User Manual Series K (or later) Medium Voltage SMC™ Flex Motor Controller Bulletin 1503E, 1560E and 1562E Publication 1560E-UM051F-EN-P
Important User Information 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 Preface Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Chapter 1 Product Overview Manual Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 1562E • Basic Control – Controlled Start only. . . . . . . . . . Bulletin 1562E • Basic Control – With Controlled Stop . . . . . . . . . Bulletin 1562E • DPI Control – Controlled Start only . . . . . . . . . . Bulletin 1562E • DPI Control – With Controlled Stop. . . . . . . . . . Bulletin 1560E • Basic Control – Controlled Start only. . . . . . . . . .
Table of Contents Chapter 3 Commissioning Procedure Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Important Commissioning Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming . . . . . . . .
Table of Contents Chapter 6 Options Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thyristor (SCR) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCR Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Snubber and Resistor Circuit Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Appendix D ArcShield Unit Information Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ArcShield Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Systems: Chimney or Plenum Option . . . . . . . . . . . . . . . . . . . . . Plenum Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plenum Exhaust Considerations . . . . . . . .
Preface Service Procedure For your convenience, the Rockwell Automation Global Manufacturing Solutions (CSM), provides an efficient and convenient method of servicing medium voltage products. Contact your local area support office to make arrangements to have a qualified service representative come to your facility. A complete listing of Area Support Offices may be obtained by calling your local Rockwell Automation Distributor or Sales Office.
Preface Notes: 10 Rockwell Automation Publication 7000A-UM200C-EN-P - June 2014
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™ Flex family of controllers. The family consists of the following Bulletin numbers: 1503E, 1560E and 1562E. TIP This user manual pertains to units with Series letter K or later, and firmware release 4.xxx (or later).
Chapter 1 Product Overview an existing or OEM/customer-supplied starter. It is comprised of several modular components, including: • Frame-mounted or loose power stacks including gate driver boards • Loose interface and voltage feedback boards • Fiber optic cables for SCR firing • Microprocessor based control module • Bypass vacuum contactor 1560E – Retrofit Controller A medium voltage solid-state controller designed to work in conjunction with an existing customer-supplied starter.
Product Overview Chapter 1 SMC Flex™ Control Module The MV SMC Flex controller offers a full range of starting and stopping modes as standard: • Soft Start with Selectable Kickstart • Soft Stop • Current Limit Start with Selectable Kickstart • Linear Acceleration with Selectable Kickstart • Linear Deceleration • Dual Ramp Start • Preset Slow Speed(1) • Full Voltage Start Other features that offer further user benefit include: • Extensive protection features • Metering • Communication capability • I/O Inno
Chapter 1 Product Overview Selectable Kickstart(2) Selectable kickstart provides a power boost at start-up that is user-adjustable from 0 to 90% of locked rotor torque. The additional power helps motors generate higher torque to overcome the resistive mechanical forces of some applications when they are started. The selectable kickstart time is user-adjustable from 0.0 to 2.0 seconds.
Product Overview Chapter 1 Dual Ramp Start(3) This starting mode is useful for applications that have varying loads (and therefore varying starting torque requirements). Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings.
Chapter 1 Product Overview 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.
Product Overview Chapter 1 Linear deceleration does not need to be used, even if linear acceleration is used. The stop time can be programmed for 0 to 120 seconds. Linear deceleration cannot brake the motor/load and reduce the stop time. IMPORTANT Consult factory if settings over 30 seconds are required. The base rating of the MV SMC Flex is two starts (or one start/stop combination) per hour, thirty seconds maximum for each operation.
Chapter 1 Product Overview Protection and Diagnostics The MV SMC Flex controller is capable of providing the following protective and diagnostic features: Overload The MV SMC Flex controller meets applicable requirements as a motor overload protection device. Thermal memory provides added protection and is maintained even when control power is removed. The built-in overload algorithm controls the value stored in Parameter 12, Motor Thermal Usage (Refer to Chapter 4, Programming).
Product Overview Chapter 1 Figure 9 - Overload Trip Curves Multiples of FLC Class 30 Approximate Trip Time (Seconds) Class 20 Approximate Trip Time (Seconds) Class 15 Approximate Trip Time (Seconds) Multiples of FLC Approximate trip time for 3-phase balanced condition from hot start Approximate trip time for 3-phase balanced condition from cold start Multiples of FLC Figure 10 - Restart Trip Curves after Auto Reset 100000 1000 100 Seconds Approximate Trip Time (Seconds) Class 10 Class 10
Chapter 1 Product Overview Underload(4) Utilizing the underload protection of the MV SMC Flex controller, motor operation can be halted if a sudden drop in current is sensed. The MV SMC Flex controller provides an adjustable underload trip setting from 0 to 99% of the programmed motor full load current rating. Trip delay time can be adjusted from 0 to 99 seconds.
Product Overview Chapter 1 Unbalance(6) The MV SMC Flex is able to detect an unbalance in line voltages. Motor operation can be halted if the unbalance is greater than the desired range. The MV SMC Flex controller provides an adjustable unbalance setting from 0 to 25% of the line voltages. Trip delay time can be adjusted from 0 to 99 seconds. An alarm (pre-fault) indication level can be programmed to indicate the unit is getting close to faulting.
Chapter 1 Product Overview Figure 12 - Jam Detection(7) Percent Full Load Current 100% Jam Running Time (seconds) 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.
Product Overview IMPORTANT Chapter 1 The ground fault inhibit timer starts after the maximum phase of load current transitions from 0A to 30% of the device’s minimum FLA Setting or the GF 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 Flt Inh Time expires.
Chapter 1 Product Overview Figure 13 illustrates the required PTC sensor characteristics, per IEC-34-11-2.
Product Overview Chapter 1 Line Faults The MV SMC Flex controller continually monitors line conditions for abnormal factors. Pre-start protection includes: • Line Fault (with phase indication) – Line voltage loss – Missing load connection – Shorted SCR Running protection includes: • Line Fault (no phase indication) – Line voltage loss – Missing load connection Phase reversal protection(8) can be toggled either ON or OFF.
Chapter 1 Product Overview Metering Power monitoring parameters include: • Three-phase current • Three-phase voltage • Power in MW • Power usage in MWh • Power factor • Motor thermal capacity usage • Elapsed time • Motor speed (full speed %, with use of optional tachometer input) Notes: 1. Voltage measurement is not available during the braking operation of the SMB Smart Motor Braking, Accu-Stop, and Slow Speed with Braking control options. 2.
Product Overview Communication Chapter 1 A serial interface port (DPI) is provided as standard, which allows connection to the Bulletin 20-HIM LCD human interface modules. Figure 14 - DPI Location DPI 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.
Chapter 1 Product Overview Status Indication All auxiliary contacts can be programmed as NO or NC for the following states except External Bypass, which can only be programmed as NO.
Product Overview Chapter 1 Network inputs can be obtained through proper programming of Option Input #1 and Option Input #2. (refer to page 159 and page 163 for available options.) MV applications have special requirements for isolation and bypass contactors (or circuit breakers). For Firmware up to and including 5.001 the following issues must be considered: 1. AUX1 must be used to control the fully-rated bypass contactor. Parameters #107 will not be displayed, and defaults to “Ext Bypass”.
Chapter 1 Product Overview Pump Application Considerations 1. Consult factory if start time settings over 30 seconds are required. The base rating of the MV SMC Flex is two starts (or one start/stop combination) per hour, thirty seconds maximum for each operation. A stopping operation counts as a start for purposes of thermal capacity calculations. 2. The Pump Control option functions only for centrifugal pumps. It is not suited for positive displacement, piston, or other types of pumps. 3.
Product Overview Chapter 1 Braking Control Options The Braking Control options (Smart Motor Braking, Accu-Stop and Slow Speed with Braking) are not offered for standard use in MV applications. Please consult factory for further assistance. 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.
Chapter 1 Product Overview 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 fiber-optic transmitters. The gating signals are sent to the gate-driver circuit board via fiber-optic cables.
4160V AC, 3Ø, 60Hz L1 L2 L3 GND CAUTION 120V X2 BLK TO SMC Flex (27, 28) W Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 WIRE CONNECTIONS FOR PHASE B CONNECTIONS SHOWN FOR PHASE C B C FROM CONTROL CIRCUIT C CLGD B A B A 1 G C T CT - CLGD G C T CT OV S C C2 TX13 TX14 TX15 TX16 TX17 TX18 TB1 L1 L2/N G U16 U18 U20 TX7 TX8 TX9 TX10 TX11 TX12 GDPS Vcom - RX1 TX1 J3 TB5 AA+ BB+ CC+ TB6 G 24C 4 FROM CLT VOLTAGE SENSING BOARD VSB 1B 2B J1 A: 4800-7200V 3B B:
24 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 WIRE CONNECTIONS FOR PHASE B CONNECTIONS SHOWN FOR PHASE C CONNECT TO GROUND ONLY IF POWER SYSTEM IS GROUNDED C G FROM CONTROL CIRCUIT B A B A 1 G C T CLGD TB1 L1 L2/N G U16 U18 U20 TX13 TX14 TX15 TX16 TX17 TX18 TX7 TX8 TX9 TX10 TX11 TX12 GDPS Vcom TB5 AA+ BB+ CC+ G 24C - C4 CLGD G C T CT OV S C S4 FROM CLT VOLTAGE SENSING BOARD VSB 1B J1 A: 4800-7200V 2B 3B B: 2500-4799V C: 1450-2499V 4B D: 800-1449V 5B 6B GND1
Product Overview Functional Description Chapter 1 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. ATTENTION: The control circuit schematics shown below assume that control power is fed from the same source as the primary circuit. If external control power is used, additional control interlocking may be required to avoid unexpected motor start-up.
Chapter 1 Product Overview If the motor has started, the unit is in the bypass mode, and a trip occurs within the SMC Flex module or from an external protection relay; “Aux #4” will open the line contactor immediately, and “Aux #1” will remain closed for 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits. A trip due to an overload or fault condition will result in a “coast” stop.
Product Overview Chapter 1 An uncontrolled, or coast stop, can be achieved via DPI or by opening the connection on terminal 18 (i.e. by pressing “Coast Stop” button). When using the optional HIM, pressing the “Jog” button will initiate the optional stop maneuver, and pressing the “O” button will initiate a coast stop. To run in “Local” mode, the “CR” contact is used to initiate a start and stop sequence (similar to Figure 21).
Chapter 1 Product Overview Bulletin 1560E • Basic Control – With Controlled Stop When wired as shown in Figure 25, the controller operates much the same as described above for the Standard module. The control signal uses terminal 16 instead of 17, and a “coast” stop can be achieved by opening the connection to terminal 17. It is more important in this configuration to integrate the control circuit of the 1560E with the existing controller, for better control of the Stop option.
Product Overview Chapter 1 Bulletin 1560E • DPI Control – With Controlled Stop The control scheme shown in Figure 27 allows the MV SMC Flex to be controlled using DPI (Drive Programming Interface). (Refer to Table 16 on page 109 for Logic Command Word bits assignment for DPI control). This special usage of DPI includes provisions for a “Local” mode of control as well.
Chapter 1 Product Overview Figure 20 - Typical Bulletin 1562E IntelliVAC Control Circuit • Without Stop Control 115V H1 H3 H2 H4 M-IV CLT X1 TO SMCLEXIB-TB6 0.6V 1 2 X2 + EC N 11 AUX. 12 L1 ØB M A M B R ØA 4 3 TCO 6 5 CCO G MOV C MAIN CONTACTOR (M) M L2/N ØC B-IV 1 2 + EC 4 3 TCO M A B B N 11 AUX.
Product Overview Chapter 1 Figure 21 - Typical Bulletin 1562E IntelliVAC Control Circuit • With Stop Control 115V H1 H3 H2 H4 M-IV CLT X1 TO SMCLEXIB-TB6 0.6V 1 2 X2 + EC N 11 AUX. 12 L1 ØB M A M B R ØA 4 3 TCO 6 5 CCO G MOV C MAIN CONTACTOR (M) M L2/N ØC B-IV 1 2 A B B + EC 11 AUX.
Chapter 1 Product Overview Figure 22 - Typical Bulletin 1562E IntelliVAC Control Circuit without Stop control • With DeviceNet (or DPI) Communication and Optional Local/Off/Remote 115V H3 H1 H2 H4 M-IV CLT X1 TO SMCLEXIB-TB6 1 2 X2 0.6V + EC MOV N 11 AUX. 12 L1 ØB M A M B R ØA 4 3 TCO 6 5 CCO G C MAIN CONTACTOR (M) M L2/N ØC B-IV 1 2 A B B + EC 11 AUX.
Product Overview Chapter 1 Figure 23 - Typical Bulletin 1562E IntelliVAC Control Circuit with Stop control • With DeviceNet (or DPI) Communication and Optional Local/Off/Remote 115V H1 H3 H2 H4 M-IV CLT X1 1 2 X2 0.6V + EC L1 ØB M MOV N 11 AUX.
Chapter 1 Product Overview Figure 24 - Typical Bulletin 1560E IntelliVAC Control Circuit • Without Stop Control 115V H1 H3 H2 H4 CLT X1 TO SMCLEXIB-TB6 0.6V X2 R B-IV ØA ØB A ØC B 1 2 B + EC L1 B-IV 13 M MOV N 11 AUX.
Product Overview Chapter 1 Figure 25 - Typical Bulletin 1560E IntelliVAC Control Circuit • With Stop Control 115V H1 H3 H2 H4 CLT X1 TO SMCLEXIB-TB6 0.6V X2 R B-IV 1 2 ØB ØA A ØC B + TCO 4 EC B-IV 6 5 CCO L1 13 MOV N B 11 AUX.
Chapter 1 Product Overview Figure 26 - Typical Bulletin 1560E IntelliVAC Control Circuit without Stop Control • With DeviceNet (or DPI) Communication and optional Local/Off/Remote 115V H1 H3 H2 H4 CLT X1 TO SMCLEXIB-TB6 X2 0.6V R B-IV 1 2 ØA ØB A ØC + EC L1 13 M 6 5 CCO G MOV N B B 11 AUX.
Product Overview Chapter 1 Figure 27 - Typical Bulletin 1560E IntelliVAC Control Circuit with Stop Control • With DeviceNet (or DPI) Communication and optional Local/Off/Remote 115V H1 H3 H2 H4 CLT X1 TO SMCLEXIB-TB6 X2 0.6V R B-IV 1 2 ØA ØB A ØC B + EC L1 B-IV M 6 5 CCO G MOV N B 11 AUX.
Chapter 1 Product Overview Notes: 38 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Chapter 2 Installation ATTENTION: Perform the installation duties correctly. Errors may cause commissioning delays, equipment damage or personal injury. IMPORTANT Receiving Safety and Codes Unpacking and Inspection For the 1503E, refer to applicable documentation from OEM installation, grounding, interlocking and wiring.
Chapter 2 Installation In addition to the precautions listed throughout this manual, the following statements, which are general to the system, must be read and understood. General Precautions 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 Chapter 2 C. The equipment must be kept clean. Dust buildup inside the enclosure inhibits proper cooling and decreases the system reliability. The equipment should not be located where liquid or solid contaminants can drop onto it. Controllers with ventilated enclosures (in particular those with fans) must be in a room free of airborne contaminants. D. Only persons familiar with the function of the controller should have access to it. E.
Chapter 2 Installation Each power feeder from the substation transformer to the controller must be equipped with properly sized ground cables. Simply utilizing the conduit or cable armor as a ground is not adequate. The conduit or cable armor and ground wires should be bonded to ground at both ends. Each enclosure and/or frame must be bonded to ground at a minimum of two locations. Each AC motor frame must be bonded to grounded building steel within 6.
Installation Chapter 2 To make power connections for a two-high cabinet, refer to Figure 28 to Figure 30, and Publication 1500-UM055_-EN-P (Chapter 2). ATTENTION: Bulletin 1562E units provided with an arc resistant enclosure must be installed in accordance with instructions in Publication 1500-UM055_-EN-P. Failure to do so may result in damage to equipment or personal injury.
Chapter 2 Installation Bulletin 1562E Figure 28 - Cabinet Layout • 1562E – 180/360A, 2400V to 4160V (with LV panels not shown) (Non arc-resistant cabinet shown) Power Stack Assembly Terminal Block Assembly Bypass Vacuum Contactor Voltage Sensing Module Non Load Break Isolation Switch Load Cable Connection Point (top exit) Current Transformers 44 Line Vacuum Contactor Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Installation Chapter 2 Figure 29 - Incoming Line Cable Connections (viewed from the rear with power bus access cover removed) (Non Arc-resistant cabinet shown) Power Cable Lugs Ground Bus Lug Figure 30 - Bottom Cable Exit Configuration (with LV panel swung open) (Non Arc-resistant cabinet shown) Cable Duct Barrier Cable Duct Boot Motor Cable Terminals Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 45
Chapter 2 Installation Bulletin 1560E Figure 31 - Power Connections • 1560E – 180/360A, 2400 to 4160V (Not available in an Arc-resistant design) Phase 2 Power Stack Assembly Phase 1 Power Stack Assembly Phase 3 Power Stack Assembly Voltage Sensing Module Load Connections (top exit shown) Phase 1 (front) through 3 (back) Line Connections Phase 1 (top) through 3 (bottom) Bypass Vacuum Contactor Current Transformers 46 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Installation Chapter 2 Figure 32 - Power Connections • 1560E – 180/360A, 5500 to 6900V (Not available in an Arc-resistant design) Phase 1 Line Connections Phase 1 Power Stack Assembly Voltage Sensing Module Phase 2 Line Connections Phase 2 Power Stack Assembly Load Connections (top exit shown) Phase 1 (front) through 3 (back) Current Transformers Phase 3 Power Stack Assembly Phase 3 Line Connections Bypass Vacuum Contactor Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 47
Chapter 2 Installation Figure 33 - Power Connections • 1560E – 600A, 2400 to 6900V (Not available in an Arc-resistant design) Phase 1 Line Connections Phase 1 Power Stack Assembly Voltage Sensing Module Phase 2 Line Connections Phase 2 Power Stack Assembly Load Connections (top exit shown) Phase 1 (front) through 3 (back) Current Transformers Phase 3 Power Stack Assembly Phase 3 Line Connections Bypass Vacuum Contactor 48 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Installation Chapter 2 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.
Chapter 2 Installation Installation TIP Rockwell Automation can assist with the selection of an appropriate interlocking method, which may include mechanical modifications to the cabinet(s) or key-type lock systems. TIP An auxiliary cabinet may be attached to the main structure. It will be raminterlocked with the main power cell door, which will not allow it to be opened until the main power cell door is opened.
Installation Chapter 2 Control Cables Control cable entry/exit should be located near the terminal blocks; customer’s connections are to be routed along the empty side of the terminals. Nylon cable tie loops are provided at the left, front corner of the cabinet to route control cables safely behind the low voltage panel hinges. Cables should be routed so they do not interfere with the swing of the low-voltage panels.
Chapter 2 Installation Figure 34 - Typical One-Line Diagram (Showing 2 Different Styles of Power Factor Capacitor Connections) Power Bus Isolation Switch Fuse Isolation Switch Fuse Contactor Isolation Contactor di/dt Inductor di/dt Inductor Capacitor Contactor PFCC PFCC (Power Factor Correction Capacitor) Bypass Contactor Motor Surge Arrestor Protection Devices Rockwell Automation highly recommends that motor surge capacitors and/or motor surge arresters not be located on the load side of the SMC
Installation Chapter 2 • The capacitance in combination with the line and motor impedance could also be excited by the voltage steps from SCR switching to create resonant voltage swings which could exceed the device voltage withstanding ratings or surge arrester rating, or cause distorted voltage signals which may be misinterpreted by the MV SMC Flex control system.
Chapter 2 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 Chapter 2 • 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.
Chapter 2 Installation Control Terminal Designations As shown in Figure 35, the SMC Flex controller contains 24 control terminals on the front of the controller.
Chapter 3 Commissioning Procedure Preliminary Setup 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.
Chapter 3 Commissioning Procedure 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:
Commissioning Procedure Chapter 3 IMPORTANT COMMISSIONING CHECKS ATTENTION: When commissioning a MV SMC Flex, it is critical that following important checks are completed. For more details, follow the commissioning guidelines that follow this page. • Inspect the equipment for any signs of physical damage. • Verify SMC Flex physical installation is complete. • Verify the integrity and operation of all safety interlocks. • Verify that motor mechanical installation is complete.
Chapter 3 Commissioning Procedure • Complete Power Supply Tests (refer to Power Supply Tests on page 64 of Chapter 3). • Program the module with correct parameter settings. • Start the unit and record scope waveforms (line voltage, motor voltage and motor current). Preliminary Check ATTENTION: 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.
Commissioning Procedure Chapter 3 If the factory settings are not suitable for the application, program the module to meet the application requirements. Contact your local Rockwell Automation representative or the factory if assistance is required. 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.
T3 6 62 GND1 T2 4 L2 3 VOLTAGE SENSING BOARD T1 2 J1 L1 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 115/230V AC 50/60Hz H4 H2 X2 X1 CURRENT LOOP CT PHASE B CS3 PHASE C C6 T1 S6 S5 C5 C5 C4 S C S C S C S C RX1 RX1 RX1 RX1 TX1 TX1 TX1 TX1 OV6 OV5 OV4 OV3 OV2 OV1 GD6 GD5 GD4 GD3 GD2 T THERMISTOR GD1 C6 G6 C5 G5 C4 G4 C3 G3 C2 G2 C1 C5 C1 C2 C6 OV6 OV5 C4 OV4 OV1 C3 OV3 OV2 RR3 RR2 RR1 THERMISTOR G6 C6 G5 C5 G
Commissioning Procedure Chapter 3 Figure 37 - Connection and Test Information for Interface Board LED (Red): ON when test pulses on SW2: When ON (up) provides test pulses to gate driver circuits. NOTE: Must be OFF (down) for normal operation.
Chapter 3 Commissioning Procedure Power Supply Tests ATTENTION: 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.
Commissioning Procedure Chapter 3 6. With the gate pulses on, check the voltage again on each gate driver board as described in Step 4 above. The voltage should be 4 - 5V DC. 7. Locate the Portable Test Power Supply that was included with the equipment, and verify that the rating corresponds to the available power system (i.e. 110/120 VAC or 220/240 VAC). Plug the unit into the power source, and plug the green connector into J1 on each of the gate driver boards (see Figure 39.
Chapter 3 Commissioning Procedure Volts Figure 40 - Gate Pulse Detail – Typical SCR (ABB) Microseconds Figure 41 - Gate Pulse Test Waveform - 2.0 - 1.5 - 1.0 - 0.5 0.0 0.5 1.0 1.5 2.0 2.5 3.0 Milliseconds 10. If no 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 ohmmeter to the gate leads.
Commissioning Procedure Chapter 3 12. Open the switch SW2 on the interface board (see Figure 38) before returning the unit to service. Ensure the red LED is off. ATTENTION: If the SW2 switch is not in the open position when the SMC is energized, the motor will start in an uncontrolled manner and may cause severe damage. 13. Check that all plugs and connectors are secure. Retrieve all hardware and tools from the equipment.
Chapter 3 Commissioning Procedure Resistance Checks To ensure that resistors and connections have not been damaged during shipment and installation, the following resistance tests should be performed before energizing the starter. 1. Remove all power from the equipment. 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.
Commissioning Procedure Chapter 3 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) Table 4 - Input Voltage Ranges Module Rated Voltage Voltage Range MV Ratio 1500 800-1500 1200 2500 1501-2500 580 4800 2501-4800 324 7200 4801-7200 195 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 3 Commissioning Procedure Notes: 70 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
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. TIP Keypad Description This User Manual pertains to SMC Flex control modules with version 4.xx firmware (or later). The keys found on the front of the SMC Flex controller are described in Table 5.
Chapter 4 Programming Figure 42 - Menu Structure Hierarchy Power-up and Status Display Lang Esc or Sel or or or Select language being deployed Choose Mode OPERATION LEVEL or MAIN MENU(1) Parameter Device Select (2) Memory Storage Preferences Log In(3) Diagnostics Esc (2) Monitoring Set Up Motor Protection Communications Utility Linear List SMC Flex Reset to Defaults Save to EEPROM Recall EEPROM Change Password User Dspl Line User Dspl Time User Dspl Video Reset User Display Alarms F
Programming Chapter 4 Figure 43 - Menu Structure Hierarchy (2) Parameter (1),(3) Esc Motor Protection Set Up Monitoring Communications Utility Metering Basic Overload Jam Comm Masters Language 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 Motor Speed SMC Option Motor Connection Line Voltage MV Ratio Starting Mode Ramp Time Initial Torque Cur Limit Lvl Kickstart
Chapter 4 Programming Table 6 - Parameter Linear List(1) Parameter No.
Programming Password Chapter 4 The SMC Flex Controller allows the user to limit access to the programming system through password protection. This feature is disabled with a factory-set default of 0. To modify the password or login after a password is programmed, complete the procedure below. Description Action Display – – 1. Press the ESC key to go from the status display to the Main menu. Esc Sel 2. Scroll with the Up/Down keys until the Preferences option is highlighted. 3.
Chapter 4 Programming 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 44 and explanations below. Figure 44 - Memory Block Diagram EEPROM RAM Esc Esc ROM Sel Sel Random Access Memory (RAM) This is the work area of the controller after it is powered up. When you modify parameters in the Setup mode, the new values are stored in RAM.
Programming Chapter 4 Electrically Erasable Programmable Read-Only Memory (EEPROM) The SMC Flex controller provides a nonvolatile area for storing user-modified parameter values in the EEPROM. Using Parameter Management with DPI HIM TIP The SMC Flex will automatically save any parameter changes made during the programming process. Memory Storage and Parameter Management perform the same function of resetting to defaults.
Chapter 4 Programming 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. If the password is set, parameters cannot be adjusted without logging in. 3. Use the Sel key to highlight a single digit. Description Display(2) Action — 1.
Programming Soft Start Chapter 4 The following parameters are specifically used to adjust the voltage ramp supplied to the motor. Parameter Option Starting Mode This must be programmed for Soft Start. Soft Start Ramp Time(1) Programs the time period that the controller will ramp the output voltage up to full voltage from the initial Torque level programmed.
Chapter 4 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 Setup programming mode. To obtain Dual Ramp control, Ramp #1 is located in the Basic Setup and Ramp #2 is located in the Option 2 Input (Dual Ramp). Parameter Option Set Up The user must select the Set-up programming mode to obtain access to the Dual Ramp parameters.
Programming Full Voltage Start Linear Speed Chapter 4 The SMC Flex controller may be programmed to provide a full voltage start (output voltage to the motor reaches full voltage within 1/4 second) with the following programming: Parameter Option Starting Mode This must be programmed for Full Voltage. Full Voltage The SMC Flex provides the user the ability to control the motor speed during starting and stopping maneuvers.
Chapter 4 Programming Preset Slow Speed This control mode may be configured to allow slow speed operation of the motor. Parameter Basic Setup Option Slow Speed Select Allows the user to program the slow speed that best fits the application. Low: 7% – Forward 10% – Reverse High: 15% – Forward 20% – Reverse Slow Speed Direction This parameter programs the slow speed motor rotational direction.
Programming Chapter 4 Parameter Option Kickstart Time A boost current is provided to the motor for the programmed time period. 0.0 to 2.0 s Kickstart Level Adjust the amount of current applied to the motor during kickstart. 0 to 90% of 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.
Chapter 4 Programming Motor Protection While the Basic Setup 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. TIP The majority of parameters have a Fault and an Alarm setting. Parameter Option Overload Allows the user to select the operation of the overload.
Programming Example Settings Chapter 4 Undervoltage(1) With Line Voltage programmed for 4160V and the Undervoltage level programmed for 80%, the trip value is 3328V. Overvoltage(1) With Line Voltage programmed for 3300V and the Overvoltage level programmed for 115%, the trip value is 3795V. Jam(2)(3) With Motor FLC programmed for 150 Amps and the Jam level programmed for 400%, the trip value is 600 Amps.
Chapter 4 Programming Motor Information The Basic Setup 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.
Chapter 5 Metering Overview 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:(1) Description Action – 1. Press any key to access the Main menu. Display – Esc Sel 2. Scroll with the Up/Down keys until the Parameter option is shown. 3. Press the Enter key to access the Parameter option. – 4.
Chapter 5 Metering Description Action Display 7. Scroll through the Metering parameters with the Up/Down keys to access the desired information. Press the Enter key to view that parameter. The metering values that are displayed on the SMC Flex can be modified to show you desired values by accessing Main Menu/Preferences.
Chapter 6 Options Overview The SMC Flex controller offers a variety of unique control programming and communication options that provide enhanced capabilities (refer to Chapter 1 for brief descriptions of each option). TIP Human Interface Module Only one option can reside in a controller. The control buttons available with the Bulletin 20-HIM Human Interface Modules are compatible with the SMC Flex controller’s control options.
Chapter 6 Options Option Action Operation Pump Control Pump Control I 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 Sel 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. O The red stop button, when pressed, will provide a coast stop, and/or reset a fault.
Options Programming Parameters Chapter 6 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 Setup and Metering groups. Diagrams supporting the options described below are shown later in this chapter. Option Parameter Range SMC Option This parameter identifies the type of control present and is not user programmable.
Chapter 6 Options Option Parameter Range SMC Option This parameter identifies the type of control present and is not user programmable. Braking Control Slow Speed Select Allows the user to program the slow speed that best fits the application. Low: 7% High:15% Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation.
Options TIP Control Wiring Chapter 6 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.
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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 Motor Protection on page 84 of Chapter 4.
Chapter 7 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. TIP A stop signal from the HIM will always stop the motor and clear the fault regardless of Logic Mask configuration (Logic Mask, parameter #87, equals ø).
Diagnostics Chapter 7 Fault Codes Table 7 provides a complete cross-reference of the available fault codes and corresponding fault descriptions.
Chapter 7 Diagnostics Fault Definitions Table 8 - Fault Definitions for the SMC Flex Fault Description Line Loss (F1, F2, F3) 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 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.
Diagnostics Chapter 7 Fault Description 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.
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Chapter 8 Communication 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. ScanPort devices are not supported by the SMC Flex.
Chapter 8 Communication Human Interface Module The SMC Flex controller can be programmed with the built-in keypad and LCD display or with the optional Bulletin 20-HIM LCD human interface modules. Parameters are organized in a three-level menu structure and divided into programming groups. TIP 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.
Communication Chapter 8 The control panel provides the operator interface to the controller. Start The green start button, when pressed, will begin motor operation. (Proper setup of the HIM port is required.) Stop The red stop button, when pressed, will halt motor operation and/or reset a fault. Jog Sel 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).
Chapter 8 Communication Connecting the Human Interface Module to the Controller Figure 46 shows the connection of the SMC Flex controller to a human interface module. Table 11 provides a description of each port. TIP 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 21 on page 31 or Figure 24 on page 34 for the control wiring diagram that enables start-stop control from a human interface module.
Communication Chapter 8 To enable motor control from a connected human interface module or communication module, you must take the following programming steps: 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.
Chapter 8 Communication If enabling control from the built-in SMC Flex programmer, the Logic Mask must be set as follows: Table 12 - Logic Mask Requirements Control Enable Mask Code Description 0 No external DPI devices are enabled 4 Only one HIM on port 2 is enabled 12 Two HIMs are enabled on ports 2 and 3 32 Only the DPI communication card on port 5 is enabled 36 One HIM on ports 2 and the DPI communication card on port 5 are enabled 44 Two HIMs on ports 2 and 3 and the DPI communication
Communication Default Input/Output Configuration Chapter 8 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 13 - Default Input/Output Configuration Produced Data (Status) Consumed Data (Control) Word 0 Logic Status Logic Command Word 1 Feedback(1) Reference(2) (1) The feedback word is always Current in Phase A.
Chapter 8 Communication SMC Flex Bit Identification Table 15 - Logic Status Word Bit # 15 14 13 12 Status Description Enabled 1 – Control Power Applied 0 – No Control Power Running 1 – Power Applied to Motor 0 – Power not Applied to Motor Phasing 1 – ABC Phasing 0 – CBA Phasing Phasing Active 1 – 3-phase is valid 0 – No valid 3-phase is detected Starting (Accel) 1 – Performing a Start Maneuver 0 – Not performing a Start Maneuver Stopping (Decel) 1 – Performing a Stop Maneuver 0 – Not perf
Communication Chapter 8 Table 16 - Logic Command Word (Control) Bit # 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 X X X — X X X X X Description Stop 1 – Stop/Inhibit 0 – No Action Start 1 – Start 0 – No Action Option #1 Input 1 – Stop Maneuver/Inhibit (Option Stop) 0 – No Action Clear Faults 1 – Clear Faults 0 – No Action Option #2 Input 1 – Perform Option 2 function 0 – No Action — Bits 5 to 10 – Not Used Aux Enable 1 – Use Aux 1 to Aux 4 0 – Ignore Aux 1 to Aux 4 Aux 1 1 – Aux 1
Chapter 8 Communication 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. Display Text Unit Equivalents 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.
Communication Chapter 8 Parameters 88 to 103 are used to configure the DataLinks. For additional information regarding DataLinks, refer to the user manual for the communication interface being used. TIP Updating Firmware 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.
Chapter 8 Communication Notes: 112 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
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.
Chapter 9 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 Chapter 9 Table 18 - Fault Display Explanation Display Fault Code Possible Causes Possible Solutions Line Loss (with phase indication) 1, 2, 3 • Missing supply phase • Motor not connected properly • Improper or missing current or voltage feedback • Check for open line (e.g.
Chapter 9 Troubleshooting Display Fault Code Possible Causes Possible Solutions Underload 23 • Broken motor shaft • Broken belts, tool bits, etc.
Troubleshooting Chapter 9 Table 19 - Motor Will Not Start – No Output Voltage to the Motor Display Possible Causes Possible Solutions Fault displayed • See fault description • See Table 18 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.
Chapter 9 Troubleshooting Table 23 - Miscellaneous Situations(1) Display Possible Causes Possible Solutions Motor current and voltage fluctuates with steady load • Motor • Erratic Load • Verity type of motor as a standard squirrel cage induction motor • Check load conditions Erratic operation • Loose connections • Shut off all power to controller and check for loose connections Accelerates too fast • • • • Starting time Initial torque Current limit setting Kickstart • • • • Increase starting
Troubleshooting Control Module Removal Chapter 9 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 HAZARD: To avoid shock hazard, ensure the main power has been disconnected before working on the controller, motor or control devices.
Chapter 9 Troubleshooting 1. Ensure there is no power to the equipment. Voltage Sensing Board Replacement SHOCK HAZARD: 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 voltagemeasuring device. Failure to do so may result in injury or death. 2. Mark the position of the ribbon cable and wires. 3.
Troubleshooting Current Loop Power Supply Chapter 9 The current loop gate driver (CLGD) boards 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).
Chapter 9 Troubleshooting 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. 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.
Troubleshooting Power Circuit Troubleshooting Chapter 9 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 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.
Chapter 9 Troubleshooting SCR Replacement Procedure TIP 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. Remove all power from the equipment. SHOCK HAZARD: To avoid shock hazard, ensure main power has been disconnected before working on the controller, motor or control devices.
Troubleshooting Chapter 9 B. Replace SCRs TIP For 600A units, it is mandatory that the entire stack be replaced. The high clamping force requires the factory to tighten the clamp hardware. See Appendix G, Spare Parts for part numbers. Proceed to step C. TIP Refer to Figure 50 to Figure 62. • SCR positions are numbered in succession from the top down. • The SCR cathode is at the end with the wide flange.
Chapter 9 Troubleshooting 8. Tighten the center nut until the indicator washer becomes loose with some friction. The clamp is now at the proper force and must not be clamped any tighter. If the indicator washer becomes too loose (no friction), back the center nut off slowly until the washer is loose with some friction. 9. Replace the shorting bar. Torque hardware to 30 N-m (20 lb-ft). For 3/8in. hardware in the “T” slots of aluminum heatsinks, the recommended torque is 22 N-m (16 lb-ft).
Troubleshooting Chapter 9 Figure 50 - Upper Low Voltage Panel and Power Cell Detail (1562E) • 2400 to 4160V, 180/360A Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 127
Chapter 9 Troubleshooting Figure 51 - Power Module Assembly (one phase) • 1000/1300/1500/2400V, 180/360A Heatsink 1 SCR 1 Heatsink 2 SCR 2 Heatsink 3 Figure 52 - Heatsink Clamp Gap (Do not loosen) Center Nut Locking Nut (Do not adjust) Indicating Washer (Do not loosen) 128 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.).
Troubleshooting Chapter 9 Figure 53 - Removal of SCR (1000 to 240 V, 180/360A) 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.
Chapter 9 Troubleshooting Figure 54 - Power Module Assembly (one phase) • 3300/4160V, 180/360A 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.
Troubleshooting Chapter 9 Figure 56 - Removal of SCR 2 and SCR 4 (3300 to 4160V, 180/360A) To Remove SCR 4: • 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.
Chapter 9 Troubleshooting Figure 57 - Power Module Assembly (one phase) • 5500/6900V, 180/360A Line connection Gate Driver Boards Load connection Figure 58 - Power Module Assembly (one phase) with Gate Driver Boards Removed • 5500/6900V, 180/360A Line connection Board Mounting Frame Load connection 132 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Troubleshooting Chapter 9 Figure 59 - Power Module Assembly (one phase) with Boards and Frame Removed • 5500/6900V, 180/360A Module retaining hardware locations (4) Figure 60 - 6900V Heatsink Assembly, 180/360A Positioned on bench for SCR replacement SCR 4 SCR 3 SCR 5 SCR 6 SCR 2 SCR 1 Note: SCR 1, SCR 2 and SCR 5 are a matched set. SCR 3, SCR 4 and SCR 6 are a matched set.
Chapter 9 Troubleshooting Figure 61 - 6900V SCR Replacement, 180/360A Do not loosen Center Nut 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 inch). A 21-mm open end wrench is required.
Troubleshooting Chapter 9 Figure 63 - Power Module Assembly (one phase) • 2300V, 600A Heatsink Assembly Line connection Load connection Gate Driver Boards Gate Driver, Snubber Circuit and Sharing Resistor Frame Assembly Figure 64 - Power Module Assembly (one phase) • 3300/4160V, 600A Heatsink Assembly Line connection Load connection Gate Driver Boards Gate Driver, Snubber Circuit and Sharing Resistor Frame Assembly Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 135
Chapter 9 Troubleshooting Figure 65 - Power Module Assembly (one phase) • 5500/6900V, 600A Heatsink Assembly Line connection Load connection Gate Driver Boards Gate Driver, Snubber Circuit and Sharing Resistor Frame Assembly 136 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Troubleshooting Snubber and Resistor Circuit Testing Chapter 9 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 HAZARD: 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.
Chapter 9 Troubleshooting Figure 66 - Voltage Sensing Board To Interface Board Ground Connections T14 PART NUMBER GND2 6SVT 63R 53R 5SVT 33R 43R 23R 13R 3SVT 92R 4SVT GND1 PB 73R MADE IN USA kV SERIAL NUMBER 03R 2SVT 2.8 M 5.6 M 10.0 M 16.9 M 72R 1.9 M 3.7 M 6.6 M 11.2 M 82R 1.5 kV 2.5 kV 4.8 kV 7.2 kV 8SVT Tap 2,4,6 J1 1SVT Tap 1,3,5 52R V rated 62R Measure 11.
Troubleshooting Chapter 9 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.) If the values for each leg vary by more than 1%, the voltage sensing module may need to be replaced. See Table 35 on page 199 in Appendix G., and refer to procedure on page 120.
140 C2 S2 C1 S1 C S C S OV OV GD2 GD1 T GATE DRIVER BOARDS THERMISTOR C2 G2 C1 G1 CS RS RR1 C2 OV2 OV1 C1 THERMISTOR Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 HS3 HS2 LOAD LINE LEGEND: RR SHARING RESISTOR RS SNUBBER RESISTOR CS SNUBBER CAPACITOR HS HEATSINKS G GATE LEAD (WHITE) C CATHODE LEAD (RED) G2 C2 G1 C1 HS1 Chapter 9 Troubleshooting Figure 67 - Typical 1500/2400V Module Wiring (180/360A)
C2 S2 C1 S1 C S C S OV OV GD2 GD1 T THERMISTOR GATE DRIVER BOARDS C2 G2 C1 G1 RS CS RR1 C2 OV2 OV1 C1 THERMISTOR G2 C2 G1 C1 LOAD LINE LEGEND: RR SHARING RESISTOR RS SNUBBER RESISTOR CS SNUBBER CAPACITOR HS HEATSINKS G GATE LEAD (WHITE) C CATHODE LEAD (RED) HS3 HS2 HS1 Troubleshooting Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 Chapter 9 Figure 68 - Typical 1500/2400V Module Wiring (600A) 141
142 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 C4 S4 C3 S3 S2 C2 C2 C1 S1 C S C S C S C S OV4 OV3 OV2 OV1 OV OV OV OV GD4 GD3 GD2 GD1 T GATE DRIVER BOARDS THERMISTOR C4 G4 C3 G3 C2 G2 C1 G1 RS2 CS2 CS1 RS1 RR1 RR2 C4 OV4 OV3 C2 OV2 OV1 C1 THERMISTOR G4 C4 G3 C3 G2 C2 G1 C1 LOAD LINE LEGEND: RR SHARING RESISTOR RS SNUBBER RESISTOR CS SNUBBER CAPACITOR HS HEATSINKS G GATE LEAD (WHITE) C CATHODE LEAD (RED) HS5 HS4 HS3 HS2 HS1 Cha
Troubleshooting Chapter 9 Figure 70 - Typical 6900V Module Wiring (180/360/600A) GATE DRIVER BOARDS S1 C1 G1 S C OV RS1 C2 GD1 C1 OV2 OV1 OV3 THERMISTOR S2 C2 HS1 C3 T CS1 RR1 G1 C1 G2 S C OV RS2 GD2 C2 HS2 OV2 G2 C2 HS3 CS2 S3 C3 G3 S C OV C1 THERMISTOR GD3 C3 OV1 OV3 LINE G3 C3 HS4 RR2 OV4 G4 C4 S4 C4 G4 S C OV HS5 GD4 C4 G5 C5 OV4 S5 C5 C5 G5 S C OV GD5 LOAD C5 C5 G6 C6 OV5 OV5 RS3 HS6 RR3 OV6 HS7 C6 CS3 S6 C6 G6 S C OV GD6 C6 OV6 Rockwell
Chapter 9 Troubleshooting Notes: 144 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
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.
Chapter 10 Maintenance 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 Chapter 10 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.
Chapter 10 Maintenance “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 Chapter 10 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.
Chapter 10 Maintenance • 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 selfextinguishing (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.
Appendix A Specifications 1560E/1562E SMC Flex Specifications Table 25 - Specifications Electrical Ratings UL/CSA/NEMA IEC Power Circuit Method of Connection Motor in delta or star; SCRs between windings and supply Number of Poles Equipment designed for three phase loads only Rated Voltage (Ur) 2400 V AC (-15%, +10%) 3300 V AC (-15%, +10%) 4200 V AC (-15%, +10%) 6900 V AC (-15%, +10%) 3.6 kV 7.2 kV Rated Insulation Voltage (Ui) 2500 V 5000 V 7200 V 3.6 kV 7.
Appendix A Specifications Electrical Ratings 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 Environmental Ratings UL/CSA/NEMA Operating Temperature Range 0°C to 40°C (32°F to 104°F) Storage and Transportation Temperature Range -20°C to +75°C (-4°F to 149°F) Altitude 0 - 1000 meters (3,300 feet) without derating(2) Humidity 5% to 95% (non condensing) Pollution Degree Seismic (UBC Rating) Appendix A IEC 2 (1) 1, 2, 3, 4 (1) Some units may require special bracing. Contact factory for more information. (2) Starter Deratings are in Table 26.
Appendix A Specifications Table 28 - Shipping Weights and Dimensions(1) Current Rating Horsepower (kW) Dimensions in inches (mm) Shipping Weight 2400 V 3300 V 4200 V 6600 V 6900 V Width Depth Height lb kg 200 A 800 (600) 1000 (746) 1250 (933) – – 26 (660) 36 (915) 91 (2315) 800 363 400 A 1500 (1119) 2250 (1679) 2750 (2051) – – 200 A – – – 2250 (1678) 2500 (1865) 36 (915) 36 (915) 91 (2315) 1220 554 400 A – – – 4500 (3357) 5000 (3730) 600A (top exit) 2750 (2
Specifications Appendix A Table 29 - Power Bus and Ground Bus Description Specifications Main Horizontal Power Bus Bus Bar Material Tin-plated copper Optional Bus Bar Material Silver-plated copper Continuous Current Rating at 40°C (104°F) 1200, 2000 and 3000 A Maximum Full Load Temperature Rise 65°C (149°F) Maximum Full Load Temperature 105°C (221°F) Fault Withstand Current Rating (3 seconds) 60 kA RMS SYM (96 kA ASYM) Type of Bus Bracing Molded glass polyester Anti-hygroscopic Dimensions
Appendix A Specifications Table 30 - 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 2R to 24R 19R, 38R Interrupting Ratings : 2.4 kV to 7.2 kV A480R – 5.0/2.4 kV A072 – 7.2 kV A051B – 5.0/2.
Specifications Appendix A Table 31 - Control Wire and Power Wire Description Specifications Control Wire All Medium Voltage structures shall be equipped with control wire which meets the following specifications: Type TEW, Stranded Copper Wire (Tinned) AWG Size (Control Circuit) #14 AWG – 1.5 mm2 AWG Size (Current Transformer Circuit) #12 AWG – 2.
Appendix A Specifications Notes: 158 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Appendix B Parameter Information Parameter List Table 32 - Parameter List Group Parameter Description Metering Basic Set Up Dual Ramp Volts Phase A-B Volts Phase B-C Volts Phase C-A Current Phase A Current Phase B Current Phase C Watt Meter Kilowatt Hours Elapsed Time Meter Reset Parameter Number 1 2 3 4 5 6 7 8 9 10 Units V V V A A A KW/MW KWH/MWH Hours Power Factor Mtr Therm Usage Motor Speed SMC Option 11 12 13 14 % % Motor Connection Line Voltage Starting Mode 15 16 17 Ramp Time Initial
Appendix B Parameter Information Group Parameter Description Parameter Number Units Min / Max Default Settings Basic Set Up Stop Mode(1) 32 Soft Stop Linear Speed SMB(2) Accu-Stop(2) Soft Stop Stop Time 33 SEC 0…120 0 Basic Set Up/Accu-Stop Braking Current 35 Preset SS/Accu-Stop Slow Speed Sel 39 % FLC 0…400 0 SS Low SS High SS High Slow Speed Dir 40 SS FWD SS REV SS FWD Slow Speed Cur 41 % FLC 0…450 0 Slow Running Cur 42 % FLC 0…450 0 Accu-Stop Stopping Current
Parameter Information Group Parameter Description Parameter Number Ground Fault Gnd Flt Enable 72 Gnd Flt Level 73 Gnd Flt Delay Min / Max Default Settings Disable Enable Disable A 1.0…5.0 2.5 74 SEC 0.1…250.0 0.5 Gnd Flt Inh Time 75 SEC 2.25 10 Gnd Flt A Enable 76 Disable Enable Disable Gnd Flt A Lvl 77 A 1.0…5.0 2.
Appendix B Parameter Information Group Parameter Description Parameter Number Basic Set Up Aux 1 Config(1) Units Min / Max Default Settings 107 Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass External Bypass Aux 3 Config 108 Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC Network Network NC External Bypass Alarm Aux 4 Config 109 Normal Normal NC Up To Speed Up To Speed NC Fault Fault NC Alarm Alarm NC N
Parameter Information Group Linear List Basic Set Up Tuning and Special Parameters (Visible with 6.001 and later firmware.) (Visible and writable only with Password 1196 on 5.00n and earlier firmware.
Appendix B Parameter Information Notes: 164 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
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 71, 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.
Appendix C 1560E and 1562E Relay Control If the motor has started, the unit is in the bypass mode, and a trip occurs within the SMC Flex module or from an external protection relay, AUX4 will open the line contactor immediately. “AUX1” will remain closed for 10 seconds to protect the power electronics from any voltage transients due to opening the motor circuits. A trip due to an overload or fault condition will result in a “coast” stop.
1560E and 1562E Relay Control Appendix C contactor. The unit initiates a controlled stop sequence, followed by opening of “Aux #4”, which opens the main contactor. An uncontrolled, or coast stop, can be achieved via DPI or by opening the connection on terminal 18 (i.e. by pressing “Coast Stop” button). When using the optional HIM, pressing the “Jog” button will initiate the optional stop maneuver, and pressing the “O” button will initiate a coast stop.
Appendix C 1560E and 1562E Relay Control Bulletin 1560E • Basic Control – With Controlled Stop When wired as shown in Figure 76, the controller operates much the same as described above for the Standard module. The control signal uses terminal 16 instead of 17, and a “coast” stop can be achieved by opening the connection to terminal 17. It is more important in this configuration to integrate the control circuit of the 1560E with the existing controller, for better control of the Stop option.
1560E and 1562E Relay Control Appendix C With the Local-Off-Remote selector switch in the “Remote” position, terminal 18 of the SMC Flex module is energized, allowing start and stop maneuvers to be executed via DPI. When a “Start” is executed, the “Aux #4” contact closes, which serves as an interlock with the main contactor (or breaker) in the existing starter. As with the other control schemes, the SMC Flex module closes “Aux #1”, energizing “BC”, as the motor approaches rated speed.
Appendix C 1560E and 1562E Relay Control Figure 71 - Typical Bulletin 1562E Relay Control Circuit • Without Stop Control 115V H1 H3 H2 H4 CLT X1 TO SMCLEXIBTB6 0.
1560E and 1562E Relay Control Appendix C Figure 72 - Typical Bulletin 1562E Relay Control Circuit • With Stop Control 120V H1 H3 H2 H4 CLT X1 TO SMCLEXIBTB6 0.
Appendix C 1560E and 1562E Relay Control Figure 73 - Bulletin 1562E Relay Control Circuit • Without Stop Control • With DeviceNet (or DPI) Communication and Optional Local/Off/Remote 115V H1 H3 H2 H4 CLT X1 TO SMCLEXIBTB6 0.
1560E and 1562E Relay Control Appendix C Figure 74 - Bulletin 1562E Relay Control Circuit • With Stop Control • With DeviceNet (or DPI) Communication and Optional Local/Off/Remote 120V H1 H3 H2 H4 CLT X1 0.
Appendix C 1560E and 1562E Relay Control Figure 75 - Bulletin 1560E Relay Control Circuit • Without Stop Control 115V CLT H1 H3 X1 TO SMCLEXIBTB6 H2 H4 0.
1560E and 1562E Relay Control Appendix C Figure 76 - Bulletin 1560E Relay Control Circuit • With Stop Control 115V CLT H1 H3 X1 TO SMCLEXIBTB6 H2 H4 0.
Appendix C 1560E and 1562E Relay Control Figure 77 - Bulletin 1560E Relay Control Circuit • Without Stop Control • With DeviceNet (or DPI) Communication and Optional Local/Off/Remote 115V CLT H1 H3 X1 TO SMCLEXIBTB6 H2 H4 0.
1560E and 1562E Relay Control Appendix C Figure 78 - Typical Bulletin 1560E Relay Control Circuit • With Stop Control • With DeviceNet (or DPI) Communication and Optional Local/Off/Remote 115V H1 H3 H2 H4 CLT X1 0.
Appendix C 1560E and 1562E Relay Control Notes: 178 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Appendix D ArcShield Unit Information Overview ArcShield units have a robust arc resistant enclosure design that has been tested per IEEE C37.20.7 (2001). Each ArcShield structure was tested to withstand the effects of an arc flash at 40 kA for 0.5 seconds. ArcShield units provide an enhanced Type 2 Accessibility level.
Appendix D ArcShield Unit Information Exhaust Systems: Chimney or Plenum Information Plenum Option A plenum can be provided for each unit, and is to be field-mounted on the top of the unit structure (some incoming units may not have a plenum if top cable entry is required). The purpose of the plenum is to direct the hazardous flames and gases away from the top of the arc resistant enclosure.
ArcShield Unit Information Appendix D Figure 80 - Cross-section of plenum extension, dimensions in mm [inches] 584 [23] 633 [25] Plenum Exhaust Considerations The following options for locating the plenum exhaust are presented: 1. Plenum ducted to an area of the control room where arc gases are permitted to escape, with plenum extensions (see Figure 81, Figure 82 and Figure 83). 2. Plenum duct to outside of control room (see Figure 81 and Figure 82). Plan the location where the plenum will exhaust.
Appendix D ArcShield Unit Information Figure 81 - Plenum Exit Left with Extension(s) to Internal Controlled Access Area (Top View) Y L Personnel Access Barriers X Figure 82 - Plenum Exit Left with Extensions to Internal Controlled Access Area (Front View) H L Personnel Access Barriers Minimum H = 3.5 m [138 inches] Minimum L = 1.
ArcShield Unit Information Appendix D Figure 83 - Chimney Exhaust Space Requirements H H H1 Minimum H1: 1.
Appendix D ArcShield Unit Information Additional Notes The walls of the plenum exit area must be capable of withstanding the pressure generated. Any painted surfaces which face direct contact with the arc products may ignite. Flame suppression is recommended. The exit point can also be outside the building. Ensure exit area can not be blocked by ice, snow, vermin nests. Access barriers are recommended as a means of restricting access by personnel while the equipment is energized.
Appendix E ArcShield Plenum Installation Instructions The following instructions are provided to ensure the proper installation and function of plenum components supplied with ArcShield enclosures. Refer to Appendix D for additional information related to ArcShield plenums before attempting to follow these instructions. Recommended Torque Values 1/4-20 Thread Fasteners – 7.
Appendix E ArcShield Plenum Installation Instructions Figure 84 - Plenum Exhaust Label DANGER DANGER ARC FLASH HAZARD HAZARD D’ARC ÉLECTRIQUE PRESSURE RELIEF EXIT SORTIE DE L’ÉVENT AREAS TO BE: - INACCESSIBLE TO PERSONNEL WHILE EQUIPMENT ENERGIZED. - FREE OF OBSTRUCTIONS (REFER TO USER MANUAL). SEVERE INJURY OR DEATH MAY RESULT. 186 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 RÉGION ÊTRE: - INACCESSIBLE AUX PERSONNEL PENDANT QUE L’ÉQUIPEMENT EST SOUS TENSION.
ArcShield Plenum Installation Instructions Appendix E Figure 85 - Various Plenum Components Available General Plenum Layout for ArcShield Line-up 18" wide Plenum Fastened directly over the 0.5 m (18 inch) wide cabinet 26" wide Plenum Fastened directly over the 0.7 m (26 inch) wide cabinet 36" wide Plenum Fastened directly over the 0.
Appendix E ArcShield Plenum Installation Instructions Figure 86 - ArcShield Line-up Sealed end 36" Exhaust extension Exhaust end Plenum exhaust can be on the left or right hand end of the line-up. Pictures and figures in this procedure are shown for a right hand exhaust exit direction. Also shown is an optional vertical (top) direction exhaust extension (see Figure 100).
ArcShield Plenum Installation Instructions Appendix E Cabinet Preparation In preparation for mounting Plenum, remove 1/4-20 fasteners from the Relief vent on the top of the MV enclosure. Leave the (4) corner fasteners in place (see Figure 89). Figure 88 - Typical Relief Vent Fasteners (top view) Figure 89 - Relief Vent Relief Vent Do not remove (4) corner fasteners Remove Fasteners The Plenums are designed to fit over the fastener heads at the (4) corners of the Relief vent.
Appendix E ArcShield Plenum Installation Instructions Figure 90 - Plenum Placement Use recommended torque value for 1/4-20 fasteners TIP STEP 2 – Alignment of “Sideby-Side” Plenums Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place. Plenums mounted side-by-side must be fastened together through the aligning holes using 5/16-inch supplied hardware (see Figure 91).
ArcShield Plenum Installation Instructions STEP 3 – Sequence of Final Assembly Appendix E All Plenums in a Line-up must be mounted to the top of each enclosure and to the Plenum directly beside it before the front duct sections are re-attached (see Figure 87). Figure 92 - Sequence of Final Assembly End Cover Plate The “End Cover Plate” must be mounted on the closed end of the Line-up at this time during the assembly using 5/16-inch hardware (see Figure 92 Left side).
Appendix E ArcShield Plenum Installation Instructions STEP 5 – Extension and Elbow Assembly The 36" Extension components and 90° Elbow Section are to be attached using 5/16-inch hardware in the following sequence: Step 5A – See Figure 96 Step 5B – See Figure 97 Step 5C – See Figure 98 TIP The Screen Cover Plate is attached in Figure 97.
ArcShield Plenum Installation Instructions STEP 6 – Mounting Extension/Elbow to Plenum “Line-up” Appendix E As referred to in STEP 4 – Closing the Front of the Plenum Sections on page 191, the last Plenum at the exhaust side of the line-up has the front duct section removed. This allows access to fastener holes in order to mount the Extension/Elbow components (see Figure 99).
Appendix E ArcShield Plenum Installation Instructions STEP 7 – Additional Mounting Support The Extension/Elbow Assembly must have additional mounting support. 90° Elbow Section: Approximate weight 64 kg (142 lbs) 36" Extension Assembly: Approximate weight 51 kg (112 lbs) Figure 100 shows an example of how the Extension/Elbow Sections can be supported by suspension from a high ceiling. Points A, B & C show where chains or high tension cables may be connected.
Appendix F ArcShield Chimney Installation Instructions The following instructions are provided to ensure the proper installation and function of chimney supplied with ArcShield enclosures. Refer to Appendix D for additional information related to ArcShield chimney before attempting to follow these instructions. Recommended Torque Values 1/4 -20 Thread Fasteners – 7.
Appendix F ArcShield Chimney Installation Instructions Figure 102 - ArcShield Line-ups Cabinet Preparation In preparation for mounting a chimney, remove 1/4-20 fasteners from the Relief vent on the top of the MV enclosure. Leave the (4) corner fasteners in place (see Figure 104).
ArcShield Chimney Installation Instructions Appendix F Chimney Placement on Structure Once the Chimney has been lifted in place directly over the relief vent (shown in Figure 104), all 1/4-20 fasteners, removed in Cabinet Preparation on page 196, are replaced to attach the chimney to the top of the enclosure. Figure 105 - Chimney Placement Use recommended torque value for 1/4-20 fasteners TIP Use silicone caulking generously to fill any air gaps once the chimney has been securely mounted in place.
Appendix F ArcShield Chimney Installation Instructions Notes: 198 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Appendix G Spare Parts Power Stacks Table 33 - Replacement SCRs(1) Description(1) SMC Rated Voltage (max.
Appendix G Spare Parts Table 36 - Common Parts Quantity 1 per SCR pair Description (1) Part Number Sharing resistor 32.5 kΩ, 225W, two 2.
Spare Parts Appendix G Notes: 1. Reference only. 2. 1503 – For OEM products, refer to OEM-supplied documentation for specific spare parts list. 1560/1562E are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list. 3. For spare parts for starter and contactor components, refer to Documentation on page 1.
Appendix G Spare Parts Notes: 202 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
Appendix H Accessories Accessories Table 38 - Accessories Description Description/Used With Catalog Number HIM Remote Door Mounted IP66 (Type 4/12) Programmer Only 20-HIM-C3 Communication Modules Remote I/O 20-COMM-R RS 485 (DF-1) 20-COMM-S DeviceNet 20-COMM-D ControlNet 20-COMM-C EtherNet/IP 20-COMM-E Profibus® 0-COMM-P InterBus 2 0-COMM-I LonWorks 20-COMM-L ControlNet (Fiber) 20-COMM-Q RS485 HVAC 0-COMM-H Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013 203
Appendix H Accessories Notes: 204 Rockwell Automation Publication 1560E-UM051F-EN-P - June 2013
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