Medium Voltage SMC Flex™ Motor Controller Bulletins 1503E, 1560E and 1562E User Manual
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.
Table of Contents Page Preface Service Procedure ............................................................................ P-1 Product Overview Chapter 1 Manual Objectives ............................................................................ 1-1 Documentation .................................................................................. 1-1 Description........................................................................................ 1-1 1503E – OEM Controller ........................
ii Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual Product Overview (cont.) Chapter 1 Page Typical MV SMC-Flex Power System Diagrams Bulletin 1562E (Without Stop Control) .................................... 1-24 Bulletin 1562E (With Stop Control) .......................................... 1-25 Bulletin 1562E (Without Stop Control) ..................................... 1-26 Bulletin 1562E (With Stop Control) ..........................................
Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual Installation (cont.) Chapter 2 iii Page Surge Arrestor Protection Devices ................................................. 2-16 Motor Overload Protection ............................................................. 2-17 EMC Compliance ............................................................................ 2-18 Control Power ..................................................................................
iv Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual Metering Chapter 5 Page Overview........................................................................................... 5-1 Motor Data Entry .............................................................................. 5-1 Options Chapter 6 Overview........................................................................................... 6-1 Human Interface Module ........................................................
Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual Troubleshooting Chapter 9 v Page General Notes and Warnings ............................................................ 9-1 Fault Display Explanation ................................................................ 9-3 Control Module Removal .................................................................. 9-6 Voltage Feedback Circuit Tests .........................................................
vi Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual Appendix A 1560E/1562E SMC-Flex Specifications Page Specifications – Table A.1 ............................................................... A-1 Altitude Derating –Table A.2 ........................................................... A-3 Area Available for Cable Entry/Exit – Table A.3 ............................ A-3 Cable Quantity and Size – Table A.4 ...............................................
Preface Service Procedure For your convenience, the Rockwell Automation Global Manufacturing Solutions (GMS), provides an efficient and convenient method of servicing medium voltage products. Contact your local area support office to make arrangements to have a qualified service representative come to your facility. A complete listing of Area Support Offices may be obtained by calling your local Rockwell Automation Distributor or Sales Office.
Preface 1560E-UM050B-EN-P - June 2013
Chapter 1 Product Overview Manual Objectives This manual is intended for use by personnel familiar with Medium Voltage and solid-state power equipment. The manual contains material which will allow the user to operate, maintain and troubleshoot the MV SMC-FlexTM family of controllers. The family consists of the following Bulletin numbers: 1503E, 1560E and 1562E. Documentation The following Rockwell Automation publications provide pertinent information for the MV SMC-Flex and components: • MVB-5.
1-2 Product Overview Description (cont.) % 5- " %. 0 *UNE % 5- " %. 0 *UNE 1560E – Retrofit Controller A medium voltage solid-state controller designed to work in conjunction with an existing customer-supplied starter.
Product Overview 1-3 % 5- " SMC-Flex™ Control Module (cont.) Other features that offer further user benefit include: • Extensive protection features • Metering • Communication capability Innovative control option provides enhanced performance: • Pump Control (Start and Stop Control modes) These modes, features and options are further described in this chapter.
1-4 Product Overview Starting Modes (cont.) Selectable Kickstart : Selectable kickstart provides a power boost at start-up that is user-adjustable from 0 to 90% of locked rotor torque. The additional power helps motors generate higher torque to overcome the resistive mechanical forces of some applications when they are started. The selectable kickstart time is useradjustable from 0.0 to 2.0 seconds. Kickstart 100% Initial Torque Start Run Time (seconds) Figure 1.
Product Overview 1-5 Dual Ramp Start : This starting mode is useful for applications that have varying loads (and therefore varying starting torque requirements). Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings. Percent Voltage Ramp #2 100% Initial Torque #2 Initial Torque #1 Ramp #1 Run #1 Start #1 Start #2 Run #2 Time (seconds) Figure 1.
1-6 Product Overview Starting Modes (cont.) Preset Slow Speed This option can be used in applications that require a slow-speed jog for general purpose positioning. Preset Slow Speed provides either 7% of base speed (low) or 15% of base speed (high) settings in the forward direction. Reverse can also be programmed and offers 10% of base speed (low) and 20% of base speed (high) settings. Forward 15% – High 7% – Low Time (seconds) Start Run 10% – Low 20% – High Reverse Figure 1.
Product Overview 1-7 Linear Speed Acceleration and Deceleration The SMC-Flex has the ability to control the motor speed during starting and stopping maneuvers. A tachometer signal (0 to 5V DC) is required to perform this start mode. The start time is selectable from 0 to 30 seconds and determines the time the motor will ramp from 0 speed to full speed. Kickstart is available with this option. 100% Motor Speed Start Run Time (seconds) Stop Figure 1.
1-8 Product Overview % 5- " %. 0 *UNE % 5- " %. 0 *UNE Starting Modes (cont.) Soft Stop This feature can be used in applications that require an extended coast-torest time. The voltage ramp-down time is user-adjustable from 0 to 60 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.
Product Overview Protection and Diagnostics 1-9 The MV SMC-Flex™ controller is capable of providing the following protective and diagnostic features: Overload The MV SMC-Flex controller meets applicable requirements as a motor overload protection device. Thermal memory provides added protection and is maintained even when control power is removed. The built-in overload algorithm controls the value stored in Parameter 12, Motor Thermal Usage (see Chapter 4, Programming).
1-10 Product Overview Protection and Diagnostics (cont.) Class 15 Class 10 1.0 0.1 1 2 3 4 5 6 7 8 9 10 1000.0 100.0 10.0 1.0 1 2 Multiples of FLC 3 4 5 Approximate Trip Time (seconds) 10.0 10000.0 10000.0 Approximate Trip Time (seconds) Approximate Trip Time (seconds) Approximate Trip Time (seconds) 100.0 Class 30 Class 20 10000.0 1000.0 1000.0 100.0 10.0 10.0 1.
Product Overview 1-11 Underload : Utilizing the underload protection of the MV SMC-Flex controller, motor operation can be halted if a sudden drop in current is sensed. The MV SMC-Flex controller provides an adjustable underload trip setting from 0 to 99% of the programmed motor full load current rating. Trip delay time can be adjusted from 0 to 99 seconds. : Underload protection is disabled during slow speed and braking operations.
1-12 Product Overview Protection and Diagnostics (cont.) 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 to 25% of the line voltages. Trip delay time can be adjusted from 0 to 99 seconds. An alarm (pre-fault) indication level can be programmed to indicate the unit is getting close to faulting.
Product Overview Percent Full Load Current 1-1 User Programmed Trip Level 600% Jam Running Time (seconds) Figure 1.12 – Jam Detection : : 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.
1-14 Product Overview Protection and Diagnostics (cont.) Ground Fault Trip (cont.) Parameter 74, Gnd Flt Delay, allows the installer to define the time period a ground fault condition must be present before a trip occurs. It is adjustable from 0.1 to 25 seconds. Parameter 73, Gnd Flt Level, allows the installer to define the ground fault current at which the MV SMC-Flex will trip. It is adjustable from 1.0 to 5.0 A.
Product Overview 1-15 Table 1.A – PTC Input Ratings Response Resistance Reset Resistance Short-circuit Trip Resistance Maximum Voltage at PTC Terminals (RPTC = 4 kΩ) Maximum Voltage at PTC Terminals (RPTC = open) Maximum Number of Sensors Maximum Cold Resistance of PTC Sensor Chain Response Time 3400 Ω ± 150 Ω 1600 Ω ± 100 Ω 25 Ω ± 10 Ω < 7.5 V 30 V 6 1500 Ω 800 ms The following figure illustrates the required PTC sensor characteristics, per IEC-34-11-2.
1-16 Product Overview Protection and Diagnostics (cont.) 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.
Product Overview 1-17 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.
1-18 Product Overview Communication A serial interface port (DPI) is provided as standard, which allows connection to the Bulletin 20-HIM LCD human interface modules. DPI Figure 1.14 – DPI Location ATTENTION Two peripheral devices can be connected to the DPI. The maximum output current through the DPI is 280 mA. Programming Setup is easy with the built-in keypad and three-line, sixteen-character backlit LCD.
Product Overview Status Indication 1-19 Four programmable hard contact outputs are provided as standard: • The Auxiliary #1 Contact is N.O. It is always programmed for Up-to-speed to control the bypass contactor in MV applications. • The fault Contact is for fault indication and is programmable for N.O./N.C. • The alarm Contact is for alarm indication and is programmable for N.O./N.C. • The Auxiliary #2 Contact is for normal indication and is programmable for N.O./N.C.
1-20 Product Overview Control Options (cont.) Pump Application Considerations 1. Consult factory if start time settings over 30 seconds are required. The base rating of the MV SMC-Flex is two starts (or one start/stop combination) per hour, thirty seconds maximum for each operation. A stopping operation counts as a start for purposes of thermal capacity calculations. 2. The Pump Control option functions only for centrifugal pumps.
Product Overview 1-21 ATTENTION Pump stopping is not intended to be used as an emergency stop. Refer to the applicable standard for emergency stop requirements. ATTENTION Pump stopping may cause motor heating depending on the mechanical dynamics of the pumping system. Therefore, select the lowest stopping time setting that will satisfactorily stop the pump.
1-22 Product Overview 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 Figures 1.18 through 1.21, Typical MV SMC-Flex Power System. Power Module The controller consists of three power modules, one for each phase.
Product Overview 1-23 Interface Board This circuit board takes current transformer signals plus line-side and loadside 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.
1-24 Product Overview * Figure 1.18 – Typical MV SMC-Flex Power System • Bulletin 1562E (Without Stop Control) % 5- " %.
Product Overview 1-25 Figure 1.19 – Typical MV SMC-Flex Power System • Bulletin 1562E (With Stop Control) % 5- " %.
1-26 Product Overview Figure 1.20 – Typical MV SMC-Flex Power System • Bulletin 1560E (Without Stop Control) % 5- " %.
Product Overview 1-27 Figure 1.21– Typical MV SMC-Flex Power System • Bulletin 1560E (With Stop Control) % 5- " %.
1-28 Product Overview Functional Description The following functional descriptions and associated control circuits are for units using IntelliVAC contactor control modules. For units with electromechanical (relay) control, refer to Appendix C. Bulletin 1562E • Basic Control – Controlled Start only When wired as shown in Figure 1.22, the controller operates as follows: Pressing the "Start" button initiates the start sequence.
Product Overview 1-29 Bulletin 1562E • Basic Control – With Controlled Stop When wired as shown in Figure 1.23, the controller operates in much the same manner as in Figure 1.22. Terminal 16 on the SMC-Flex module now controls the start and stop maneuvers. Terminal 16 must remain energized for the module to run. When the “Stop” button is pressed, and “CR” opens, the SMC-Flex module will initiate the option stop. An uncontrolled, or coast stop, is achieved by opening the connection to terminal 17.
1-30 Product Overview Functional Description (cont.) Bulletin 1560E • Basic Control – Controlled Start Only The Bulletin 1560E is intended for addition to an existing motor controller, which provides circuit isolation, motor switching, and overload and overcurrent protection. When wired as shown in Figure 1.25, the controller operates as follows: When a start is initiated in the existing motor controller and the contactor (or breaker) closes, a contact must be supplied to tell the 1560E to start also.
Product Overview 1-31 Bulletin 1560E • DPI Control – Controlled Start only The control scheme shown in Figure 1.27 allows the MV SMC-Flex to be controlled using DPI. This special usage of DPI includes provisions for a "Hand" mode of control as well. With the Hand-Auto selector switch in the "Auto" position, and closure of the existing starter main contactor, terminal 18 is energized, allowing a start command to be executed via DPI.
1-32 Product Overview Figure 1.22 – Bulletin 1562E IntelliVAC Control Circuit • Without Stop Control % 5- " %.
Product Overview 1-33 Figure 1.23 – Bulletin 1562E IntelliVAC Control Circuit • With Stop Control % 5- " %.
1-34 Product Overview % 5- " %. 0 *UNE Figure 1.24 – Bulletin 1562E IntelliVAC Control Circuit • With DeviceNet (or DPI) Communication and optional Hand/Auto % 5- " %.
Product Overview 1-35 Figure 1.25 – Bulletin 1560E IntelliVAC Control Circuit • Without Stop Control % 5- " %.
1-36 Product Overview Figure 1.26 – Bulletin 1560E IntelliVAC Control Circuit • With Stop Control % 5- " %.
Product Overview 1-37 Figure 1.27 – Bulletin 1560E IntelliVAC Control Circuit • DeviceNet (or DPI) Communication and optional Hand/Auto % 5- " %.
1-38 Product Overview % 5- " %.
Chapter 2 Installation ATTENTION Perform the installation duties correctly. Errors may cause commissioning delays, equipment damage or personal injury. Important: For the 1503E, refer to applicable documentation from OEM installation, grounding, interlocking and wiring.
2-2 Installation General Precautions Transportation and Handling In addition to the precautions listed throughout this manual, the following statements, which are general to the system, must be read and understood. ATTENTION The controller contains ESD (electrostatic discharge) sensitive parts and assemblies. Static control precautions are required when installing testing, servicing, or repairing the assembly. Component damage may result if ESD control procedures are not followed.
Installation Installation Site 2-3 Consider the following when selecting the installation site: A. The operating ambient temperature should be between 0°C and 40°C (32°F and 104°F) for NEMA Type 1 or 12 enclosures. For higher ambient conditions, please consult Rockwell Automation factory. B. The relative humidity must not exceed 95%, non-condensing. Excessive humidity can cause electrical problems from corrosion or excessive dirt build-up. C. The equipment must be kept clean.
2-4 Installation Installation Site (cont.) Grounding Practices The purpose of grounding is to: A. Provide safety for Personnel. B. Limit dangerous voltages to ground on exposed parts. C. Facilitate proper overcurrent device operation under ground fault conditions. D. Provide for electrical interference suppression. Important: Generally, grounding should be in accordance with the Canadian Electrical Code (CEC) or National Electrical Code (NEC) and other local codes.
Installation Power Connections 2-5 The controller requires a three-phase supply and an equipment grounding conductor to earth ground. A neutral conductor of the three-phase supply is not necessary and is usually not routed to the controller. Three-phase wiring will connect the controller to the motor. Bulletin 1562E The Bulletin 1562E unit is available in two main configurations: 1. A modified two-high cabinet (180/360A, 2400 to 4160 V) 2.
2-6 Installation Power Connections (cont.) Power Stack Assembly Bypass Vacuum Contactor Voltage Sensing Module Non Load Break Isolation Switch Load Cable Connection Point (top exit) Line Vacuum Contactor Current Transformers Figure 2.1 – Cabinet Layout • 1562E – 180/360 A, 2400 V to 4160 V (with LV panels not shown) % 5- " %.
Installation 2-7 Power Cable Lugs Ground Bus Lug Figure 2.2 – Incoming Line Cable Connections (viewed from the rear with power bus access cover removed) Cable Duct Barrier Cable Duct Boot Motor Cable Terminals Figure 2.3 – Bottom Cable Exit Configuration (with LV panel swung open) % 5- " %.
2-8 Installation Power Connections (cont.) Bulletin 1560E Refer to Figures 2.4 to 2.6 to make power connections for a 1560E unit. Note: The CT assembly can be oriented to allow either top or bottom load cable exit. Phase 2 Power Stack Assembly Phase 1 Power Stack Assembly Phase 3 Power Stack Assembly Line Connections Phase 1 (top) through 3 (bottom) Load Connections (top exit shown) Phase 1 (front) through 3 (back) Bypass Vacuum Contactor Current Transformers Figure 2.
Installation 2-9 Phase 1 Line Connection Phase 1 Power Stack Assembly Phase 2 Line Connection Phase 2 Power Stack Assembly Load Connections (top exit shown) Phase 1 (front) through 3 (back) Phase 3 Power Stack Assembly Current Transformers Phase 3 Line Connection Voltage Sensing Module Bypass Vacuum Contactor Figure 2.5 – Power Connections • 1560E – 180/360A, 5500 to 6900 V % 5- " %.
2-10 Installation Power Connections (cont.) Phase 1 Line Connection Phase 1 Power Stack Assembly Phase 2 Line Connection Load Connections (top exit shown) Phase 1 (front) through 3 (back) Phase 2 Power Stack Assembly Current Transformers Phase 3 Line Connection Phase 3 Power Stack Assembly Bypass Vacuum Contactor Voltage Sensing Module Figure 2.6 – Power Connections • 1560E – 600A, 2400 to 6900 V % 5- " %.
Installation 2-11 Important: For retrofit units (Bul. 1560E), the CEC and NEC require that branch-circuit protection of the AC line input to the controller be provided by a circuit breaker or motor starter. This function is included with a Bulletin 1562E. Important: The control and signal wires should be positioned at least six (6) inches (150 mm) from power cables. Additional noise suppression practices (including separate steel conduits for signal leads, etc.) are recommended.
2-12 Installation Power Wiring The wire sizes must be selected individually, observing all applicable safety and CEC or NEC regulations. The minimum permissible wire size does not necessarily result in the best operating economy. The minimum recommended size for the wires between the controller and the motor is the same as that used if a main voltage source connection to the motor was used. The distance between the controller and motor may affect the size of the conductors used.
Installation Installation 2-13 Physical Location The controller is designed for limited front access (components may have to be removed) and should be installed with adequate and safe clearance to allow for total door opening. The back of the unit may be placed against a wall and several units may be set end to end. In special cases where floor space is limited and the unit is not against a wall, certain cabinet sections may be placed back to back.
2-14 Installation Installation (cont.) Power Factor Correction Capacitors The controller can be installed on a system with power factor correction capacitors. The capacitors must be located on the line side of the controller. This is required to prevent damage to the SCRs in the MV SMC-Flex controller. A separate switching contactor is recommended to apply the capacitors only after the bypass contactor has closed, and to remove them when the bypass contactor opens. See Figure 2.
Installation 2-15 Power Bus Isolation Switch Isolation Switch Fuse Fuse Contactor Isolation Contactor di/dt Inductor di/dt Inductor Capacitor Contactor PFCC PFCC (Power Factor Correction Capacitor) Bypass Contactor Motor Figure 2.7 – Typical One-Line Diagram (Showing 2 Different Styles of Power Factor Capacitor Connections) % 5- " %.
2-16 Installation Surge Arrestor Protection Devices % 5- " %. 0 *UNE Rockwell Automation highly recommends that motor surge capacitors and/or motor surge arresters not be located on the load side of the SMC. The issues that warrant this are: • Motor and system inductance limits the rate at which the current can change through the SMC. If capacitance is added at the motor, the inductance is negated.
Installation Motor Overload Protection 2-17 Thermal motor overload protection is provided as standard (though it must be programmed) with the MV SMC-Flex controller. If the overload trip class is less than the acceleration time of the motor, nuisance tripping may occur. ATTENTION Overload protection should be properly coordinated with the motor to avoid damage to equipment. Two special applications require consideration: Two-speed Motors, and Multi-motor Protection.
2-18 Installation EMC Compliance ATTENTION This product has been designed for Class A equipment. Use of the product in domestic environments may cause radio interference, in which case, the installer may need to employ additional mitigation methods. The following guidelines are provided for EMC installation compliance. Enclosure Install the product in a grounded metal enclosure. Wiring Wire in an industrial control application can be divided into three groups: power, control, and signal.
Installation 2-19 • To meet produce susceptibility requirements, ferrite cores need to be added to the communication lines. All cores specified below are the split core type, so they can be added to existing connections. – When using an external HIM (or DPI interface), a core should be added to the HIM cable near the SMC-Flex control module. The recommended core is Fair-Rite no. 0431167281 or equivalent.
2-20 Installation Control Terminal Designations As shown in Figure 2.10, the SMC-Flex controller contains 24 control terminals on the front of the controller. Figure 2.10 – SMC-Flex Controller Control Terminals Terminal Number 11 12 13 14 15 16 17 18 19 20 21 22 Description Control Power Input Control Power Common Control Enable Input : Control Module Ground Option Input #2 : Option Input #1 : Start Input : Stop Input : N.O. Aux. Contact #1 (Up-to-Speed) ; ➍ N.O. Aux.
Chapter 3 Commissioning Procedure Preliminary 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: • Test power supply, supplied with each controller • Multimeters • Hi-Pot Tester (recommended) or Megger • Oscilloscope with memory (optional) C. Complete drawing package and parts list. D. Specification of project.
3-2 Commissioning Procedures1 System Characteristics Job Name: _____________________________ Job Number: ________________________________ Rated Voltage: _________________________ Rated Current: _____________ Actual Motor Load Load Type: Fan ___Pump___Conveyor___Compressor___Mixer___ Other_________________________________________ Constant Torque_______ or Variable Torque _______ Actual Motor Data: __________________________________________ Motor HP: _________________________________________________ M
Commissioning Procedures Preliminary Check ATTENTION 3-3 Ensure that all sources of power are isolated and locked out before working on installed equipment. Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device. Failure to do so may result in severe burns, injury or death. A. Verify correct power cable phase sequencing, and that connections are tight. B. Verify power fuse ratings and condition. C. Verify control fuse ratings and condition. D.
3-4 Commissioning Procedures Hi-Pot and Megger Test It is recommended that insulation levels be checked before energizing power equipment. This may be done with a High Voltage AC insulation tester (HI-POT) or a Megger. See Vacuum Contactor User Manual for suggested HI-POT testers, and for test procedures for vacuum contactors. If using a Megger, a 5000 volt type is recommended. ATTENTION Solid-state devices can be destroyed by high voltage.
3-5 * Points for disconnection, to allow Hi-Pot or Megger tests (refer to Chapter 3) Commissioning Procedures * * * * * * Figure 3.
3-6 Commissioning Procedures SW2: When ON (up) provides test pulses to gate driver circuits. NOTE: Must be OFF (down) for normal operation. LED (Red): ON when test pulses on.
Commissioning Procedures Power Supply Tests ATTENTION 3-7 Servicing energized industrial control equipment can be hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment. Before proceeding, ensure that all sources of power are isolated and locked out. Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device.
3-8 Commissioning Procedures Power Supply Tests (cont.) NOTE: Systems with optional Pump Control or Soft Stop include continuous gate drive power supplies (IGDPS); therefore, step 5 does not apply. 5. Since the gate driver circuits normally receive power from the snubber circuits when the SMC is operating, an alternate source must be used for testing. Locate the Portable Test Power Supply that was included with the equipment, and verify that the rating corresponds to the available power system (i.e.
Commissioning Procedures 3-9 7. The gate-driver board voltage may be checked by connecting a DC voltmeter to TP2 (+) and TP1 (-) (See Figure 3.4). With the specified power supply connected, the voltage should be 12 ± 2 VDC. 8. The actual gate pulse may be checked by connecting an oscilloscope between TP7 and TP1 (See Figure 3.4). The pulse should appear as shown in Figure 3.5. 14 Volts 12 10 8 6 4 2 0 -2 -2 0 2 4 6 8 Microseconds Figure 3.5 – Gate Pulse Detail – Typical SCR (ABB) -2.0 -1.5 -1.
3-10 Commissioning Procedures 10. When each gate driver circuit has been checked, disconnect the power supply and remove it from the cabinet. NOTE: Systems with optional Pump Control or Soft Stop include continuous gate drive power supplies (IGDPS); therefore, step 10 does not apply. ATTENTION The gate-drive circuits operate at high voltage when the SMC is energized. Failure to remove the portable test power supply will result in equipment damage and may cause severe injury or death. 11.
Commissioning Procedures Resistance Checks 3-11 To ensure that resistors and connections have not been damaged during shipment and installation, the following resistance tests should be performed before energizing the starter. 1. Remove all power from the equipment. ATTENTION Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device. Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment. 2.
3-12 Commissioning Procedures Table 3.B – Input Voltage Ranges Tap Voltage Range MV Ratio D C B A 800 – 1449 V 1450 – 2499 V 2500 – 4799 V 4800 – 7200 V 1020 390 165 105 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.
Chapter 4 Programming Overview 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. Keypad Description The keys found on the front of the SMC-Flex controller are described below. Esc Escape Sel Select Up/Down Arrows Enter Exit a menu, cancel a change to a parameter value, or acknowledge a fault/alarm.
Programming 4-2 Programming Menu (cont.
Programming 4-3 uw Parameter Parameter v Esc Monitoring Motor Protection Set Up Communications Utility Linear List Metering Basic Overload Jam Comm Masks Language Linear List Volts Phase A-B Volts Phase B-C Volts Phase C-A Current Phase A Current Phase B Current Phase C Watt Meter Megawatt Hours Elapsed Time Meter Reset Power Factor Mtr Therm Usage SMC Option Motor Connection Line Voltage MV Ratio Starting Mode Ramp Time Initial Torque Cur Limit Lvl Kickstart Time Kickstart Lvl Option 2 I
4-4 Programming Programming Menu (cont.) Parameter No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 1560E-UM050B-EN-P - June 2013 Table 4.
Programming Password 4-5 The SMC-Flex Controller allows the user to limit access to the programming system through password protection. This feature is disabled with a factory-set default of 0. To modify the password or login after a password is programmed, complete the procedure below. Description Action – – 1. Press the ESC key to go from the status display to the Main menu. 2. Scroll with the Up/Down keys until the Preferences option is highlighted. 3.
4-6 Programmi Parameter Management Before you begin programming, it is important to understand how the controller memory is: • structured within the SMC-Flex controller • used on power-up and during normal operation Refer to Figure 4.3 and explanations below. EEPROM RAM Esc ROM Sel Figure 4.3 – Memory Block Diagram Random Access Memory (RAM) This is the work area of the controller after it is powered up. When you modify parameters in the Set Up mode, the new values are stored in RAM.
Programming 4-7 Using Parameter Management Description Action Display Saving to EEPROM To ensure that the newly modified parameters are not lost if control power is removed from the controller, store the values into EEPROM. Recalling from EEPROM Parameters stored in EEPROM can be manually brought to RAM by directing the controller to recall the values in its EEPROM. Recalling Defaults After parameter values have been modified and saved to EEPROM, factory default settings can still be re-initialized.
4-8 Programming Parameter Modification All parameters are modified using the same method. The basic steps to performing parameter modification are described below. Note: Parameter values modified while the motor is operating are not valid until the next start sequence begins. Description Action – – 1. Press the ESC key to go from the status display to the Main menu. 2. Scroll with the Up/Down keys until the Preferences option is highlighted. 3. Press the Enter key to access the Parameter menu.
Programming Soft Start The following parameters are specifically used to adjust the voltage ramp supplied to the motor. Parameter Starting Mode This must be programmed for Soft Start. Ramp Time u This programs the time period that the controller will ramp the output voltage up to full voltage from the initial Torque level programmed. Initial Torque The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter.
4-10 Programming Dual Ramp Start The SMC-Flex controller provides the user with the ability to select between two Start settings. The parameters below are available in the 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). Parameter 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.
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: Parameter Starting Mode This must be programmed for Full Voltage. Linear Speed Option Full Voltage The SMC-Flex provides the user the ability to control the motor speed during starting and stopping maneuvers. A tach input is required as specified in Linear Speed Acceleration on page 1-7.
4-12 Programming Basic Setup (cont.) Parameter Current Limit Level v The current limit level that is applied for the Ramp time selected. Kickstart Time A boost current is provided to the motor for the programmed time period. Kickstart Level Adjusts the amount of current applied to the motor during kickstart. Option 2 Input Allows the user to select a Dual Ramp or Preset Slow Speed (SS). Stop Mode Allows the user to program the SMC-Flex controller for the type of stopping that best fits the application.
Programming Motor Protection 4-13 While the Basic Set Up group allows the user to get started with a minimum number of parameters to modify, the Motor Protection group allows full access to the SMC-Flex controller's powerful parameter set. Following is a listing of the additional setup parameters provided. Note: The majority of parameters have a Fault and an Alarm setting. Parameter Overload Allows the user to select the operation of the overload.
4-14 Programming Example Settings Undervoltage u With Line Voltage programmed for 4160 V and the Undervoltage level programmed for 80%, the trip value is 3328 V. Overvoltage u With Line Voltage programmed for 3300 V and the Overvoltage level programmed for 115%, the trip value is 3795 V. Jam v With Motor FLC programmed for 150 Amps and the Jam level programmed for 400%, the trip value is 600 Amps.
Programming Motor Information 4-15 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.
4-16 Programming 1560E-UM050B-EN-P - June 2013
Chapter 5 Metering Overview While the SMC-Flex controller operates your motor, it also monitors several different parameters, providing a full function meteringu package. Viewing Metering Data To access the metering information, follow the procedure below: Description Action – – Display Esc 1. Press any key to access the Main menu. 2. Scroll with the Up/Down keys until the Parameter option is shown. 3. Press the Enter key to access the Parameter option. 4.
5-2 Metering Viewing Metering Data (cont.) 1560E-UM050B-EN-P - June 2013 Description 7. Scroll through the Metering parameters with the Up/Down keys to access the desired information. Press the Enter key to view that parameter.
Chapter 6 Options Overview The SMC-Flex controller offers a variety of unique control programming and communication options that provide enhanced capabilities. (See Chapter 1 for brief descriptions of each option.) Note: Only one option can reside in a controller. Human Interface Module The control buttons available with the Bulletin 20-HIM Human interface modules are compatible with the SMC-Flex controller’s control options.
6-2 Optio Human Interface Module (cont.) Option Action Operation Pump Control I Pump Control The green start button, when pressed, will commence motor acceleration to full speed. O The red stop button, when pressed, will provide a coast stop, and/or reset a fault. Jog The jog button, when pressed, will initiate a pump stop maneuver. I The green start button, when pressed, will commence motor acceleration to full speed.
Options Programming Parameters 6-3 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. Option Parameter Range Standard Soft Stop SMC Option This parameter identifies the type of control present and is not user programmable.
6-4 Options Programming Parameters (cont.) Option Parameter Range Braking Control Ë SMB Smart Motor Braking Accu-Stop Slow Speed with Braking SMC Option This parameter identifies the type of control present and is not user programmable. Braking Control Braking Current u Allows the user to program the intensity of the braking current applied to the motor. 0…400% of full load current SMC Option This parameter identifies the type of control present and is not user programmable.
Options Control Wiring 6-5 Refer to Chapter 1 – Product Overview for typical control wiring examples used with various control schemes.
6-6 Options 1560E-UM050B-EN-P - June 2013
Chapter 7 Diagnostics Overview 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 through the programming parameters provided. For further details on programming, refer to the Motor Protection section in Chapter 4, Programming.
7-2 Diagnostics Clear Fault You can clear a fault using any of several methods: • Program the SMC-Flex controller for a Clear Fault, which can be found in Main Menu/Diagnostics/Faults. • If a human interface module is connected to the controller, press the Stop button. Note: The stop signal will not clear a fault if Logic Mask is disabled (Logic Mask, parameter #87, equals ø). • Cycle control power to the SMC-Flex controller.
Diagnostics 7-3 Fault Codes Table 7.A provides a complete cross-reference of the available fault codes and corresponding fault descriptions. Table 7.
Diagnostics 7-4 Fault Definitions Table 7.B shows the fault definition for the SMC-Flex. Table 7.B – Fault Definitions Ì Fault Description Line Loss The SMC-Flex can determine if a line connection has been lost, and will indicate this accordingly. Shorted SCR Shorted SCRs will be detected and starting will be prohibited by the SMC-Flex. Open gate indicates that an abnormal condition that causes faulty firing (e.g., open SCR gate or faulty gate driver) has been sensed during the start sequence.
Chapter 8 Communications Overview The SMC-Flex provides advanced communications capabilities that allow it to be started and stopped from multiple sources as well as provide diagnostic information through the use of communication interfaces. The SMC-Flex uses the DPI method of communication, therefore all standard DPI communication interfaces used by other devices (i.e., PowerFlex™ Drives) can be used in the SMC-Flex.
8-2 Communications Human Interface Module (cont.) Keypad Description The functions of each programming key are described below. Table 8.B – Keypad Descriptions Escape Select Up/Down Arrows Enter Exit a menu, cancel a change to a parameter value, or acknowledge a fault/alarm. Select a digit, select a bit, or enter edit mode in a parameter screen. Scroll through options increase/decrease a value, or toggle a bit. Enter a menu, enter edit mode in a parameter screen, or save a change to a parameter value.
Communications 8-3 The control panel provides the operator inteface to the controller. I Start The green start button, when pressed, will begin motor operation. (Proper setup of the HIM port is required. O Stop The red stop button, when pressed, will halt motor operation and/or reset a fault. Jog Jog The jog button is active only when a control option is present.
8-4 Communications Connecting the Human Interface Module to the Controller Figure 8.1 shows the connection of the SMC-Flex controller to a human interface module. Table 8.C provides a description of each port. See Figure 1.24 or 1.27 for the control wiring diagram that enables start-stop control from a human interface module. Port 5 – DPI Communications Port 2 Ports 2 and 3 when two HIMs are connected with a splitter Figure 8.1 – SMC-Flex Controller with Human Interface Module Table 8.
Communications 8-5 Series A 1. Disconnect the HIM and allow to power down. 2. Reconnect the HIM. On Initializing screen, the bottom right corner of LCD shows Port X. Note this port number. 3. Go to Logic Mask, found as follows: Main Menu: Parameter/Communications/Comm Mask/Logic Mask 4. Set b0X equal to 1 (where X is the port number noted in step 2). 5. Go to Parameter Management and save as User Store.
8-6 Communications If enabling control from the built-in SMC-Flex programmer, the Logic Mask must be set as follows: Table 8.D – Logic Mask Requirements Mask Code 0 4 12 32 36 44 Control Enable 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.
Communications Default Input/Output Configuration 8-7 The default configuration for I/O is 4 bytes in and 4 bytes out (TX = 4 bytes, RX = 4 bytes) and is arranged according to the following table. Table 8.E Consumed Data (Control) Word 0 Logic Status Logic Command Word 1 Feedback Ê Reference v The feedback word is always Current in Phase A. The reference word is not used with the SMC-Flex, however the space must be reserved.
Communications 8-8 SMC-Flex Bit Identification Table 8.
Communications 8-9 Reference/Feedback The SMC-Flex does not offer the analog Reference feature. The analog Feedback feature is supported and will provide Parameter 1, Current in Phase A, automatically as the feedback word. Parameter Information A complete listing of the SMC-Flex parameters is located in Appendix B. Scale Factors for PLC Communication The parameter values stored and produced by the SMC-Flex through communication are unscaled numbers.
8-10 Communications Configuring DataLinks DataLinks are supported in the SMC-Flex. A DataLink is a mechanism used by most drives to transfer data to and from the controller without using an Explicit Message. The SMC-Flex supports 16-bit DataLinks, therefore the device can be configured to return up to four additional pieces of information without the need for an explicit message. Rules for Using DataLinks • Each set of DataLink parameters in an SMC-Flex can be used by only one adapter.
Chapter 9 Troubleshooting General Notes and Warnings For safety of maintenance personnel as well as others who might be exposed to electrical hazards associated with maintenance activities, follow the local safety related work practices (for example, the NFPA 70E, Part II in the United States). Maintenance personnel must be trained in the safety practices, procedures and requirements that pertain to their respective job assignments.
9-2 Troubleshooting Important: In the case of the 1503E, refer to applicable documentation from OEM for troubleshooting or repair. This manual should be utilized in conjunction with the OEM supplied documentation, and is suitable for commissioning, programming, calibration, metering, serial communications, diagnostics, troubleshooting and maintenance of a standard solid-state controller. The following flowchart is provided to aid in quick troubleshooting.
Troubleshooting 9-3 Table 9.
9-4 Troubleshooting Table 9.A – Fault Display Explanation (cont.) Display Fault Code Phase Reversal 26 Comm Loss 27, 28, 29 Network Ground Fault 30, 31, 32 33 Excess Starts/Hr.
Troubleshooting 9-5 Table 9.D – Motor Stops While Running Display Fault displayed Display is blank Stopped 0.0 Amps Starting Possible Causes • • • • • • See fault description Control voltage is absent Failed control module Pilot devices Failed control module Two or three power phases are missing • Failed control module Possible Solutions • • • • • • • • See Table 9.
9-6 Troubleshooting Control Module Removal The control module is not intended for field repair. The entire module must be replaced in the event of failure. The following procedure must be followed before unplugging the control module. 1. Remove all power from the equipment. SHOCK HAZ ARD To avoid shock hazard, ensure the main power has been disconnected before working on the controller, motor or control devices.
Troubleshooting Voltage Feedback Circuit Tests 9-7 The most straightforward means of checking the feedback circuits is to perform the "snubber and resistor testing" procedure, found on page 9-27. Another possible test involves measuring the feedback voltages at the interface board (see Figure 3.2). This can only be done with line voltage applied.
9-8 Troubleshooting Voltage-Sensing Board Replacement 1. Ensure there is no power to the equipment. S HOCK HAZ ARD To prevent electrical shock, ensure the main power has been disconnected before working on the sensing board. Verify that all circuits are voltage free using a hot stick or appropriate high voltage-measuring defice. Failure to do so may result in injury or death. 2. Mark the position of the ribbon cable and wires. 3.
Troubleshooting IGDPS Boards 9-9 MV SMC units provided with optional stop capabilities (soft stop, linear deceleration or pump control) utilize isolated gate drive power supply (IGDPS) boards. These boards provide a continuous source of power to the gate drive boards. The IGDPS boards are fed from a 50 V DC power supply provided with the MV SMC. The circuitry for the IGDPS is encapsulated in epoxy.
9-10 Troubleshooting IGDPS Board LEDs A green LED is provided inside each of the six (6) output module boxes (channels) to indicate the presence of a healthy output voltage (20 V DC). • LED ON: Output Healthy • LED OFF: Output Voltage is below 18 V DC If the IGDPS is healthy, then all six (6) LEDs will be illuminated. If this is not true, this may indicate either a bad connection to the board or a defective output module.
Troubleshooting Circuit Board Replacement 9-11 The replacement of printed circuit boards is straightforward, however, there are a number of precautions which must be considered when handling the boards. ATTENTION Some circuit boards may contain CMOS components which can be destroyed by static charges generated by friction of materials made with synthetic fibres. Use of damaged circuit boards may also damage related components.
9-12 Troubleshooting Power Circuit Troubleshooting Thyristor (SCR) Testing If a power semiconductor is suspected of malfunctioning, it may be checked as follows: 1. Remove all power from the equipment. SHOCK HAZ ARD 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.
Troubleshooting 9-13 5. Complete heatsink assemblies with matched SCRs are available as a renewal part (see Appendix D). In most cases, the assembly can be dismantled to replace the SCRs. SCR Replacement Procedure Note: This procedure applies to 180A and 360A units < 5000V only. Important: Refer to OEM documentation for SCR stack location in 1503E. A. Remove SCR Stack from Unit For all types of SMCs, the stack requiring new SCRs must first be removed from the unit as follows: 1.
9-14 Troubleshooting Power Circuit Troubleshooting (cont.) SCR Replacement Procedure (cont.) 6. Remove two (2) nuts at bottom front of heatsink assembly so the module can be removed using the pull handle. (Phase C requires angling the module to clear the front cabinet flange). Position fibre-optic cables and wiring so they will not be damaged as the module is removed from the cabinet. 7. Pull module out slowly, and slide onto a platform lift, or lift the module out of the cabinet.
Troubleshooting 9-15 SCR Replacement Procedure (cont.) Important: DO NOT loosen any of the nuts on the fiber rods on either side of the clamp bars. They must remain as they are to maintain squareness. See Figures 9.6, 9.9 and 9.15. 2. Loosen the clamp by rotating the centre nut below the indicator washer at the top end of the clamp. Refer to Figures 9.6, 9.9 and 9.15. As the centre nut is rotated, the entire spring assembly is retracted from the top heatsink.
9-16 Troubleshooting Power Circuit Troubleshooting (cont.) SCR Replacement Procedure (cont.) C. Install Refurbished Stack 1. Inspect all connections on the module. Inspect wire insulation and components for damage. 2. Install the module in the cabinet. Watch for power cables and fibre-optic cables as module is slid into place. Tighten locking nuts at the bottom of the module. 3. Connect power cables and tighten hardware to 30 N-m (20 ft-lb). 4.
Troubleshooting 9-17 Figure 9.4 – Upper Low Voltage Panel and Power Cell Detail (1562E) • 2400 to 4160 V, 180/360 A % 5- " %.
9-18 Troubleshooting Heatsink 1 SCR 1 Heatsink 2 SCR 2 Heatsink 3 Figure 9.5 – Power Module Assembly (one phase) • 1000/1300/1500/2400 V, 180/360 A Gap (Do not loosen) Centre Nut Locking Nut (Do not adjust) Indicating Washer (Do not loosen) To remove clamp pressure, loosen lower center nut so that the gap between the clamp surface and the heatsink is approximately 6 mm (0.25 in.). Figure 9.6 – Heatsink Clamp % 5- " %.
Troubleshooting 9-19 To Remove SCR: • Remove shorting bar hardware • Pry opposing Heatsinks apart • Extract SCR To Insert New SCR: • Apply thin film of electrical joint compound to surfaces of SCR • Install SCR so that it is seated in locating pin of heatsink (note orientation of SCR). • Pry heatsinks to close gap, ensuring that SCR is seated properly in both its locating pins. • Rotate SCR so that all leads have same direction.
9-20 Troubleshooting Heatsink 1 SCR 1 Heatsink 2 SCR 2 Heatsink 3 SCR 3 Heatsink 4 SCR 4 Heatsink 5 Note: SCR 1 and SCR 3 are a matched set. SCR 2 and SCR 4 are a matched set. Figure 9.8 – Power Module Assembly (one phase) • 3300/4160 V, 180/360 A Gap (Do not loosen) Centre Nut Locking Nut (Do not adjust) Indicating Washer (Do not loosen) To remove clamp pressure, loosen lower center nut so that the gap between the clamp surface and the heatsink is approximately 6 mm (0.25 in.). Figure 9.
Troubleshooting 9-21 To Remove SCR4: • Remove shorting bar hardware • Pry Heatsinks 4 and 5 apart • Extract SCR To Insert New SCR: • Apply thin film of electrical joint compound to surfaces of SCR • Install SCR so that it is seated in locating pin of heatsink (note orientation of SCR). • Pry heatsinks to close gap, ensuring that SCR is seated properly in both its locating pins. • Rotate SCR so that all leads have same direction. Proceed to replace SCR’s matched pair (SCR2).
9-22 Troubleshooting Line Connection Gate Driver Boards Load Connection Figure 9.11 – Power Module Assembly (one phase) • 5500/6900 V, 180/360 A Board Mounting Frame Line Connection Load Connection Figure 9.12 – Power Module Assembly (one phase) with Gate Driver Boards Removed • 5500/6900 V, 180/360 A % 5- " %.
Troubleshooting 9-23 Module retaining hardware locations (4) Line Connection Load Connection Figure 9.13 – Power Module Assembly (one phase) with Boards and Frame Removed • 5500/6900 V, 180/360 A SCR 4 SCR 5 SCR 6 Heatsink 7 Heatsink 6 Heatsink 5 SCR 3 SCR 2 SCR 1 Note: SCR1, SCR2 and SCR5 are a matched set. SCR3, SCR4 and SCR6 are a matched set. Heatsink 1 Heatsink 2 Heatsink 3 Heatsink 4 Spacer block (must be flat): Minimum Height = 30 mm (1.25 in.) Maximum Width = 200 mm (8.0 in.
9-24 Troubleshooting Do not loosen Centre Nut To remove clamp pressure, loosen lower centre nut so that the gap between the clamp surface and the heatsink is approximately 6 mm (0.25 inch). A 21-mm open end wrench is required. Locking Nut (Do not adjust) Indicating Washer Do not loosen Gap Figure 9.
Troubleshooting 9-25 Snubber Resistors Heatsink Assembly Sharing Resistor Snubber Capacitor Frame Assembly Gate Driver Board Figure 9.17 – Power Module Assembly (one phase) • 2300 V, 600 A Snubber Resistors Heatsink Assembly Sharing Resistor Snubber Capacitors Gate Driver Board Figure 9.18 – Power Module Assembly (one phase) • 3300/4160 V, 600 A % 5- " %.
9-26 Troubleshooting Snubber Resistors Heatsink Assembly Snubber Capacitor Sharing Resistors Frame Assembly Gate Driver Boards Snubber Capacitor Figure 9.19 – Power Module Assembly (one phase) • 5500/6900 V, 600 A % 5- " %.
Troubleshooting Snubber and Resistor Circuit Testing 9-27 If the resistance checks from the Thyristor testing section were abnormal and the thyristors checked out OK, there may be a problem in the snubber or resistor circuits. 1. Remove all power from the equipment. SHOCK HAZ ARD To avoid shock hazard, ensure main power has been disconnected before working on the controller, motor or control devices. Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device.
9-28 Troubleshooting To Interface board 24 23 J1 VOLTAGE FEEDBACK 80190-258- REV 24 23 2 1 MADE IN USA 2 1 10 9 J2 WW WW 2 1 Ground Connections J3 PART NUMBER SERIAL NUMBER GND1 GND2 Measure 11.3 k Ω 1D 2D 3D 4D 5D 6D 1C 2C 3C 4C 5C 6C 1B 2B 3B 4B 5B 6B 1A 2A 3A 4A 5A 6A Tap D 2MΩ Tap C 4.3 M Ω Tap B 9.5 M Ω Tap A 15 M Ω L1 T1 L2 T2 Figure 9.20 – Voltage Sensing Board % 5- " %.
Troubleshooting 9-29 Measure across R36, R73, R110, R147, R184 and R221 located at the bottom of each leg of the module. The resistance should be 11.3 kohm. (The two ground connections must be connected to ground, or to each other if the module has been removed.) If the values for each leg vary by more than 1%, the voltage sensing module may need to be replaced. See Renewal Parts listing in Appendix D, and refer to procedure on page 9-8.
9-30 Troubleshooting Snubber Resistor Replacement % 5- " %. 0 *UNE When replacing the ceramic wire-wound type snubber resistors, use caution when handling the parts. The resistor element is under a thin coating on the ceramic tube, and it may be damaged if dropped, struck or scraped.
Troubleshooting 9-31 Figure 9.21A – 1500/2400 V Module Wiring (180/360 A) (Without Optional Pump Control or Soft Stop) % 5- " %.
9-32 Troubleshooting Figure 9.21B – 1500/2400 V Module Wiring (600 A) (Without Optional Pump Control or Soft Stop) % 5- " %.
Troubleshooting 9-33 Figure 9.22A – 1500/2400 V Module Wiring (180/360 A) (With Optional Pump Control or Soft Stop) % 5- " %.
9-34 Troubleshooting Figure 9.22B – 1500/2400 V Module Wiring (600 A) (With Optional Pump Control or Soft Stop) % 5- " %.
Troubleshooting 9-35 Figure 9.23A – 3300/4160 V Module Wiring (180/360 A) (Without Optional Pump Control or Soft Stop) % 5- " %.
9-36 Troubleshooting Figure 9.23B – 3300/4160 V Module Wiring (600 A) (Without Optional Pump Control or Soft Stop) % 5- " %.
Troubleshooting 9-37 Figure 9.24A – 3300/4160 V Module Wiring (180/360 A) (With Optional Pump Control or Soft Stop) % 5- " %.
9-38 Troubleshooting Figure 9.24B – 3300/4160 V Module Wiring (600 A) (With Optional Pump Control or Soft Stop) % 5- " %.
Troubleshooting 9-39 Figure 9.25 – 6900 V Module Wiring (180/360/600 A) (Without Optional Pump Control or Soft Stop) % 5- " %.
9-40 Troubleshooting Figure 9.26 – 6900 V Module Wiring (180/360/600 A) (With Optional Pump Control or Soft Stop) % 5- " %.
Chapter 10 Maintenance Safety and Preventative 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.
10-2 Maintenance Periodic Inspection (cont.) ATTENTION Allen-Bradley magnetic starters, contactors and relays are designed to operate without lubrication – do not lubricate these devices since oil or grease on the pole face (mating surfaces) of the operating magnet may cause the device to stick in the "ON" mode. Erratic operation can result with injury or death.
Maintenance 10-3 Solid-State Devices Solid-state devices require little more than a periodic visual inspection. Printed circuit boards should be inspected to determine whether all cables are properly seated in their connectors. Board locking tabs should also be in place. Necessary replacements should be made only at the PC board or plug-in component level. Solvents should not be used on printed circuit boards.
10-4 Maintenance Periodic Inspection (cont.) "Keep Good Maintenance Records" This rule will be most helpful in locating possible intermittent problems by pointing to a particular area of recurring trouble within the overall system. Furthermore, good maintenance records will help reduce major, costly shutdowns by demanding the use of proper test equipment and an appropriate inventory of spare parts.
Maintenance Environmental Considerations 10-5 Hazardous materials Environmental protection is a top priority for Rockwell Automation. The facility that manufactured this medium voltage product operates an environmental management system that is certified to the requirements of ISO 14001. As part of this system, this product was reviewed in detail throughout the development process to ensure that environmentally inert materials were used wherever feasible.
10-6 Maintenance Environmental Considerations (cont.) • Chromate Plating Some sheet steel and fasteners are plated with zinc and sealed with a chromate-based dip (gold-coloured finish). Shipping and handling of chromate plated parts is not restricted under any regulations, however, chromate is considered a hazardous substance. Chromate plated parts must be disposed of according to local regulations and must not be disposed of with general landfill refuse.
Appendix A 1560E/1562E SMC-Flex Specifications Table A.
A-2 Specifications Table A.1 – Specifications (cont.) Electrical Ratings (cont.) UL/CSA/NEMA IEC Short Circuit Protection The power electronics unit must be protected by current -limiting fuses (to be included by customer in existing starter with 1560E). The combination controller includes appropriate fusing (coordinated with motor).
Specifications A-3 Table A.1 – Specifications (cont.) Environmental Ratings UL/CSA/NEMA Operating Temperature Range Storage and Transportation Temperature Range Altitude Humidity Pollution Degree Seismic (UBCRating) u u v IEC 0°C to 40°C (32°F to 104°F) -20°C to +75°C (-4°F to 149°F) 0 - 1000 meters (3,300 feet) without derating v 5% to 95% (non condensing) 2 1, 2, 3, 4 Some units may require special bracing. Contact factory for more information. Starter Deratings are in Table A.2. Table A.
A-4 Specifications Table A.4 – Cable Quantity and Size Bulletin Size Structure Code Unit Size Inches (mm) Max. No. & Size of Max. No. & Size of Max. No. & Size of Incoming cables-no bus Incoming Cables-w/bus Exiting Load Cables 1560E 200/400A 14.60 26 W X 91 H (660 X 2311) (1) 500/ (2) 250mcm/phase (1) 500/ (2) 250mcm/phase (1) 500/ (2) 250mcm/phase 1560E 200/400A 14.
Specifications A-5 Table A.
A-6 Specifications1 Table A.6 – Power Bus and Ground Bus Description Specifications Main Horizontal Power Bus Bus Bar Material Tin-plated copper Optional Bus Bar Material Silver-plated copper Continuous Current Rating at 40°C (104°F) 1200, 2000 and 3000 A Maximum Full Load Temperature Rise 65°C (149°F) Maximum Full Load Temperature 105°C (221°F) 60 kA RMS SYM (96 kA ASYM) Fault Withstand Current Rating (4.
Specifications A-7 Table A.7 – Power Fuses and Losses Description Specifications Power Fuses and Fuse Holders This section details the power fuse and fuse holder technical information that each medium voltage product conforms to. It includes information on R-rated fuses, as well as mounting dimensions. Fuse Types R Rated : 2R to 24R A480R – 5.0/2.4 kV 2R to 24R A072 – 7.2 kV 19R, 38R A051B – 5.0/2.4 kV Interrupting Ratings : 2.4 kV to 7.
Specifications A-8 Table A.8 – Control Wire and Power Wire Description Specifications Control Wire All Medium Voltage structures shall be equipped with control wire which meets the following specifications: TEW, Stranded Copper Wire (Tinned) Type AWG Size (Control Circuit) #14 AWG – 1.5 mm2 AWG Size (Current Transformer Circuit) #12 AWG – 2.
Appendix B Parameter Information Table B.
B-2 Parameter Information Table B.1 – Parameter List (cont.
Parameter Information B-3 Table B.1 – Parameter List (cont.
Parameter Information B-4 Table B.1 – Parameter List (cont.) Parameter Description Parameter Number CT Ratio 105 1…1500 MV Ratio Ê 106 1…10000 Aux1 Config Ë 107 Fault Contact 108 Alarm Contact 109 Aux2 Config 110 Language Language 111 All Parameter Mgmt 115 Basic Set Up Backspin Timer 116 Group Basic Set Up Units SEC Ê Refer to Chapter 3, Commissioning Procedures, to determine the appropriate setting. Ë This parameter does not appear for MV applications.
Appendix C 1560E and 1562E Relay Control Functional Description The following functional descriptions and associated control circuits are for units using electromechanical (relay) control. Bulletin 1562E • Basic Control – Controlled Start only When wired as shown in Figure C.1, the controller operates as follows: Pressing the "Start" button initiates the start sequence. Relay "CR" closes and applies control power to terminal 17 of the SMC-Flex module.
C-2 1560E and 1560E Relay Control Functional Description (cont.) Bulletin 1562E • Basic Control – With Controlled Stop When wired as shown in Figure C.2, the controller operates in much the same manner as in Figure C.1. Terminal 16 on the SMC-Flex module now controls the start and stop maneuvers. Terminal 16 must remain energized for the module to run. When the “Stop” button is pressed, and “CR” opens, the SMC-Flex module will initiate the option stop.
1560E and 1560E Relay Control C-3 Bulletin 1560E • Basic Control – Controlled Start Only The Bulletin 1560E is intended for addition to an existing motor controller, which provides circuit isolation, motor switching, and overload and overcurrent protection. When wired as shown in Figure C.4, the controller operates as follows: When a start is initiated in the existing motor controller and the contactor (or breaker) closes, a contact must be supplied to tell the 1560E to start also.
C-4 1560E and 1560E Relay Control Figure C.
1560E and 1560E Relay Control C-5 Figure C.
C-6 1560E and 1560E Relay Control Figure C.
1560E and 1560E Relay Control C-7 Figure C.
C-8 1560E and 1560E Relay Control Figure C.
1560E and 1560E Relay Control C-9 Figure C.
C-10 1560E and 1560E Relay Control11 1560E-UM050B-EN-P - June 2013
Appendix D Spare Parts Table D.1 Bulletin 1503E • 1000-1500 Volt, 180/360 Amp, 6-device Ì Qty per controller Description Part Number 180 A 6 Individual SCR, 5STP04D5200 (matching not required) Ê Ë 80156-815-61-R 6 Individual SCR, 5STP08G6500 (matching not required) Ê Ë 80156-894-71-R 360 A Common Components Í SCR Gate Driver Board Î (2 devices) IGDPS Board Î Voltage Sensing Module MV SMC Interface Circuit Board Snubber Resistor Snubber Capacitor 1000 V, 1.0 µF (4.5 kV peak) 1300-1500V, 0.
Spare Parts D-2 Table D.2 Bulletin 1503E, 1560E, 1562E • 2300 Volt, 180/360 Amp, 6-device Í Qty per controller Description Part Number 180 A Individual SCR, DCR820 or 5STP03D6500 (matching not required) ÊË 6 80156-893-71-R 360 A Individual SCR, DCR1020 or 5STP03D6500 (matching not required) ÊË Common Components Î SCR Gate Driver Board 3 Ï (2 devices) 1 IGDPS Board Ï 1 Voltage Sensing Module 1 MV SMC Interface Circuit Board 9 Snubber Resistor 3 Snubber Capacitor 0.
Spare Parts D-3 Table D.3 Bulletin 1503E, 1560E, 1562E • 2300 Volt, 600 Amp, 6-Device Ë Qty per controller 3 Description Heatsink Assembly 600A with Thermistor Part Number 80187-326-51-R Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly be replaced. Contact the Rockwell Automation factory.
Spare Parts D-4 Table D.4 Bulletin 1503E, 1560E, 1562E • 3300 and 4160 Volt, 180/360 Amp, 12-device Í Qty per controller Description Part Number 180 A 6 SCR, DCR820 or 5STP03D6500 (matched set of 2) ÊË 80156-893-72-R 6 SCR, DCR1020 or 5STP08G6500 (matched set of 2) ÊË Common Components Î SCR Gate Driver Board 3 (4 devices) Ï 2 IGDPS Board Ï 1 Voltage Sensing Module 1 MV SMC Interface Circuit Board 6 Snubber Resistor 6 Snubber Capacitor 0.68 µF, 4510 V peak 6 Sharing Resistor, 32.5 k, 225 W, Two 2.
Spare Parts D-5 Table D.5 Bulletin 1503E, 1560E, 1562E • 3300 and 4160 Volt, 600 Amp, 12-device Ë Qty per controller 3 Description Heatsink Assembly 600A with Thermistor Part Number 80187-309-51-R Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly be replaced. Contact the Rockwell Automation factory.
Spare Parts D-6 Table D.6 Bulletin 1503E, 1560E, 1562E • 5500/6900 Volt, 180/360 Amp, 18-device Í Qty per controller Description Part Number 180 A 6 180A : Matched Set 3 SCRs DCR820 or 5STP03D6500 uË 80156-893-73-R 360 A 6 360A : Matched Set 3 SCRs DCR1020 or 5STP08G6500 uË Common Components Î SCR Gate Driver Board 9 (2 devices) Ï 3 IGDPS Board Ï 1 Voltage Sensing Module 1 MV SMC Interface Circuit Board 9 Snubber Resistor 9 Snubber Capacitor 0.68 µF 9 Sharing Resistor 32.5K, 225W 2.
Spare Parts D-7 Table D.7 Bulletin 1503E, 1560E, 1562E • 5500/6900 Volt, 600 Amp, 18-device Ë Qty per controller 3 Description Part Number Heatsink Assembly 600A with Thermistor 80187-285-51-R Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly be replaced. Contact the Rockwell Automation factory.
Spare Parts D-8 Table D.8 Accessories Qty per controller 1 1 Description Part Number Control Module (Standard) 41391-454-01-S1FX Control Module (Pump Control) 41391-454-01-B1FX Fan (120 V) Ê 80025-248-01-R Fan (240 V) Ê 80025-248-02 Fuse Extractor 80144-491-02 Ê Optional equipment. Note : Reference only. 1503E – For OEM products, refer to OEM-supplied documentation for specific spare parts list. 1560/1562E are Allen-Bradley manufactured starters.
Appendix E Accessories Table E.
E-2 Accessories 1560E-UM050B-EN-P - June 2013
Medium Voltage Business, 135 Dundas Street, Cambridge, ON N1R 5X1 Canada, Publication 1560E-UM050B-EN-P – June 2013 Supersedes Publication 1560E-UM050A-EN-P – August 2004 Tel: (1) 519 623-1810, Fax: (1) 519 623-8930 Web Site: www.ab.com/mvb © 2013 Rockwell International Corporation. All rights reserved. Printed in Canada.
