Note The Aux 1 contact is always programmed Up to speed for 7762 and 7763 applications or External Bypass N O for 7760 applications to control the bypass circuit breaker contactor The Aux 2 contact is typically programmed for fault indication it can configured for N O N C The Aux 3 contact is typically programmed for alarm indication it can be configured for N O N
128. ontrol state controls may result in damage to the control or test equipment or ATTENTION Use of other than factory recommended test equipment for solid 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 Keep Good Maintenance Records Good maintenance records will help reduce major costly shutdowns by demanding the use of proper test equipment and an appropriate inventory of spare parts This suggestion will be most helpful in locating possible intermittent problems by pointing to a particular area of recurring trouble within the overall system For additional information see NFPA 70B RECOMMENDED PRACT
129. or closes before motor is up to speed Ramp time too short Motor characteristics cause Up to Speed sensing too early Increase ramp time parameter 18 Adjust parameter 114 higher more than 5 at a time Motor is up to speed but bypass contactor is delayed in closing or does not close at all Ramp time too long Motor characteristics cause Up to Speed sensing too late or not at all Decrease ramp time Adjust parameter 114 lower no more than 5 at a time Rough start erratic current growling from the motor may see Line Faults Poor grounding of the power system or controller Poor power quality electrical noise harmonics VFD line notching Resolve ground issues Adjust parameter 117 higher Typical settings are 35 or 40 Not recommended to exceed 75 or go below 25 During a Pump Stop the motor takes more than 5 seconds to begin to decelerate or takes longer than the programmed stop time Motor or pump characteristics do not match the default setting Adjust parameter 34 to between 20 and 30 not recommended to go above 40 Note Although the default settings accommodate the vast majority of applications these tuning parameters may require more than one adjustment to achieve optimal results Some parameters are affected by motor loading and power system conditions so one setting may not be optimal for all conditions Table 40 Miscellaneous Situations Display Possible Causes Po
130. ors and connections have not been damaged during shipment and installation the following resistance tests should be performed before energizing the starter 9 10 11 12 13 Perform Power Brick DC resistance checks per the procedure PowerBrick SCR Testing on page 108 Check that all connections are secure and tight and all fibre optic cables are fully seated in their sockets Re connect the current loop cables to the terminal blocks Apply rated control voltage to the control circuits Check voltage on each gate driver board by connecting a DC voltmeter at TP4 and TP3 Figure 28 The voltage should 18 22V DC 54 Rockwell Automation Publication 7760 UM001E EN P December 2014 Commissioning Procedure Chapter 2 14 Locate the SMC Flex Interface board in the LV control 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 see Figure 29 This starts a pulse generator to supply simulated gate pulse signals via fibre optic cables to the gate driver boards A red LED beside the switch and the three yellow LEDs on the left side of the interface board should be lit Note They may appear dim depending on ambient light conditions Figure 30 SCR Power Truck showing mechanical bolting power and control connections
131. ot accelerated motor to full speed Miscellaneous situations Motor stops Irregular while running Starts See Table 40 See See See See Table 36 Table 37 Table 38 Table 39 See Table 35 Table 35 Fault Display Explanation Display Fault Code Possible Causes Possible Solutions Line Loss with phase indication 1 2 and 3 Missing supply phase Check for open line e g blown line fuse Motor not connected properly e Check for open load lead e Improper or missing current or voltage Check current transformer connections and module programming feedback Check voltage sensing board connections and module programming e 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 on page 108 Open Gate with phase indication 7 8 and 9 Open gate circuitry Perform power supply tests Chapter 3 Loose gate lead e Check gate lead connections to the gate driver boards and fiber optics 98 Rockwell Automation Publication 7760 UM001E EN P December 2014 Troubleshooting Chapter 8 Display Fault Code Possible Causes Possible Solutions PTC Power Pole 10 Controller ventilation blocked e Check for proper ventilation Controller duty cycle exceeded e Check applicat
132. oup em 6 Scroll to Basic Set Up and press Enter neo 7 Scroll to the Starting Mode parameter by using the Up Down keys and press Enter FGI Parameter Starting Mode 8 Press Enter to select the option Scroll to the option of your choice by using the Up FGH 1 Down keys For this example we will choose Current Limit Starting Mode Current Lim 9 Press the Enter key to accept the new setting EX 10 Scroll to the next parameter by using the Down key Continue the process until all Fa desired settings are entered Ramp Time Secs 1 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 2 To complete the programming process re enter the Main Menu mode to log out This will eliminate unauthorized access to the programming system Rockwell Automation Publication 7760 UM001E EN P December 2014 67 Chapter 3 Programming Soft Start The following parameters are specifically used to adjust the voltage ramp supplied to the motor Table 12 Soft Start Parameters and Options Parameter Description Option Starting Mode This must be programmed for Soft Start Soft Start Ramp Time Programs the time period that the controller will ramp the output voltage to full voltage from the initial 0 30 50 Torque level programmed Initial Torque The initi
133. owable under some electrical codes for loads which have long acceleration times i e High inertia As a general rule of thumb this time should never exceed the programmed start time Setting this parameter longer than necessary can result in motor overheating that is not being accounted for in the thermal model Linear List 134 OL Trip Enable Disable 49 0 Disable 1 Enable Enable This parameter disables the overload from tripping during slow speed pump stopping and braking maneuvers Motor Thermal Usage MTU continues to increment during these maneuvers Setting this parameter to disable can result in motor overheating or potential damage Rockwell Automation Publication 7760 UM001E EN P December 2014 Group Overload Parameter Name Overload A Lvl Parameter Number 50 Units MTU Min Max Default Settings SMC Flex Module Parameter Information Parameter Description Allows the user to set an overload level of motor thermal usage that will cause an alarm when the level exceeds the setting User Settings Appendix B Underload Underload F Lvl 51 FLC Allows the user to set a current 96 of line FLC that will cause a fault when the motor current falls below this value A zero value is the off setting Underload Underload F Dly 52 Secs Allows the user the ability to prevent some nuisance faults by entering a delay
134. ower Pole PTC Overtemperature The power pole temperature in each phase is monitored If the temperature rises above the predetermined level the unit will fault to protect the power pole A reset can be performed once the temperature falls below this level This fault may also represent loss of gate driver power during gating MV applications only 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 Open Bypass Power Pole bypass contacts are monitored for proper operation In 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 83 Chapter6 Diagnostics Fault Line Unbalance Description 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 Vd Va Vu Percent voltage unbalance Vd Maximum voltage deviation from the average voltage Va Average voltage The controller will shut down when the calculated voltage unbalance reaches the user programmed trip percentages Overvoltage and Undervoltage Protection m Overvoltage and undervoltage protection are user defined as a percenta
135. peed 13 0 100 speed when linear ramp is selected and an external tachometer is used Standard Brake This a read only parameter that identifies to the Basic Set Up SMC Option if Pump Control user the type of control module installed This parameter allows the user the ability to select the power wiring configuration of the SMC to the Do not setto Basic Set Up Motor Connection 15 Line Delta Line attached motor WYE or DELTA A fault controlled Delta elta means of disconnecting the line should always be use in the DELTA mode Rockwell Automation Publication 7760 December 2014 131 Appendix B SMC Flex Module Parameter Information Group Parameter Parameter Units Min Max DefaultSettings Parameter Description User Settings Name Number This parameter sets the base voltage for the under over voltage protective features For medium BasicSetUp Line Voltage 16 V 0 15 000 480 voltage applications the controller has internal capabilities set of multipliers that correspond to the line voltage dividers Full Voltage Current Limit Soft Start Allows the user to select the type of start provided Basic Set Up Starting Mode u Linear Soft Start with controller configuration Speed Pump Start Allows the user to program the time 0 30 s that the controller performs the starting maneuver The starting maneuver will automatically transition to Bas
136. period that provides a window that the motor current condition must persist within for the controller to fault Underload Underload A Lvl 53 96FLC Allows the user to set a current 96 of line FLC that will cause an Alarm when the motor current falls below this value A zero value is the off setting Underload Underload A Dly 54 Secs Allows the user the ability to prevent some nuisance Alarm conditions by entering a delay period that provides a window that the motor current condition must persist within for the controller to Alarm Under voltage Undervolt F Lvl 55 90V Allows the user to set a voltage 96 of line Voltage that will cause a fault when the voltage falls below this value A zero value is the off setting gt 80 recommended Under voltage Undervolt F Dly 56 Secs Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the voltage condition must persist within for the controller to fault 1 sec recommended Under voltage Undervolt A Lvl 57 90V Allows the user to set a voltage 96 of line Voltage that will cause an Alarm when the voltage falls below this value A zero value is the off setting Under voltage Undervolt A Dly 58 Secs Allows the user the ability to prevent some nuisance Alarms by entering a delay period that provides a window that the voltage condition m
137. pping or SCR damage due to true SCR overheating Not applicable to MV applications Linear List Notch Position 120 40 0 100 0 87 5 This parameter allows for the starting control algorithm to be manually modified It is recommended that you do not make changes to this parameter without specifically talking with Technical Support Do not change Linear List Notch Maximum pump control 121 50 70 70 This parameter allows for the pump stopping control algorithm to be manually modified It is recommended that you do not make changes to this parameter without specifically talking with Technical Support Do not change Linear List Start Delay 122 Sec An internal on delay timer Ensures that a subsequent start can not be initiated for a preset amount of time Rockwell Automation Publication 7760 UM001E EN P December 2014 139 Appendix B SMC Flex Module Parameter Information Group Parameter Parameter Units Min Max DefaultSettings Parameter Description User Settings Name Number For applications that routinely see fast spikes of current or overload conditions more than 12596 of the 5 5 frame rating this parameter can be used Notanplicibleta Linear List By pass Delay 123 Sec 0 15 0 to reduce the cycling between SCR and by pass This MVa AREE time delay parameter will allow the SMC to stay pp under SCR control
138. r Replacement 113 Voltage Feedback Circuit Test 103 Voltage Sensing Board Testing 112 Voltage Sensing Board Replacement 103 2 kV 104 14 4 kV 104 U Unbalance Protection and Diagnostics overview 31 Underload Protection and Diagnostics overview 30 Undervoltage Protection and Diagnostics overview 30 V Vacuum Bottles Maintenance 116 Viewing Metering Data 75 Voltage Feedback Circuit Test 103 Voltage Sensing Board Testing 112 Voltage Sensing Module overview 58 Voltage Sensing Board Replacement 103 2 kV 104 14 4 kV 104 Rockwell Automation Publication 7760 UM001E EN P December 2014 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www
139. r cables or apparatus Verify Power System Grounding Earthing Check if there are any Power Factor Correction Capacitors For correct installation requirements of these capacitors refer to Installation Instructions publication 7760 IN001_ EN P Check if Surge Capacitors and or Surge Arrestors are installed at the motor Open motor junction box and verify it by yourself These must be disconnected from the circuit Refer to Installation Instructions publication 7760 IN001_ EN P Verify fiber optic cables are connected at the right location FO cables on Phase A power pole go to Phase A on the fiber optic board Phase B of power pole to Phase B on the fiber optic board and Phase C of power pole to Phase C on the fiber optic board and the connectors are fully seated in their sockets Verify that fiber optic cables from the Interface board are connected to the proper through panel connectors at the right front corner of the low voltage compartment Note that the cable connectors that mate with the through hole connectors are round not rectangular The grey gate signal transmitters on the Interface board connect to the rear 3 grey connectors phase 1 2 3 top to bottom and the three blue receivers at the lower left corner of the interface board connect to the front 3 blue connectors Rockwell Automation Publication 7760 UM001E EN P December 2014 49 Chapter2 Commissioning Procedure Programming Hi Pot and Megger
140. r possible test involves measuring the feedback voltages at the interface board see Figure 27 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 approximately 1 volt rms It is important that the level in each phase is the same as the other phases within 1 If any voltage is well outside this range there may be a problem either 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 1 Ensure there is no power to the equipment disconnected before working on the sensing board Verify that all circuits are voltage free using a hot stick or appropriate high voltage measuring device Failure to do so may result in injury or death A SHOCK HAZARD To prevent electrical shock ensure the main power has been 2 Mark the position of the ribbon cable and wires 3 Disconnect the high voltage wires from the end that connects to the bus bars and release the wires from the plastic stand off cl
141. raped Rockwell Automation Publication 7760 UM001E EN P December 2014 113 Chapter8 Troubleshooting 114 Rockwell Automation Publication 7760 UM001E EN P December 2014 Safety and Preventative Periodic Inspection Chapter 9 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 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 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 ATTENTION Servicing energized industrial control equipment can be Note For OEM supplied components refer to documentation provided by the OEM for recommended periodic maintenance procedures Industrial control equipment should be inspected periodically Inspection intervals should be based on environmental and operating condi
142. rd and mounting plate refer to Figure 44 The voltage sensing board has six independent channels with different sized resistors base on voltage range which convert system voltages down to low voltage levels which can be used by the SMC Hex control logic Table 6 shows the input voltage ranges for the voltage sensing module The output voltages are scaled to provide close to 10V peak for a 14096 input voltage at the high end of each of the voltage ranges 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 in Table 50 on page 131 Table 6 Input Voltage Ranges Module Rated Voltage Voltage Range MV Ratio 12 000 10 000 12 000 126 14 400 12 001 15 000 97 The MV ratios shown above are nominal values and may be fine tuned to achieve better accuracy on the display of the SMC Flex control module While running the motor in bypass mode compare the voltage displayed on the control module to a known accurate meter connected to the same source voltage as the motor the MV SMC Flex is controlling Parameter 106 MV Ratio may be changed up or Rockwell Automation Publication 7760 UM001E EN P December 2014 Start Up Commissioning Procedure Chapter 2 down to match the Flex display to the external meter A small change in ratio can make a large change in the display so 2 or 3 units at a time is recommended Increasing the ratio will decrease the
143. rdware 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 PowerBrick SCR Testing power semiconductor is suspected of malfunctioning it may be checked as follows 1 Remove all power from the equipment 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 f SHOCK HAZARD To avoid shock hazard ensure the main power has been 2 Measure DC resistance as follows Complete power pole from line side to load side 12 kV 5 PowerBricks 100 145 k 15 kV 6 PowerBricks 125 175 k Note It may be necessary to isolate one side of the power pole by disconnecting one of the flex braid connections at the top of the power pole assembly Parallel resistance paths may be created due to earthing connections motor windings or other connected equipment Variations may also be noted based on the devices used in different ratings of PowerBricks The key is to look for notable differences between individual PowerBricks or power poles Rockwell Automation Publication 7760 UM001E EN P December 2014 Troubleshooting Chapter 8 If the power pole resistance is a multiple of 25 k lower than specifie
144. re dod fuses kee uoc EE dts da MeL cd 115 Contaminatlom SUPER REV EFFUDIT 115 Vac um DOLOS catene ERE cios 116 PPE TIRING cri eth Deed obe orien Edid 116 CDI Isa duos cw qu eri acte Be qaos oie a 116 Solid State Devices 116 Static Sensitive 6 115 0 cc ccc cece cence cence ees 117 Overload Maintenance After a Fault Condition 117 Panal peeks Ota sides ated ree ee atus Sate Dns 117 Keep Good Maintenance 117 Power Comiponcits Susie Cr EINE MEAN RI I MPO SER 117 Control Components Electronic 22 ree rene 118 118 118 as EL Metus 118 Environmental 118 Hazardous materials dad det ro prt dash 118 cech alte tell oh nd uie oe 119 Appendix Specifications ERE re ERES 121 Appendix B Table 131 Appendix PowesBricks duce eee e Okie ol 141 Rockwell Automation Publication 7760 UM001E EN P December 2014 Accessories History of Changes Index Table of Contents Appendix D Table of Accessories 143 Appendix E 7760 UMO001D EN P October 20 e e oo UR eae canes 145
145. rface Board 41 Power Module 41 Human Interface Module HIM 77 1 0 36 Metering 36 75 Options 77 Programming 37 61 Protection and Diagnostics Excessive Starts Hour 35 Ground Fault 32 Jam Detection 31 Line Faults 35 Open Gate 34 Overload 28 Overtemperature 35 Overvoltage 30 PTC Protection 33 Stall Protection 31 Thermistor 33 Unbalance 31 Underload 30 Undervoltage 30 Starting Modes 22 Current Limit 23 Dual Ramp 24 Full Voltage 24 Linear Speed Acceleration and Decelera tion 26 Preset Slow Speed 25 Rockwell Automation Publication 7760 UM001E EN P December 2014 Selectable Kickstart 23 Soft Start 22 Soft Stop 27 Status Indication 38 Voltage Sensing Module 58 Overvoltage Protection and Diagnostics overview 30 P parameters programming 64 management 66 Electrically Erasable Programmable Read only Memory EEPROM 66 Random Access Memory RAM 66 Read Only Memory ROM 66 modification 67 Password Programming 65 modification procedure 65 Power Components Maintenance 117 Power Factor Correction Capacitors 18 Implementation 20 Typical Bulletin 7760 Line Diagram 18 Typical Bulletin 7762 Line Diagram 19 Typical Bulletin 7763 Line Diagram 19 Power Module overview 41 Power Resistor Replacement 113 PowerBrick Accessories 142 Common Parts 142 Replacement Parts 141 Preset Slow Speed Programming 71 Preset Slow Speed starting mode overview 25 Programming Basic Set up 71 Current Limit Start 68 Dual Ramp Start 69 Ex
146. rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www
147. rogrammed 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 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 TIP 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 For after hours technical support call pager no 519 654 5616 Rockwell Automation Publication 7760 UM001E EN P December 2014 97 Chapter8 Troubleshooting IMPORTANT Inthe 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 Figure 41 Troubleshooting Flowchart YES Fault Displayed NO Define Nature of Trouble Motor will not start Motor rotates but no output voltage to does n
148. rotective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information Changes throughout this revision are marked by change bars as shown to the right of this paragraph New and Updated This table contains the changes made to this revision Information Topic Page Added 160 340 and 580 A 10 12 and 12 4 14 4 kV Complete Rollout 141 Assembly to Spare Parts list Added Fiber Optic Cable Kit Low Voltage Panel to Common Parts 142 Revised Part Numbers in Common Parts 142 Revised Part Numbers in Accessories 142 Rockwell Automation Publication 7760 UM001E EN P December 2014 3 Summary of Changes Notes 4 Rockwell Automation Publication 7760 UM001E EN P December 2014 Preface Product Overview Table of Contents Service aya Matt anta ci odd R 11 Chapter 1 Manual OD dea cattle td 13 Documentatioh c eie edt 13 D scriptiofixic cess suse ee UE oe ee eee E LR cae NS 13 7703 OEM Controller so iis e x E RA RE ERES 13 7760 Retrofit 14 7761 Combination
149. rrect line voltage 1 1000 see Table 6 on page 58 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 0 305 Initial Torque m The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter 0 90 locked rotor torque Current Limit Level 2 The current limit level that is applied for the Ramp time selected 50 600 FLC Kickstart Time A boost current is provided to the motor for the programmed time period 0 0 2 0 Kickstart Level Adjusts the amount of current applied to the motor during kickstart 0 90 locked rotor torque Stop Input Allows the user to select the operation of terminal 18 Stop Input Coast Stop Option Option 1 Input Allows the user to select the operation of terminal 16 Option Input 1 Disable Stop Option Fault Fault NC Network Option 2 Input Allows the user to select the operation of terminal 15 Option Input 2 Disable Preset Slow Speed Dual Ramp Fault Fault NC Network Clear Fault Emergency Run Stop Mode Allows the user to program the SMC Flex controller for the type of stopping that best fits the application Soft Stop Linear Speed Stop Time This sets the time
150. rrent for 7 period peak 55 value Category AC4 100 closing operations A 4000 Rated load and overload characteristics in category of use Category AC4 25 opening operations A 4000 Electrical Life at rated current verified as in Category Operations 1000000 Mechanical Life Operations 1000000 Short circuit breaking capacity 0 3min CO 3min CO A 4000 Short circuit making capacity 0 3min CO 3min CO A Peak 8000 Opening Time lower and upper limit ms 20 30 Switching Times Closing Time lower and upper limit ms 30 50 Relative Humidity without condensation 96 95 Operating Temperature C 5 50 with derating 1 The voltage and current ratings listed are valid up to 1000 m 3300 feet Please refer to Controller Derating chart for ratings above this altitude Rockwell Automation Publication 7760 UM001E EN P December 2014 129 AppendixA 7760 7761 7762 and 7763 SMC Flex Specifications Notes 130 Rockwell Automation Publication 7760 UM001E EN P December 2014 Appendix B SMC Flex Module Parameter Information Table of Parameters Table 50 Parameter List Group Parameter Parameter Units Min Max Default Settings Parameter Description User Settings Name Number Provides the phase to phase supply voltage Metering Volts Phase A B 1 V measurements at all times including bypass operation Provides th
151. rt parameter allows the user to select the type of ramp mode used for the second ramp profile Speed Pump Start When the dual ramp mode is selected this parameter allows the user to program the time Dual Ramp Ramp Time 2 26 Secs 0 30 10 0 30 s that the controller performs the starting maneuver for profile 2 Also refer to Parameter 130 When using the soft start mode for profile 2 this parameter allows the user to adjust the initial Dual Ramp Initial Torque 2 a ALRT 0 90 n torque level applied to the motor at the beginning ofthe start maneuver When using the current limit starting mode for DualRamp CurLimitLevel2 28 OFLC 50 600 350 profile 2 this parameter allows the user to adjust 132 the current level applied to the motor during the start maneuver Rockwell Automation Publication 7760 UM001E EN P December 2014 Group Dual Ramp Parameter Name Reserved Parameter Number 29 Units Min Max Default Settings SMC Flex Module Parameter Information Parameter Description Reserved User Settings Appendix B Dual Ramp Kickstart Time 2 30 Secs 0 0 2 0 0 0 This parameter provides torque pulse for the programmed time period at the beginning of the starting maneuver for ramp profile 2 Dual Ramp Kickstart Level2 31 LRT 0 90 This parameter provides the user with the ability to set the level of the torque pulse applie
152. rvoltage trip setting from 0 199 of the programmed motor voltage Trip delay time can be adjusted from 0 99 seconds Note For medium voltage applications overvoltage protection should be set at or below 110 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 Unbalance The MV SMC Flex is able to detect an unbalance in line voltages Motor operation can be halted if the unbalance is greater than the desired range The MV SMC Flex controller provides an adjustable unbalance setting from 0 25 of the line voltages Trip delay time can be adjusted from 0 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 Sta
153. s 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 Maintenance Chapter 9 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 are typically not restricted by environmental 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 handling 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
154. s signaled to stop gating and initiate a temperature fault For a detailed layout of this circuit board refer to Figure 28 in Chapter 2 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 Ifthe 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 27 in Chapter 2 Rockwell Automation Publication 7760 UM001E EN P December 2014 41 44 Y LOZ 199 19590 d NI JLOOWN 09ZZ uone qng IMH CUSTOMER S INCOMING LINE 5 ei gt Figure 23 Typical OneGear SMC Flex Power System Bulletin 7763
155. s 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 79 Chapter5 Options Parameter Option Range SMC Option Braking Control This parameter identifies the type of control present and is not user programmable Slow Speed Select Low 7 Allows the user to program the slow speed that best fits the High 15 Slow Speed with Braking application 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 spe
156. ssible Solutions Motor current and voltage fluctuates with steady load Motor Verity type of motor as a standard squirrel cage e Erratic Load induction motor e Check load conditions Erratic operation Loose connections Shut off all power to controller and check for loose connections Accelerates too fast Starting time e Increase starting time Initial torque e Lower initial torque setting Current limit setting Decrease current limit setting e Kickstart e Lower kickstart time or turn off Accelerates too slow Starting time e Decrease starting time e Initial torque e Increase initial torque setting Current limit setting e Increase current limit setting e Kickstart e Increase kickstart time or turn off Fan does not operate e Wiring e Check wiring and correct if necessary Failed fans s Replace fan s Motor stops too quickly with Soft Stop option Rockwell Automation Publication 7760 UM001E EN P December 2014 Time setting Verify the programmed stopping time and correct if necessary 1 Various faults may occur if Parameter 15 is set to Delta It must be set to Line for all MV applications 101 Chapter8 Troubleshooting Display Motor stops too slowly with Soft Stop option Possible Causes Stopping time setting e Misapplication Possible Solutions Verify the programmed stopping time and correct if necessary The Soft Stop option is intended to extend the stopping time for loads that stop su
157. supplied for each speed motor 2 Automatic reset of an overload fault requires the start input to be cycled in a 2 wire control scheme 3 The trip rating is 117 of the programmed FLC Figure 14 and Figure 15 provide the overload trip curves for the available trip classes Separate protection relay c w instantaneous overcurrent protection is required when used with vacuum breakers Rockwell Automation Publication 7760 UM001E EN P December 2014 Approximate Trip Time seconds 1000 0 100 0 10 0 Product Overview Chapter 1 Figure 14 Overload Trip Curves Class 10 Class 15 Class 20 Class 30 10000 0 10000 0 10000 0 1000 0 4000 0 1000 0 100 0 4000 100 0 10 0 10 0 10 0 Approximate Trip Time seconds Approximate Trip Time seconds Approximate Trip Time seconds 2 3 4 5678910 5 1 2 3 4 5 6 78910 2 3 4 5678910 1 2 3 4 5 6 78910 Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC Approximatetriptimefor3 phaee a a Approximate trip time for 3 phase balanced condition from cold start balanced condition from cold start Figure 15 Restart Trip Curves after Auto Reset 100000 1000 100 Y L 85510 xy 316 Class 20 SS Class 30 Seconds Auto Reset Times 1 4 Class 10 905 Class 15 1355 Class 20 1805 Class 30 270s
158. t Datalink DataLinks Data In A2 89 0 16 bit Datalink DataLinks Data In B1 90 0 16 bit Datalink DataLinks Data In B2 91 0 16 bit Datalink DataLinks Data In C1 92 0 16 bit Datalink DataLinks Data In 2 93 0 16 bit Datalink DataLinks Data In D1 94 0 16 bit Datalink DataLinks Data In D2 95 0 16 bit Datalink DataLinks Data Out A1 96 0 16 bit Datalink DataLinks Data Out A2 97 0 16 bit Datalink DataLinks Data Out B1 98 0 16 bit Datalink DataLinks Data Out B2 99 0 16 bit Datalink DataLinks Data Out C1 100 0 16 bit Datalink DataLinks Data Out C2 101 0 16 bit Datalink DataLinks Data Out D1 102 0 16 bit Datalink DataLinks Data Out D2 103 0 16 bit Datalink Allows the user the ability to assign a specific identification number to a motor and controller Motor Data Motor ID 104 0 65535 0 combination This can be useful for network applications where you may need to locate a specific motor controller based on a network address Sets the proper current ratio when an external Motor Data CT Ratio 105 1 1500 current transformer is used for Medium Voltage applications example for 150 5 set 150 Motor Data MV Ratio 106 1 10000 Sets the proper feedback scaling when used for Sae Table 6 Medium Voltage applications Rockwell Automation Publication 7760 UM001E EN P December 2014 137 Appendix B Group Basic Set Up SMC Flex Module Parameter Information Parameter Name Aux1 Config Parameter Number 107 Units Min Max Normal
159. t Restart Delay 8 Sus 0 60 0 Provides a delay time between restart attempts to allow for the condition to be removed This parameter gives the user the ability to selectively disable specific fault codes such as F1 F2 and F41 F42 F43 These faults are used to detect um problems with incoming power and the detection of 1 Disable F1 appropriate zero crosses F1 or the firing of the Linear List Line Fault Disable 84 2 DisableF41 Enable SCRs based on the current and voltage 3 Enable Characteristics associated with the SCR turning off F41 These faults can only occur during starting or stopping and are usually related to the incoming power condition This parameter defeats all running faults and is only 0 Disable effective in the run mode It will not override Linear List Emergency Run 85 Enabl Disable faults prior to starting i e shorted SCR This 1 Enable parameter is reset to off disable when control power is recycled 0 Disable This parameter allows the user to override current Linear List Current Loss 86 Enabl Enable loss fault This is indicative of the typical failure 1 Enable mode of a damaged CT Allows the user to enable or disable control from various serial interface ports DPI with a 0 Comm Masks Logic Mask 87 8 bit binary 0 setting If a port is set to 1 the port will be allowed to control the SMC and will produce a comm fault if disconnected DataLinks Data In A1 88 0 16 bi
160. t at start up that is user adjustable from 0 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 2 0 seconds Figure 9 Selectable Kickstart Percent Voltage 100 Kickstart Initial Torque lt Start gt lt Run gt Time Seconds Current Limit Start This starting mode provides a true current limit start that is used when limiting the maximum starting current is necessary The Current Limit level is user adjustable from 50 600 of the motor s full load ampere rating and the current limit time is user adjustable from 0 30 seconds Once the MV SMC Flex controller senses that the motor has reached the up to speed condition during the current limit starting mode the output voltage automatically switches to full voltage and the bypass contactor is closed Figure 10 Current Limit Start Percent Full Load Current 600 EL Start gt Time seconds Kickstart is also available with Current Limit Start Dual Ramp Start and Linear Acceleration Rockwell Automation Publication 7760 UM001E EN P December 2014 23 Chapter1 Product Overview Dual Ramp Start This starting mode is useful for applications that have varying loads and therefore varying starting torque requirements Dual Ramp Start allows t
161. t time There are two standard stop modes e Soft Stop e Linear Speed Deceleration Table 17 Stop Control Parameters and Options Parameter Description Option Stopping Mode This may be set to one of two standard choices Soft Stop Linear Speed Stop Time Allows the user to set the time period for the stopping function 0 120 8 1 Refer to Chapter 6 for optional stop control modes 2 A motor tachometer is required refer to page 26 3 Consult factory if settings over 30 seconds are required The base rating of the MV SMC Flex is two starts or one start stop combination per hour 30 seconds maximum for each operation A stopping operation counts as a start for purposes of thermal capacity calculations Note Options that control the stopping of the motor Soft Stop Pump Stop Linear Speed Braking require the self powered gate drivers to be pre charged by the current loop power supply If this supply is not present an alarm symbol will appear at the upper right corner of the control module display and the options will be inhibited When the motor is stopped it will coast If the supply is restored the alarm symbol will be cleared and the module will perform the programmed sequence 70 Rockwell Automation Publication 7760 UM001E EN P December 2014 Preset Slow Speed Parameter Slow Speed Select motor Table 18 Preset Slow Speed Parameters and Options Description Allows the user to pr
162. tactor or Breaker User Manual for service instructions 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 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 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 Maintenance Chapter 9 see NEMA Standards Publication No ICS 1 1 1987 entitled Safety Guidelines for the Application Installation and Maintenance of Solid State C
163. tended to be used as an emergency stop Refer to the applicable standards for ATTENTION The Bulletin 20 HIM interface module s stop push button is not emergency stop requirements 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 Connecting the Human Interface Module to the Controller Figure 38 shows the connection of the SMC Flex controller to a human interface module Table 28 provides a description of each port Note The SMC Flex only supports the use of DPI communication modules and DPI HIM Modules Scanport devices are not supported by the SMC Flex See Figure 25 on page 45 or Figure 26 on page 46 for the control wiring diagram that enables start stop control from a human interface module Rockwell Automation Publication 7760 UM001E EN P December 2014 87 Chapter7 Communications Figure 38 SMC Flex Controller with Human Interface Module Connected Port 5 DPI Communications Ports 2 and 3 when two HIMs are connected with a splitter Table 28 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 HIM Control Enable To enable motor control from a connected human interfa
164. 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 C and refer to Voltage Sensing Board Replacement on page 103 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 Special care must be taken when working with the white high voltage wire to ensure it is not damaged The ribbon cable must be connected to J1 on the voltage sensing board or the equipment will not function 2 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 ATTENTION Make sure ground wires from the Voltage Sensing Module are N securely connected to the ground bar in the low voltage panel or ground bus Failure to do so may result in severe injury or equipment damage 3 Repeat PowerBrick SCR Testing on page 108 and Resistance Checks and Power Supply Tests on page 53 Power Resistor Replacement When replacing the ceramic wire wound type 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 sc
165. tions 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 115 Chapter 9 116 Maintenance 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 ATTENTION Allen Bradley magnetic starters contactors and relays are 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 vacuum to operate properly and to interrupt current Refer to Vacuum Con
166. tor Linear List Braking Time SMB 36 Sec 0 999 This parameter provides the ability to over ride the SMB function zero speed detection and set an exact time in which the braking current is applied to the motor This can be used for applications where detecting zero speed is difficult or when the purpose is to reduce the number of overload trips associated with driving the motor to a complete stop Setting this to a specific value will turn off the braking at a set time each time a stopping maneuver is performed An ideal setting can be accomplished through trial and error and should always allow for some small coast time Setting this value to long will cause braking current to be applied to a stopped motor and likely result in overload trips Linear List Load Type SMB 37 0 Standard 1 Hi Inertia 2 Hi Friction 3 Ramp 89 0 Standard Allows the user the ability to modify the braking profile to match a particular load type This parameter is designed to only be used with the SMB algorithm and not with timed brake For the majority of applications the standard profile will work sufficiently Adjusting this parameter should really only be used when some type of problem during braking is being encountered Rockwell Automation Publication 7760 UM001E EN P December 2014 133 Appendix B Group Linear List SMC Flex Module Parameter Information Parameter Name
167. tor for option 2 Dual Ramp Ramp Time 2 This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Start set up 0 3059 Dual Ramp Initial Torque 2 The initial reduced output voltage level for the second Start set up is established and adjusted with this parameter 1 The Dual Ramp feature is available on the standard controller 2 Kickstart can be programmed for both start modes 0 90 locked rotor torque 3 For ramp times greater than 30 s set Ramp Time 2 to zero and program Start Time 2E parameter 130 for the new time Do not exceed the thermal capacity of the controller Dual Ramp Start is available only with the standard controller Full Voltage Start This starting mode is used for applications requiring across the line starting The output voltage to the motor will reach full voltage within 1 4 second Table 3 Full Voltage Start Parameter Option Starting Mode This must be programmed for Full Voltage Full Voltage 24 Rockwell Automation Publication 7760 UM001E EN P December 2014 Product Overview Chapter 1 Preset Slow Speed This option can be used in applications that require a slow speed jog for general purpose positioning Preset Slow Speed provides either 7 of base speed low or 15 of base speed high settings in the forward direction Reverse can also be programmed and offers 10 of base speed low and 20
168. trollers It includes e Removable PowerBrick SCR assemblies e Voltage sensing board e Fiber optic connection from SMC Flex control module to gate driver boards on PowerBricks e A low voltage control panel complete with microprocessor based control module and control terminations e A continuous bare copper ground bus 8 x 50 mm e Provision for bottom fed line and load connections Figure 2 Typical OneGear Single Line Diagram Bulletin 7761 10 14 4 kV SMC Hex Control Module Customer Supplied Output Rockwell Automation Publication 7760 UM001E EN P December 2014 15 Chapter1 Product Overview 7762 Combination Controller Vacuum Contactor A medium voltage solid state controller that provides isolation and protection for new installations It includes e Tin plated insulated copper horizontal power bus e A continuous bare copper ground bus 8 x 50 mm e Removable PowerBrick SCR assemblies e Drawout main isolation START vacuum contactor Drawout bypass RUN vacuum contactor Six current limiting power fuses e Six current transformers e Fiber optic connection from SMC Flex control module to gate driver board on PowerBricks e A low voltage control panel complete with microprocessor based control module Space for necessary auxiliary control and metering devices Motor overload protection included in SMC Flex control module Earthing switch optional Fig
169. ts 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 Regardless of the type of interface being used the information below can be used to configure the rest of the system Rockwell Automation Publication 7760 UM001E EN P December 2014 Default Input Output Configuration Variable Input Output Communications Chapter 7 The default configuration for I O is 4 bytes in and 4 bytes out TX 4 bytes RX 4 bytes The total size may very when used with a communication card The default configuration is arranged according to the following table Table 30 Default Input Output Configuration Parameter Produced Data Status Consumed Data Control Word 0 Word 1 Feedback Reference Logic Status Logic Command 1 The feedback word is always Current in Phase 2 Thereference word is not used with the SMC Flex however the space must be reserved Note The total size produced or consumed may vary depending on the communication card being used For more information refer to the User Manual for the communication card The SMC Flex supports 16 b DataLinks Therefore the device can
170. ues 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 D for a listing of human interface module catalog numbers that are compatible with the controller Note Bulletin 20 HIM Rev3 002 or later must be utilized with the SMC Flex Note Extension cables are available up to a maximum of 10 m in total length Note A maximum of two HIM modules can be installed The control panel provides the operator interface to the controller Rockwell Automation Publication 7760 UM001E EN P December 2014 Communications Chapter 7 Table 27 Operator Interface Keys Key Name Description G Start The green start button when pressed will begin motor operation Proper setup of HIM port is required Stop The red stop button when pressed will halt motor operation and or reset a fault m Jog The jog button is active only when a control option is present Pressing the jog button will initiate the option maneuver for example Pump Stop in
171. ulses on SMC Flex Control Module Ribbon connectors to connect to SMC Flex Control Module underneath control module uu y LED Yellow ON when Phase A gate signal active TP4 Phase A gate signal TP8 Common for Gate Pulse TPs ca LED Yellow ON La when Phase B gate Phase C Fibre Optic Transmitters w w m eo E gt to m m signal active Phase gate signal ___ LED Yellow ON when Phase C gate signal active P13 Phase C gate signal TP15 Common for SW3 Used to defeat T temperature feedback channels Temperature Feedback Fibre Optics Receivers 52 o o m Gate Pulse TPs p TE LED Green ON when power is present LEDs Green ON when signal present at temperature feedback fibre optic receivers Voltage feedback test points Module common Do not connect to earth ground LED Green ON when current loop power supply is present 84
172. ure 3 Typical OneGear Single Line Diagram Bulletin 7762 10 12 kV Start Controller Power Converter Bypass Controller 4 4 S T S T ST SMC Flex Control Module To Optional MPS Optional IED To SMC Flex E Control ection Module Optional Earthing Switch b Ce nn en ny ey eee ee Fe ee 16 Rockwell Automation Publication 7760 UM001E EN P December 2014 Start Controller R S T Optional Product Overview 7763 Combination Controller Vacuum Breaker A medium voltage solid state controller that provides isolation and protection for new installations It includes Tin plated insulated copper horizontal power bus A continuous bare copper ground bus 8 x 50 mm Removable PowerBrick SCR assemblies Drawout main isolation START vacuum breaker Drawout bypass RUN vacuum breaker Six current transformers Fiber optic connection from SMC Flex control module to gate driver board on PowerBricks Chapter 1 A low voltage control panel complete with microprocessor based control module Space for necessary auxiliary control and metering devices Motor overload protection Earthing switch optional Figure 4 Typical OneGear Single Line Diagram Bulletin 7763 10 14 4 kV Bypass Controller R S T Power Converter
173. ust persist within for the controller to Alarm Over voltage Overvolt F Lvl 59 Allows the user to set a voltage of line Voltage that will cause a fault when the voltage falls above this value A zero value is the off setting Over voltage Overvolt F Dly 60 Secs Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the voltage condition must persist within for the controller to fault Over voltage Overvolt A Lvl 61 Allows the user to set a voltage of line Voltage that will cause an Alarm when the voltage falls above this value A zero value is the off setting Over voltage Overvolt A Dly 62 Secs Allows the userthe ability to prevent some nuisance Alarms by entering a delay period that provides a window that the voltage condition must persist within for the controller to Alarm Unbalance Unbalance F Lvl 63 90V Allows the user to set a percentage of line to line Voltages that will cause a fault when the voltage falls above this value A zero value is the off setting Unbalance Unbalance F Dly 64 Secs Allows the userthe ability to prevent some nuisance faults by entering a delay period that provides a window that the voltage unbalance condition must persist within for the controller to fault Unbalance Unbalance A Lvl 65 90V Allows th
174. ut 69 Jam 114 UTS Level 25 Starting Mode 2 70 Jam 115 Parameter Mgmt 26 Ramp Time 2 7 Stall Delay 116 Backspin Timer 27 Initial Torque 2 72 Gnd Fit Enable 117 V Shutoff Level 28 Cur Limit Level 2 73 Gnd Fit Level 118 OL Reset Level 29 Reserved 74 Gnd Fit Delay 119 Ambient Temp 30 Kickstart Time 2 75 Gnd Fit Inh Time 120 Notch Position 31 Kickstart Level 2 76 Gnd Fit A Enable 121 Notch Maximum 1 32 Stop Mode 7 Gnd Fit A Lvl 122 Start Delay 33 Stop Time 78 Gnd Fit A Dly 123 Bypass Delay 34 Pump Pedestal 79 PTC Enable 124 Fault 1 35 Braking Current 80 Phase Reversal 125 Fault 2 36 Braking Time 81 Starts Per Hour 126 Fault 3 37 Load 82 Restart Attempts 127 Fault 4 38 High Eff Brake 83 Restart Delay 128 Fault 5 39 Slow Speed Sel 84 Line Fault 129 Start Time E 64 Rockwell Automation Publication 7760 UM001E EN P December 2014 Programming Chapter3 ParameterNo Description ParameterNo Description ParameterNo Description 40 Slow Speed Cur 85 Emergency Run 130 Start Time 2E 41 Slow Accel Cur 86 Current Loss 131 Stop Time E 42 Slow Running Cur 87 Logic Mask 132 Option 1 Input 43 Stopping Current 88 Data In A1 133 Stop Input 44 Overload Class 89 Data In A2 134 Elapsed Time 2 45 Service Factor 90 Data In B1 1 Do not change these parameters from the default settings 2 Pump Control module only see Troubleshooting section for guidance 3 Brake m
175. value or acknowledge a fault alarm Select Lan Select a digit select a bit or enter edit mode in a parameter screen ED Will get to menu to change the language being displayed Up Down Arrows Scroll through options increase decrease value or toggle a bit Enter Enter a menu enter edit mode in a parameter screen or save a change to a parameter value e 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 Prog ramming Menu Parameters are organized in a three level menu structure for straightforward programming Figure 33 details che 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 Rockwell Automation Publication 7760 UM001E EN P December 2014 61 Chapter3 Programming Figure 33 Menu Structure Hierarchy Power up and Status Display Lang o Select language being displayed Choose Mode OPERATION LEVEL E3 i Memor Log Parameter Device gt St y Preferences In Diagnostics e Select 6 MAE SMC Flex Rest to Defaults Change Password Alarms etUp Save to EEPROM User Dspl Line Faults Motor Protection Recall EEPROM User Dspl Time Device Revision Communications User Dsp
176. within for the controller to Alarm Stall Stall Delay 7 Secs 0 0 10 0 This feature allows the user to program the amount of time beyond the initial start maneuver for the motor to be at speed A setting of zero means that the stall detection feature is disabled 1 sec recommended Ground Fault Gnd Fit Enable 72 Disable Enable Disable Enables ground fault protection when used with an external core balanced ground fault sensor Ground Fault Gnd Fit Level 73 1 0 5 0 2 5 Allows the user to set a current core balance current that will cause a fault when the current is above this value Ground Fault Gnd Fit Delay 74 Secs 0 1 250 0 0 5 Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the ground fault condition must persist within for the controller to fault Ground Fault Gnd Fit Inh Time 75 Secs 0 250 10 Allow the user the ability to disable inhibit ground fault protection for a selected time when starting Ground Fault Gnd Fit A Enable 76 Disable Enable Disable Enables a ground fault protection Alarm when used with an external core balanced ground fault sensor Ground Fault Gnd Fit A Lvl 77 1 0 5 0 2 0 Allows the user to set a current core balance current that will cause an Alarm when the current is above this value Ground Fault
177. x RX1 RX2 TP2 Li terminal N 3 oo x I OU i Gate cathode En Oo I connector 7 Cathode E J I u L wi terminal O Coo oO Common test 20V test point Overvoltage point Resistance Checks and Power Supply Tests sense terminal 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 ATTENTION Servicing energized industrial control equipment be Isolate incoming power to the Incoming Line Unit and if provided close Earthing Switch in the Bypass Unit Open the doors providing access to the SCR Power trucks as detailed below Open the Phase U SCR Power Truck Door first open V and W phase next as they are interlocked For re closing operation the operation sequence is the reverse The SCR Power Trucks have to be isolated from Main Power and control before racking out The SCR Power trucks are to be racked out to carryout the Power Supply Test and Resistance Checks The Main Power connection of the SCR Power Truc
178. x will indicate a Ground Fault Alarm if e No warning currently exists e Ground fault alarm is enabled GF Inhibit Time has expired GF Current is equal to or greater than the Gad Fit A Lvl Parameter 77 Gnd Fit A Lvl allows the installer to define the ground fault current at which an alarm will be indicated It is adjustable from 1 0 5 0 A Parameter 78 Grd Flt A Dl allows the installer to define the time period ground fault alarm condition must be present before a trip occurs It is adjustable from 0 1 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 sensors resistance transitions from 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 Table 5 PTC Input Ratings Response Resistance 34000 1500 Reset Resistance 1600 0 1000 Short circuit Trip Resistance 250 100 Maximum Voltage at PTC Terminals RPTC 4 lt 75V Maximum Voltage at PTC Terminals RPTC open 30V
179. y for further assistance 78 ATTENTION The Bulletin 20 HIM interface module stop push button is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements Rockwell Automation Publication 7760 UM001E EN P December 2014 Programming Parameters Option Pump Control Options Chapter 5 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 supporting the options described below are shown later in this chapter Parameter Range Pump Control SMC Option This parameter identifies the type of control present and is not user programmable Pump Control Pump Stop Time Allows the user to set the time period for the pump stopping function 0 1205 Starting Mode Allows the user to program the SMC Flex controller for the type of starting that best fits the application Pump Start Soft Start Current Limit Start Full Voltage 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 userto program the intensity ofthe braking current applied to the motor 0 400 of full load current Accu Stop SMC Option This parameter identifie
180. y 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 It is recommended that insulation levels be checked before energizing power equipment This may be done with a High Voltage AC insulation tester HI POT or a Megger See Vacuum Contactor User Manual for suggested HI POT testers and for test procedures for vacuum contactors If using a Megger a minimum 5000V type is recommended Rockwell Automation Publication 7760 UM001E EN P December 2014 Commissioning Procedure Chapter 2 wires between line and load terminals above the power poles to short out the SCRs before applying high test voltages to the power circuit Disconnect ground wires from the voltage sensing board and remove the plug connector If voltage transformers are present remove one primary fuse from each device ATTENTION Solid state devices be destroyed by high voltage Use jumper voltage testing is potentially hazardous and may cause severe burns injury or death Where appropriate the case of the test equipment should be connected to ground ATTENTION Use caution when performing the HI POT Megger Test High Insulation may be tested from phase to phase and phase to ground The recommended level for AC HI POT testing is 2 X VLL Volts where VLL is the rated line to line voltage of the power system The le

Download Pdf Manuals

Related Search

Related Contents

StarTech.com 1 ft USB Y Cable for External Hard Drive - Dual USB A to Micro B  Beckett Water Gardening RFPG User's Manual      pro 4000 User Manual未转曲_1    R&S®BBA100 Broadband Amplifier Specifications  GUIDE D`INSTALLATION / INSTALLATION GUIDE  R&S FSW-K10x (LTE Downlink) LTE Downlink  

Copyright © All rights reserved. Failed to retrieve file