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178

Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019

Chapter 9

Troubleshooting

Figure 58 - Removal of SCR 2 and SCR 4 (3300…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.

Proceed to replace SCRs matched pair (SCR 2).

Note: You must replace both SCRs of a matched set.

SCR 4

SCR 2

Shoring Bar Hardware

Heatsink 2

Heatsink 5

Locating Pin

Shoring Bar

Hardware

Summary of Contents for SMC-50

Page 1: ...CENTERLINE Medium Voltage SMC 50 Motor Controller Bulletin Numbers 1503E 1560F and 1562F User Manual OriginalInstructions ...

Page 2: ...information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Labels may also be on or inside the equipment to provide specific precautions WARNING Identifies informati...

Page 3: ...al Ramp Start 20 Emergency Bypass Run Full Voltage Start 20 Stopping Modes 21 Coast 21 Soft Stop 21 Linear Speed Deceleration 22 Pump Stop 23 Motor and Starter Protection Features 24 Overload Protection 25 Underload Protection 27 Undervoltage Protection 27 Overvoltage Protection 27 Voltage Unbalance Protection 28 Current Imbalance 28 Stall Protection and Jam Detection 28 Ground Fault 29 Thermistor...

Page 4: ...neral Precautions 50 Transportation and Handling 50 Installation Site 51 Mounting 52 Grounding Practices 52 Recommended Torque Values 53 Power Connections 53 Bulletin 1562F 53 Bulletin 1560F 54 Bulletin 1503E 60 Line and Load Power Wiring 60 Interlocking 60 Installation 61 Physical Location 61 Ground Bus Bar 61 Power and Control Wiring 61 Control Cables 61 Fiber Optic Cables 62 Power Factor Correc...

Page 5: ...he HIM 85 Parameter Access Level Modification Using the HIM 86 Parameter Management 87 RAM Random Access Memory 88 ROM Read only Memory Set Defaults 88 EEPROM 89 Parameter Configuration 89 Using the START UP Configuration Tool 20 HIM A6 or 20 HIM C6S 89 Parameter Search and Configuration 93 Parameter Search and Configuration by Parameter Number 93 Parameter Search and Configuration by File Group S...

Page 6: ...Time 126 Peak Start Current 127 Total Starts 127 Total Harmonic Distortion THD 127 Line Frequency 128 Current Imbalance 128 Voltage Unbalance 129 Chapter6 Optional HIM Operation Overview 131 HIM Control Buttons 131 HIM Control Screen 132 CopyCat Function of the 20 HIM A6 133 Chapter7 Communications Overview 135 Communication Ports 135 HIM Keypad and Displays 136 Connecting the HIM to the Control M...

Page 7: ...leshooting Introduction 157 Control Module Removal 164 Real Time Clock RTC Battery Replacement 164 Voltage Feedback Circuit Tests 166 Voltage Sensing Board Replacement 167 Current Loop Power Supply 168 Circuit Board Replacement 169 Power Circuit Troubleshooting 170 Thyristor SCR Testing 170 SCR Replacement Procedure 171 Snubber and Resistor Circuit Testing 184 Snubber Resistor Replacement 186 Chap...

Page 8: ...y 241 AppendixC 1560F and 1562F Relay Control Functional Description 243 Bulletin 1562F Standard Control 243 Bulletin 1562F Programming Interface Control 244 Bulletin 1560F Standard Control 245 Bulletin 1560F Programming Interface Control 245 AppendixD ArcShield Unit Information Overview 251 ArcShield Design 251 Exhaust Systems Chimney or Plenum Option 252 Plenum Information 252 Plenum Exhaust Con...

Page 9: ...lues 267 General Plenum Layout for ArcShield Line up 268 Cabinet Preparation 268 Chimney Placement on Structure 269 AppendixG Using DeviceLogix Introduction 271 Parameters 271 Function Block Elements 271 Macro Blocks 272 Bit and Analog I O Points 272 Bit Inputs 273 Bit Outputs 273 Analog Inputs 274 Analog Outputs 275 Tips 275 Data Types 275 DeviceLogix Scratchpad Registers 275 SMC 50 Control Modul...

Page 10: ...10 Rockwell Automation Publication 1560F UM001A EN P June 2019 Table of Contents Notes ...

Page 11: ...installations contact your Rockwell Automation representative You can also call 1 519 740 4790 for assistance Monday through Friday from 9 00 a m to 5 00 p m Eastern time zone Resource Description Industrial AutomationWiring and Grounding Guidelines publication 1770 4 1 Provides general guidelines for installing a Rockwell Automation industrial system GeneralHandlingProceduresforMVControllers publ...

Page 12: ...12 Rockwell Automation Publication 1560F UM001A EN P June 2019 Preface Notes ...

Page 13: ... 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 1560F Retrofit Controller A medium voltage solid state controller designed to work in conjunction with an existing customer...

Page 14: ...oprocessor based control module Space for necessary auxiliary control and metering devices Top and bottom plates to accommodate power cables Motor overload protection included in SMC 50 control module available in Arc Resistant enclosures SMC 50 Control Module The SMC 50 control module offers a full range of starting and stopping modes as standard Soft Start with Selectable Kickstart Soft Stop Cur...

Page 15: ...imit Start 17 Selectable Kickstart 17 Pump Control Mode 18 Dual Ramp Start 20 Emergency Bypass Run FullVoltage Start 20 TIP For any of the following starting modes the motor only accelerates in the programmed time if that time and the current limit setting is appropriate for the connected load If the set time is too short or the load is too great the motor will take longer to reach full speed TIP ...

Page 16: ...time This is done using a proprietary motor speed feedback algorithm to sense motor speed NOTE An external speed sensor is NOT required This starting mode presents the least amount of stress on mechanical components An initial torque value is configured to define a motor starting value A current limit value is also available to limit the starting current throughout the linear acceleration start ma...

Page 17: ...art Figure 3 Torque Control Start Timing Diagram Current Limit Start 1 This method provides a current limit controlled start by maintaining a constant current to the motor and is used when it is necessary to limit the maximum starting current The starting current and current limit starting ramp time is user adjustable Current Limit Start can also be used in conjunction with Soft Start Torque Contr...

Page 18: ...al pump and monitors operation during start to ensure reliable pump starts 1 Consult factory if start time settings over 30 seconds are required See Appendix B for controller duty cycle ratings 2 The Pump Control option functions only for centrifugal pumps It is not suited for positive displacement piston or other types of pumps 3 The Pump Stop option functions only for a centrifugal pump running ...

Page 19: ...re 6 Pump Control Mode Timing Diagram 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 100 Time seconds Run Motor Sp...

Page 20: ...Emergency Bypass Run when Power switching devices are faulted for example shorted SCRs and any of the soft starting modes cannot be utilized When programmed for Emergency Bypass Run a Start command will first close the bypass contactor then the line contactor for an across the line Full voltage start of the motor A Stop command will open the line contactor first and allow the motor to coast regard...

Page 21: ...ring an extended stop time The voltage ramp down time is user adjustable from 0 999 seconds This load stops when the programmed stop time has elapsed or the voltage ramp drops to a point where the load torque is greater than the motor torque Stopping Mode Page Coast 21 Soft Stop 21 Linear Speed Deceleration 22 Pump Stop 23 TIP Except for Coast stop all other optional stopping modes will increase t...

Page 22: ...top time A current limit value is also available to limit the stopping current throughout the Linear Speed Deceleration maneuver Figure 11 Linear Speed Deceleration Timing Diagram Voltage 100 Time seconds StopTime Run Soft Stop ATTENTION Linear deceleration is not intended to be used as an emergency stop Such usage may result in severe injury or death Refer to the applicable standards for emergenc...

Page 23: ...opping is not intended to be used as an emergency stop See 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 IMPORTANT The Braking Control options Smart Motor Braking and Slow Speed with Braking are...

Page 24: ...ult Alarm history In addition to the fault alarm code and description a time and date stamp is provided by the SMC 50 controller s Real Time Clock RTC The Fault Buffer holds the last five faults which provide the time and date the Alarm Buffer holds the last 100 alarm events which detail the time date parameter change Start Stop Coast Operation Alarm Fault and Fault Reset As standard the SMC 50 mo...

Page 25: ...sage see Chapter 4 An Overload Fault will occur when this value reaches 100 The parameters below provide application flexibility and easy setup If the SMC 50 is used to control a multi speed motor or more than one motor the Overload Class parameter must be programmed to OFF and separate overload relays must be supplied for each speed motor The trip rating is 118 of the programmed FLC Figure 13 and...

Page 26: ... 1 100 1 2 3 4 5 10 1 2 3 4 5 10 1 2 3 4 5 10 Class 5 Class 10 Class 15 Class 20 Class 25 Class 30 Approximate Trip Time Approximate Trip Time Approximate Trip Time Approximate Trip Time Approximate Trip Time Approximate Trip Time Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC Approximate trip time for 3 phase balanced condition Hot Start Cold Start Multiples ...

Page 27: ...An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the HIM Communication if applicable and alarm contact closing Overvoltage Protection Utilizing the overvoltage protection of the SMC 50 motor operation can be halted if a sudden increase in voltage is detected The SMC 50 module provides an ...

Page 28: ...t detection helps to extend the motor s life expectancy and minimize potential damage and loss of production The current imbalance calculation is equal to the largest deviation of the three current signals RMS phase current from the average phase current divided by the average phase current Note that the power pole current is used for the current imbalance calculation Current imbalance setting is ...

Page 29: ...ation breakdowns or entry of foreign objects Detection of such ground faults can be used to interrupt the system to prevent further damage or to alert the appropriate personnel to perform timely maintenance The SMC 50 module can provide ground fault indication when used with the 150 SM2 Option Module and an external core balance current transformer Percent Full Load Current 600 Programmed StartTim...

Page 30: ...erature Table 1 defines the required PTC thermistor input and response ratings for operation with the 150 SM2 module Table 1 PTC Thermistor Input Response Ratings Figure 17 shows the required PTC sensor characteristics for operation with the 150 SM2 Option Module per IEC 34 11 2 Figure 17 PTC Sensor Characteristics per IEC 34 11 2 Thermistor Input Response Ratings Response Resistance 3400 Ω 150 Ω ...

Page 31: ...normal 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 3 can be toggled either ON or OFF The SMC 50 control module can individually identify and provide a Fault and or Alarm if a power line loss o...

Page 32: ... the power module temperature is reduced to allowable levels the fault can be cleared see Troubleshooting on page 157 for instructions Overcurrent Protection This feature provides protection to the controller from high level of current during starting and stopping The trip level is hard coded to be 9 times of the controller s rated current and this protection cannot be disabled Also SMC provides u...

Page 33: ...ses In addition the current power demand and the maximum power demand is provided Power Factor The value of the power factor is provided for each phase and as a total of all three Peak Starting Current The SMC 50 control module stores the peak average RMS motor current consumed for the last 5 start cycles Total Harmonic Distortion THD The SMC 50 control module calculates and provides user access t...

Page 34: ...e for Rated Torque Parameter 47 and Rated Speed Parameter 48 must be correctly configured The Motor Speed meter parameter is only valid when using the Linear Speed Starting or Linear Speed Stopping modes It provides the estimated motor speed during either the starting or stopping maneuver When the SMC 50 control module is not in these modes the Motor Speed meter parameter reads zero except when th...

Page 35: ...icated to a 20 COMM xx network communications module when inserted into the space alloted for module option Port 9 All four communication ports can be used simultaneously DeviceLogix DeviceLogix is an embedded control technology in selected Allen Bradley products that can control outputs and manage status information on board a device The SMC 50 control module with DeviceLogix technology can help ...

Page 36: ...control module only supports the use of DPI communication modules and DPI 20 HIM A6 Modules DPI Port Number Source 1 Front Mounted HIM HIM Bezel 2 Remote DPI top of SMC 50 control module 3 Remote DPI top of SMC 50 control module with splitter 4 1 1 When using a 20 COMM x network communication module it must physically be located in control module hardware port 9 However its DPI Port Number assignm...

Page 37: ...cription Normal Normal NC The contact state changes when the unit receives a Start Stop signal Up to Speed Up to Speed NC The contact state changes when the motor approaches rated speed Alarm Alarm NC The contact state changes when an Alarm condition is detected Fault Fault NC The contact state changes when a Fault condition is detected Network Control Network Control NC The contact state is contr...

Page 38: ...rcuit Voltage sharing resistors are connected across each SCR pair to provide static voltage balance for series connected SCRs These resistors are tapped to provide a reference for overvoltage protection circuitry on the gate driver board A voltage sensing board is used to reduce the line side and load side voltages to lower levels that can be measured by the SMC 50 control module Current Loop Gat...

Page 39: ... 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 The interface board also receives temperature feedback from the gate driver board via fiber optic cable s If the heatsink temperature rises above a set value a signal is sent to the SMC 50 to stop gatin...

Page 40: ... C TEST CLGD CT RX1 TX1 G C T L1 L2 L3 CL CT2 CT1 CT3 MTR T1 T2 T1 CAUTION MAXIMUM TWO STARTS PER HOUR WITH A MINIMUM OF FIVE MINUTES BETWEEN STARTS WIRE CONNECTIONS FOR PHASE A WIRE CONNECTIONS FOR PHASE B CONNECTIONS SHOWN FOR PHASE C CURRENT LOOP CONDUCTORS PASS THROUGH THE C T S ON THE GATE DRIVER BOARDS CLGD REMOTE EQUIPMENT SMC 50 INTERFACE BOARD IB VOLTAGE SENSING BOARD VSB GATETRANSMITTERS...

Page 41: ... C CURRENT LOOP CONDUCTORS PASS THROUGH THE C T S ON THE GATE DRIVER BOARDS CLGD REMOTE EQUIPMENT SMC 50INTERFACE BOARD IB VOLTAGE SENSING BOARD VSB GATETRANSMITTERS PHASE A PHASE B CT INPUTS TX1 TX2 TX7 TX8 TX13 TX14 TX3 TX4 TX9 TX10 TX15 TX16 TX5 TX6 TX11 TX12 TX17 TX18 RX1 RX2 RX3 TEMP POWER IN POWER OUT FROM CONTROL CIRCUIT TB1 L1 L2 N G TB7 TO SMC 50 TB5 A 6 A 5 B 4 B 3 C 2 C 1 TB6 TB21 VSB G...

Page 42: ... 50 module closes the Aux 1 Ext Bypass auxiliary contacts energizing B IV which closes the bypass contactor The motor then runs at full line voltage When the Stop button is pressed the CR relay opens terminal A2 of 150 SM4 Digital I O card that is inserted in SMC 50 module If terminal A2 is programmed to be Coast to Stop the Aux2 Normal contact opens dropping out the main contactor allowing the mo...

Page 43: ...e transients due to opening the motor circuits A trip due to an overload or fault condition will result in a coast stop Bulletin 1562F Programming Interface Control The control scheme shown in Figure 25 allows the SMC 50 to be controlled using Programming Interface Control See SMC 50 Control Module Bit Identification on page 140 for Logic Command Word bits assignment This interface includes provis...

Page 44: ...f possible it is better to have the SMC 50 module control the main contactor directly In this case the control circuit would look like and function like the descriptions above for the Bulletin 1562F Bulletin 1560F Programming Interface Control The control scheme shown in Figure 27 allows the SMC 50 to be controlled using Programming Interface Control See SMC 50 Control Module Bit Identification on...

Page 45: ...TATUS CR B IV 13 14 MODULE STATUS M IV 13 14 MODULE STATUS CR C N M M C N B M B A M B A B B IV M IV R CLT H1 H3 H2 H4 X1 X2 115V 0 6V 1 2 3 4 5 6 7 8 9 10 11 12 L1 L2 GND Aux1 Aux2 COM Enable Input 1 DC Input 2 DC 24V DC A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Aux A1 Input A1 Input A2 Input A3 Input A4 COM Aux A2 Aux A3 NC SLOT 7 150 SM4 SLOT 8 SLOT 9 DPI COMM SMC 50 EXT BYPASS NORMAL START STOP OP...

Page 46: ...IV 13 14 MODULE STATUS M IV 13 14 MODULE STATUS CR C N M M C N B M B A M B A B B IV M IV R CLT H1 H3 H2 H4 X1 X2 115V 0 6V 1 2 3 4 5 6 7 8 9 10 11 12 L1 L2 GND Aux1 Aux2 COM Enable Input 1 DC Input 2 DC 24V DC A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Aux A1 Input A1 Input A2 Input A3 Input A4 COM Aux A2 Aux A3 NC SLOT 7 150 SM4 SLOT 8 SLOT 9 DPI COMM SMC 50 EXT BYPASS NORMAL START STOP OPTION COAST ...

Page 47: ...1 2 3 4 5 6 7 8 9 10 11 12 L1 L2 GND Aux1 Aux2 COM Enable Input 1 DC Input 2 DC 24V DC A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Aux A1 Input A1 Input A2 Input A3 Input A4 COM Aux A2 Aux A3 NC SLOT 7 150 SM4 SLOT 8 SLOT 9 DPI COMM SMC 50 EXT BYPASS NORMAL START STOP OPTION COAST Emer Byp FAULT 3 4 SMC 50IB_TB6 CL_FLT From SMC 50IB TB7 CR CL_FLT CR CR CR CL_FLT ESTOP START STOP SIGNAL FROM EXISTING ST...

Page 48: ...7 8 9 10 11 12 L1 L2 GND Aux1 Aux2 COM Enable Input 1 DC Input 2 DC 24V DC A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Aux A1 Input A1 Input A2 Input A3 Input A4 COM Aux A2 Aux A3 NC SLOT 7 150 SM4 SLOT 8 SLOT 9 DPI COMM SMC 50 EXT BYPASS NORMAL START STOP OPTION COAST Emer Byp FAULT 3 4 SMC 50IB_TB6 CL_FLT From SMC 50IB TB7 CR CL_FLT CR CR CR CL_FLT ESTOP START STOP SIGNAL FROM EXISTING STARTER X O O ...

Page 49: ...equipment Safety and Codes ATTENTION Perform the installation duties correctly Errors may cause commissioning delays equipment damage or personal injury IMPORTANT For the 1503E refer to applicable documentation from OEM installation grounding interlocking and wiring This manual should be utilized in conjunction with the OEM supplied documentation and is suitable for commissioning programming calib...

Page 50: ...or frame units Round rollers can be used to assist in moving the controller to the installation site Once at the final site the pipe rolling technique can be used to place the cabinet in the desired position ATTENTION The controller contains ESD electrostatic discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing the assembly...

Page 51: ...ing on the unit size that tends to warm the air in the room Attention must be given to the room ventilation and cooling requirements to ensure that the proper environmental conditions are met F Operational altitude is 1 km 3300 ft maximum without derating Higher altitudes may require optional components Please consult Rockwell Automation factory G The area of the controller should be free of radio...

Page 52: ...operly 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 1 m 20 ft of its location and tied to the controller s ground b...

Page 53: ...binet refer to Figure 28 to Figure 30 and publication 1500 UM055 Chapter 2 To make power connections for a one high FVNR cabinet and a 1560F unit proceed as follows Make line connections within the one high cabinet Make load connections at the primary load current transformer terminals Hardware RecommendedTorque 1 4 in M6 8 N m 6 lb ft 5 16 in M8 15 N m 11 lb ft 3 8 in M10 27 N m 20 lb ft 1 2 in M...

Page 54: ...efer to Figure 31 to Figure 33 to make power connection for a 1560F unit depending on the rating of the unit Make line connections to the line connection terminals Make load connections to the current transformer terminals TIP The CT assembly can be oriented to allow either top or bottom load cable exit ...

Page 55: ...4160V with LV panels not shown Non arc resistant cabinet shown 1 1 6900V arc resistant and 600 A models available Terminal Block Assembly Load Cable Connection Point top exit Power Stack Assembly BypassVacuum Contactor Voltage Sensing Module Non Load Break Isolation Switch LineVacuum Contactor CurrentTransformers Bar type shown donut style also used ...

Page 56: ...Installation Figure 29 Incoming Line Cable Connections Rear View with Cover Removed Non Arc resistant Cabinet Figure 30 Bottom Cable Exit Configuration LV Panel Open to the left Non Arc resistant Cabinet Power Cable Lugs Ground Bus Lug Cable Duct Barrier Motor CableTerminals ...

Page 57: ...s 1560F 180 360A 2400 4160V Not available in an Arc resistant design Phase 3 Power Stack Assembly Voltage Sensing Module Load Connections top exit shown Phase 1 front through 3 back CurrentTransformers BypassVacuum Contactor Line Connections Phase 1 top through 3 bottom Phase 2 Power Stack Assembly Phase 1 Power Stack Assembly ...

Page 58: ...6900V Not available in an Arc resistant design Voltage Sensing Module BypassVacuum Contactor Phase 1 Line Connections Phase 1 Power Stack Assembly Phase 2 Power Stack Assembly Phase 3 Power Stack Assembly Phase 2 Line Connections Phase 3 Line Connections Load Connections top exit shown Phase 1 front through 3 back CurrentTransformers ...

Page 59: ...e 1 Power Stack Assembly Phase 2 Power Stack Assembly Phase 3 Power Stack Assembly Phase 2 Line Connections Phase 3 Line Connections Load Connections top exit shown Phase 1 front through 3 back CurrentTransformers IMPORTANT For retrofit units Bulletin 1560F the CEC and NEC require that branch circuit protection of theAC lineinputtothecontroller be provided by acircuit breaker or motor starter This...

Page 60: ...rlocking Hinged doors and panels which provide access to medium voltage components must be mechanically interlocked to ensure circuit isolation If a combination SMC 50 1562F is purchased from Rockwell Automation all medium voltage compartments will be mechanically interlocked such that they cannot be opened unless the isolating switch for the unit is open Each medium voltage door is interlocked to...

Page 61: ...ming end of the line up When the sections are brought together bus links are used to connect the bus bars Power and ControlWiring Controllers consisting of two or more sections will require that the power and control wiring be connected per the schematic drawings provided Control Cables Control cable entry exit should be located near the terminal blocks customer s connections are to be routed alon...

Page 62: ... has essentially zero impedance For switching sufficient impedance should be connected in series with the capacitor bank to limit the inrush current A method of limiting the surge current is to add inductance in the capacitor circuit This can be accomplished by putting turns or coils of wire in the power connections to the capacitors For more information refer to NEMA standard ICS 2 Part 2 Capacit...

Page 63: ...occur due to the fact that the motor cables are generally short in length There is very little impedance between the capacitor and SCR to limit the di dt of this capacitor charging current This can result in damage to the power semiconductors SCRs in the SMC It is essential to understand the clamping voltage of the arresters and type of grounding used in the distribution system The switching of th...

Page 64: ...an the acceleration time of the motor nuisance tripping may occur Two special applications require consideration Two speed Motors and Multi motor Protection Two speed Motors The SMC 50 control module has overload protection available for single speed motors When the SMC 50 control module is applied to a two speed motor the Overload Class parameter must be programmed to OFF and separate overload re...

Page 65: ...onal guidelines please refer to Wiring and Ground guidelines publication DRIVES IN001 Wire earth ground to control terminal 14 Use shielded wire for PTC Input Tach Input Ground Fault Input Terminate shielded wires to terminal 14 Ground fault CT must be inside or within 3 m of metal enclosure To meet produce susceptibility requirements ferrite cores need to be added to the communication lines All c...

Page 66: ...trol modules come standard with two 24V DC digital on off inputs and two relay outputs for auxiliary control functions The standard digital I O wiring terminal block is on the upper right portion of the SMC 50 module The terminal block is removable Control Wiring Specifications The following table provides the specifications for all SMC 50 module control wiring and option module terminal blocks Ea...

Page 67: ...mmon L2 3 Ground To connect to the system control ground point 4 1 3 3 When setto external bypass mode the auxiliary contact is usedto control aproperlysizedexternalcontactor andoverload once the motor is at full speed Auxiliary Relay Contact 1 rated 3 A 120V AC 1 5 A 240V AC 5 1 3 Auxiliary Relay Contact 1 rated 3 A 120V AC 1 5 A 240V AC 6 1 3 Auxiliary Relay Contact 2 rated 3 A 120V AC 1 5 A 240...

Page 68: ...68 Rockwell Automation Publication 1560F UM001A EN P June 2019 Chapter 2 Installation Notes ...

Page 69: ...Specification of project System Characteristics Job Name _________________________________ Job Number ____________________________________ Rated Voltage ______________________________Rated Current ____________S F ________________ Actual Motor Load Load Type Fan ____ Pump____ Conveyor____ Compressor____ Mixer___ ___ Other________________________________________________ Constant Torque_________orVar...

Page 70: ...lling power cables Check if there are any Power Factor Correction Capacitors refer to Power Factor Correction Capacitors on page 62 of Chapter 2 for correct installation requirements of these capacitors Check if Surge Capacitors and or Surge Arrestors are installed at the motor Open motor junction box and verify it by yourself These must be disconnected from the circuit refer to Surge Arrestor Pro...

Page 71: ...ctions are tight B Verify power fuse ratings and condition C Verify control fuse ratings and condition D Check that power cable installation has not damaged components and that electrical spacings have not been reduced E Check that fiber optic cables are fully seated in their connectors F Check that circuit board plug connectors are installed and fully inserted in their sockets G Check that the co...

Page 72: ...is 2 X VLL Volts where VLL is the rated line to line voltage of the power system The leakage current may be recorded for future comparison testing and must be less than 20 mA IMPORTANT The module should be programmed with an understanding of how the SMC functions and the characteristics of the motor and driven load Inappropriate settings may elicit unexpected results such as lack of acceleration t...

Page 73: ...s the identification of the motor parameters and the detection of the motor connection type Line or Delta The SMC 50 control module uses the motor tuning data in its control algorithm During the tuning process the motor does not turn and makes some audible noise including pulsing and buzzing The time to complete the tuning process is approximately 10 to 20 seconds but varies based on the size and ...

Page 74: ...9 Table 6 lists Parameter 194 Force Tuning along with the key motor parameters checked by the SMC 50 control module during a motor tuning cycle Table 6 Key Motor Parameters Checked During a MotorTuning Cycle TIP If a motor that is smaller or larger than normal is used for initial system testing you must perform a motor tuning cycle on the motor used in the final installation Parameter Number Param...

Page 75: ...C6 HS6 LOAD G5 HS5 THERMISTOR RR2 RR1 G3 G4 HS4 C3 HS3 C2 G2 LINE HS2 C1 G1 HS1 CS2 RS1 CS1 RS3 CS3 TB6 RX1 TX17 TX18 RX2 RX3 TX10 TX16 TX15 TX5 TX6 TX11 TX12 TX14 TX13 TX9 TX4 TX3 TX8 GDPS C 1 A 6 A 5 B 3 B 4 TB5 C 2 TX2 TX1 TX7 VSB TB21 SMC 50 INTERFACE BOARD PHASE B PHASE C TX1 RX1 S2 L1 S3 C3 S1 C1 C5 C5 S5 C4 S4 S6 T1 C5 0V5 0V6 C6 C1 0V1 0V4 C2 0V2 0V3 C3 C4 CURRENT LOOP TRANSFORMER H1 H3 H2...

Page 76: ...eedback Test Points TB5 Current Transformer Connections Module Common DO NOT CONNECT to this terminal LED Green ON when signal present at temperature feedback fibre optic receivers LED Yellow ON when Phase A gate signal active Phase A Fiber Optic Transmitters send gate signals to driver boards Phase B Fibre Optic Transmitters Phase C Fibre Optic Transmitters Temperature Feedback Fibre Optic Receiv...

Page 77: ...rface board should be lit in the following sequence DS11 A DS12 A DS5 B DS6 B DS7 C DS8 C and repeat after 2 seconds With the correct fiber optic connection to interface board the LEDs on Gate Driver Board should be lit in the same sequence Note They may appear dim depending on ambient light conditions 6 With the gate pulses on check the voltage again on each gate driver board as described in Step...

Page 78: ...nected to a bad gate driver board The power supply adapter will burn up if the gate driver board is shorted 9 A more detailed check is performed by verifying the actual gate pulses by connecting an oscilloscope between TP1 and TP3 see Figure 38 To check gate pulses the pulse generator must be enabled i e SW2 toggled up and the Portable Test Power Supply should be connected to J1 The pulse should a...

Page 79: ...ceiver The end of the connector should glow red to indicate the presence of a gate signal If it does not remove the other end of the cable from the interface board and check that the gray transmitter is emitting red light If it is the fiber optic cable must be replaced If it isn t the interface board should be replaced 11 When each gate driver circuit has been checked disconnect the power supply a...

Page 80: ...resistance tests should be performed before energizing the starter 1 Remove all power from the equipment 2 Measure DC resistance per the following chart ATTENTION If the SW2 switch is not in the open position when the SMC is energized themotorwillstartinanuncontrolledmannerandmaycausesevere damage ATTENTION Servicing energized industrial control equipment can be hazardous Severe injury or death ca...

Page 81: ...oltage Ranges The MV ratios shown above are nominal values and may be fine tuned to achieve better accuracy on the display of the SMC 50 control module While running the motor in bypass mode compare the voltage displayed on the control module to a known accurate meter connected to the same source voltage as the motor the SMC 50 is controlling Parameter 169 MV Ratio may be changed up or down to mat...

Page 82: ... the equipment Any tools or hardware used or dropped during installation and commissioning must be retrieved and accounted for 3 Check that all barriers or covers removed during installation or commissioning have been securely mounted 4 Close and secure all doors and verify function of all interlocks that prevent access to medium voltage compartments when the unit is energized 5 The controller is ...

Page 83: ...50 SM4 digital I O etc and use the SMC 50 module s general startup configuration wizard The 20 HIM A6 is typically inserted into the HIM bezel port located on the upper right of the control module Inserting the HIM into the bezel provides operation in a NEMA Type 1 environment The 20 HIM C6S a remote door mount version of the 20 HIM A6 provides operation in a NEMA 4X 12 environment and includes a ...

Page 84: ...gle Function Keys Key Function Start Starts the controller if the control module s Logic Mask is enabled for the port the HIM is connected to 1 1 If the device port is enabled and removed under power or an expansion device is removed a fault is generated The bit location for example 0 1 2 etc corresponds to the DPI port numbers Folders Accesses folders for parameters diagnostics memory functions p...

Page 85: ...des password protection by numeric code 0 65 535 to prevent unwanted modification of parameters You can view or monitor data and parameter values without entering the password but modification requires password entry The password can be modified from the PROPERTIES folder screen of the 20 HIM A6 or 20 HIM C6S as shown in Figure 42 Soft Key Description Function Multi Function Blue Scrolls through m...

Page 86: ...ain parameters To view modify the current access level perform the following steps using the 20 HIM A6 1 From the initial power up screen press the FOLDERS single function key 2 Press the forward or back arrow key until the DEV PARAM folder screen appears TIP If the default password 0 default is modified ensure the modified password is written down in a secure place There is no way to reset the pa...

Page 87: ... access level 5 Press Enter 5 to view that access level Parameter Management Before you begin programming it is important to understand how the memory is structured within the SMC 50 and used on power up and during normal operation Figure 43 Memory Block Diagram Linear List File Group Changed Parameters Param Access Level AUTO F 00 Stopped 0 Amps Allen Bradley ESC DEV PARAM SMC 50 Control Module M...

Page 88: ...ule comes with factory default parameter values These settings are stored in non volatile ROM and are displayed the first time you enter the Program mode via the Linear List or File Group mode using the HIM To restore factory parameter defaults 1 Navigate to the Memory folders screen with Port 00 displayed 2 Select highlight the Set Defaults line then press ENTER 5 The following text is displayed ...

Page 89: ...or example Soft Linear Pump etc and stopping for example Coast Pump etc modes are displayed on the HIM via this tool Not all parameters are configured with this tool You can configure any non configured startup parameters by using the parameter number or File Group search method See Basic Configuration using the HIM on page 112 AccessingtheGeneralSTARTUPTool 1 Select the FOLDERS single function ke...

Page 90: ...red selection 2 Enter the desired value then press the ENTER soft key TIP Depending on the answers to the Start and Stop processes some screens may not be displayed EXAMPLE If Soft Start Linear Speed or Pump Start is selected Then StartingTorque MaxTorque RatedTorque and Rated Speed will not be displayed Reason These parameters are specific to theTorque Start parameter group Allen Bradley Abort SM...

Page 91: ...pressing the ENTER soft key to move onto the next parameter If necessary press the ESC soft key to review the previous parameter TIP If you enter an incorrect value Press the ESC soft key to return to the previous screen then enter the desired value Use the left arrow soft key to delete asingledigitatatimefrom thedatafieldto enter thecorrectdigit If a group of selections is displayed the left arro...

Page 92: ... RampTime RampTime RampTime RampTime RampTime Current Limit Current Limit Current Limit Current Limit InitialTorque InitialTorque InitialTorque Starting Max Torque RatedTorque Rated Speed Linear Speed StopTime StopTime StopTime Soft Stop Pump Stop Coast Input 1 Overload Class Motor FLC Input2 OL Class 2 Input1orInput2 Overload Select Input1orInput2 Dual Ramp Done Aux 2 Config Aux 1 Config Starting...

Page 93: ...arameter number search and modification perform the following steps ParameterSearchandConfigurationbyParameterNumber 1 Ensure that the initial controller Power Up screen appears on the HIM 2 Using the PAR soft key type the desired parameter number to display press the ENTER soft key then press the EDIT soft key The following screen appears 3 Press ENTER to load the changed value into memory TIP To...

Page 94: ... on page 109 of this chapter ParameterSearchandConfigurationbyFile Group SMC 50ControlModuleCategorySearch 1 From the HIM Power Up screen press the FOLDERS single function key 2 Press the LEFT or RIGHT arrow key until the screen displays DEV PARAM Ensure Port 00 SMC 50 control module is selected from the PORTS screen 3 Using the DOWN arrow key scroll to the File Group selection then press ENTER 5 ...

Page 95: ...y to save the value 9 Press the ESC key to return to the Basic category 10 To modify another parameter in the Basic category follow steps 5 though 7 To return to a higher level category press the BACK arrow key TIP Using the DEV PARAM folder screen and the File Group selection the controller parameters can be selected and configured by functional category See the Parameter File Group Structure on ...

Page 96: ...mit Level 2 UTS Level A Aux 1 Config Total R Phase Shift 20 A Overload Class InitialTorque InitialTorque 2 Stall Position A Aux 1 Invert Coupling Factor Phase Shift 30 A RampTime StartingTorque StartingTorque 2 Stall Level A Aux 1 On Delay Inductance Phase Shift 40 A InitialTorque Service Factor MaxTorque MaxTorque 2 V Shut Off Level A Aux 1 Off Delay Speed PGain A Phase Shift 50 A MaxTorque Kicks...

Page 97: ...e ConnectedWye or Inside the Delta 1 Line Delta Auto Detect Auto Detect LineVoltage Select the value of line voltage being used in the system You must enter the correct line voltage value for the voltage protection functions to work properly 0 15 000V 4160V Starting Mode This mode must be programmed for Soft Start Soft Start 5 6 SoftStart 5 6 RampTime Programsthetimeperiodthatthecontrollerwillramp...

Page 98: ...rt 0 100 000 N m 10 N m Rated Speed NOT used for a Soft Start 750 900 1000 1200 1500 1800 3500 3600 rpm 1800 rpm 1 In the AUTO Detect default selection the controller automatically checks the motor configuration 2 Enter a value to limit the current but not low enough to inhibit the start cycle 3 The stopping mode does not need to match the starting mode for example a Soft Start can have a stop mod...

Page 99: ...e control function of the Auxiliary Output Contact 2 wired across control terminal 6 and 7 Overload Class Required for motor protection Lets you select the time to trip for the built in Motor Overload This selection is based on the type of motor being used and the application it is being applied to 5 30 10 Service Factor Required for motor protection This programmed value is taken directly from th...

Page 100: ...oft Stop Linear Speed Pump Stop Coast StopTime Programs the amount of time desired to ramp from full to zero voltage for Soft Linear and Pump Stop mode Actual ramp stop time depends on the stopping mode selected and load inertia 0 999 s 0 s Input 1 Programs the desired operation of the Control Module to a change in status of Input 1 wired to control terminal 11 24V DC Disable Start Coast Stop Opti...

Page 101: ...ion Options DefaultValue Motor Config Setting for the motor configuration Line ConnectedWye or Inside the Delta 1 Line Delta Auto Detect Auto Detect LineVoltage Select the value of line voltage being used in the system The correct line voltage value must be entered for the voltage protection functions to work properly 0 15 000V 4160V Starting Mode This mode must be programmed forTorque Ramp Torque...

Page 102: ...50 control module s Reset button for 10 seconds with the motor stopped 6 You can also program a start delay time to delay starting for a period of time after the initiation of the START command You can access the Start Delay parameter from the Group Starting selection See Table 11 7 Kickstart is available when usingTorque Start You must configure a Kickstart Level andTime if you use this mode is A...

Page 103: ...ly from the motor nameplate 1 2200 A 1 A StartingTorque NOT used for Pump Start 0 300 RMT 100 RMT MaxTorque NOT used for Pump Start 0 300 RMT 250 RMT RatedTorque NOT used for Pump Start 0 100 000 N m 10 N m Rated Speed NOT used for Pump Start 750 900 1000 1200 1500 1800 3500 3600 rpm 1800 rpm 1 In the AUTO Detect default selection the controller automatically checks the motor configuration 2 Enter...

Page 104: ...a 0 999 s 0 s Input 1 Programs the desired operation of the Control Module to a change in status of Input 1 wired to control terminal 11 24V DC Disable Start Coast Stop Option Start Coast Start Stop DualRamp OLSelect Fault Fault NC Clear Fault Emerg Run Start Coast Input 2 Programs the desired operation of the Control Module to a change in status of Input 2 wired to control terminal 10 24V DC Disa...

Page 105: ...ured for Aux Control using the AuxX Config parameter is under control of its associated bit fromthe Aux Control Parameter 180 See Parameter 180 information for bit assignments NOTE This function enables forcing an output ON or OFF ATTENTION ForOverloadProtection itiscriticalthatyouenterthedatainto the SMC 50 control module as itappears on the motor nameplate TIP The Stop mode selected in the Basic...

Page 106: ...educed output voltage torque level for the Profile 2 Voltage Ramp to the motor is established and adjusted with this parameter The torque level at which the ramp begins for Profile 2 NOTE Not used forTorque Ramp 0 90 LRT 70 LRT StartingTorque 2 StartingTorque 2 For aTorque Ramp Start the programmed initial or start torque point for Profile 2 This parameter is not used for other starting modes 0 30...

Page 107: ...he desired group 2 Press ENTER number 5 from keypad to display the associated bit parameters PROPERTIES AUTO Stopped 0 Amps Allen Bradley ESC Port 00 Param File Group F FILE Motor Protection GROUP Overload GROUP Underload GROUP Undervoltage GROUP Overvoltage PROPERTIES AUTO Stopped 0 Amps Allen Bradley ESC Port 00 Param File Group F FILE Motor Protection GROUP Overload Motor Fault En Motor Alarm E...

Page 108: ... 1 to enable or 0 to disable then press ENTER to load the change into the control module TIP The UPPER and LOWER soft key allows for switching between the upper 16 to 31 and lower 0 to 16 bits PROPERTIES AUTO Stopped 0 Amps Allen Bradley ESC PAR Port 00 Dev Param 230 Motor Fault Enable 0000 0000 0000 0000 Bit 01 Underload EDIT UPPER F PROPERTIES AUTO Stopped 0 Amps Allen Bradley ESC Port 07 Host P...

Page 109: ...Time 2 THDVb Current Average Volts Phase B C Current Phase B Real Power B Apparent Power B StartTime 3 RunningTime THDVc Torque Volts Phase C A Current Phase C Real Power C Apparent Power C StartTime 4 Energy Savings THDVave Motor Speed Volts P N Ave Current Imbal Real Demand Apparent Demand StartTime 5 MotorTherm Usage THD Ia Power Factor Volts Phase A N Max Real Demand MaxApparent Demand Peak Cu...

Page 110: ...pTime MaxTorque Num of Periods BA Aux Control Transient Mag A Phase Shift 100 A Input 1 RatedTorque Rated Speed Ping Degree A Pings A Table 21 Motor Protection Group Motor Protection File Group Parameters Overload BA Underload BA Undervoltage BA Overvoltage BA Jam BA Stall BA Real Power BA Reactive Power BA Motor Fault Enable Motor Fault Enable Starter Fault Enable Starter Fault Enable Motor Fault...

Page 111: ...Lag PF A Delay Voltage Unbal F Delay Current Imbal A Level THDV A Level THD I A Delay MVAR Un F Level MVA Un F Level Lead PF F Level Lag PF F Level THDV A Delay MVAR Un F Delay MVA Un F Delay Lead PF F Delay Lag PF F Delay Voltage Unbal A Level Current Imbal A Delay MVAR Un A Level MVA Un A Level Lead PF A Level Lag PF A Level MVAR Un A Delay MVA Un A Delay Lead PF A Delay Lag PF A Delay Voltage U...

Page 112: ...1 Press the FOLDERS single function key Communications File Group Parameters Communications Masks BA Data Links BA Logic Mask Data In A1 Data Out A1 Logic Mask Act Data In A2 Data Out A2 Write Mask Cfg Data In B1 Data Out B1 Write Mask Act Data In B2 Data Out B2 Port Mask Act Data In C1 Data Out C1 Data In C2 Data Out C2 Data In D1 Data Out D1 Data In D2 Data Out D2 Utility File Group Parameters P...

Page 113: ...ile Group selection For additional information using the FOLDERS function of the HIM see the 20 HIM A6 user manual publication 20HIM UM001 TIP Parameters can be restored to factory defaults using its respective Parameter Management parameter or the Set Defaults function from the HIM s memory screen Ensure the correct port number of the device to be restored is displayed before restoring AUTO F 09 ...

Page 114: ...he display will show the current setting of the input 3 Press the EDIT soft key to change the selected input function 4 Use the up or down arrow to select the desired function for example Start Stop Coast etc then press the ENTER soft key to load the selection If necessary use the back arrow to return to the previous selection For additional information using the FILE GROUP function of the HIM see...

Page 115: ...lay or Aux X Off Delay then press ENTER keypad or soft key 3 Modify the auxiliary relay output as desired If necessary use the back arrow to return to the previous selection DigitalI OOptionModuleParameterList The allowable selections for the 150 SM4 are listed in Table 24 TIP Before proceeding with the following steps perform steps 1 through 4 in Basic Configuration using the HIM PROPERTIES AUTO ...

Page 116: ... Aux 1 Off Delay 0 0 10 0 0 0 R W seconds X 10 Aux 2 Config Normal UTS Up to Speed Fault Alarm Ext Bypass Ext Brake DeviceLogix Aux Control 2 Network 1 Network 2 Network 3 Network 4 Fan Control Normal R W NA X 11 Aux 2 Invert Disable Enable Disable R W NA X 12 Aux 2 On Delay 0 0 10 0 0 0 R W seconds X 13 Aux 2 Off Delay 0 0 10 0 0 0 R W seconds X 14 Aux 3 Config Normal UTS Up to Speed Fault Alarm ...

Page 117: ... first START occurs after the 150 SM2 installation and when the CT Enable Parameter X 12 Enable after a Load Defaults occurs and when you force tuning of the SMC 50 control module through the Force Tuning Parameter 194 or the HOLD TO TEST button on the SMC 50 control module is held for 10 seconds when stopped To configure the 150 SM2 follow the steps in Basic Configuration using the HIM on page 11...

Page 118: ...R Bit 0 Disable Bit 1 Enable X 2 Fault Enable Bit 0 PTC Bit 1 Ground Fault R W Bit 0 Disable Bit 1 Enable X 3 Alarm Enable X 4 Restart Enable X 5 Turns Ratio 2 100 2000 1000 R W NA X 6 Ground Fault Level 3 0 00 5 00 2 5 R W Amps X 7 Ground Fault Delay 0 1 250 0 0 5 R W Seconds X 8 Ground Fault A Level 0 00 5 00 2 5 R W Amps X 9 Ground Fault A Delay 0 1 250 0 0 5 R W Seconds X 10 Ground Fault Inh T...

Page 119: ... 150 SM6isconnectedtotheSMC 50controlmodule Thisportnumberisdisplayed on the HIM screen below the AB brand logo 2 ConfigureTurns Ratio to the value of the Ground Fault sensor CTTurns Ratio for example 825 CBCT 100 1 Set X 5 to 100 3 The sensing range of the module 4 InhibitTime lets you inhibit disable ground fault protection for the time selected during starting Table 25 150 SM2 Parameters Contin...

Page 120: ...120 Rockwell Automation Publication 1560F UM001A EN P June 2019 Chapter 4 Programming Notes ...

Page 121: ...oup File Monitoring screen appears with seven GROUP metering selections Metering Basics Metering Volts Metering Current Metering Power Start Stats Monitoring Power Quality 5 Use the up or down arrow key to select the desired GROUP then press the ENTER key number 5 on the keypad 6 Select the desired parameter from the previous group selected then press the ENTER key to monitor the metering paramete...

Page 122: ...r is reset to zero with the exception of the Starts to PM Metering Parameters Current The SMC 50 control module calculates true RMS current based on Current Transformer CT feedback for all three phases It also calculates an average value of the three phase currents During Braking operation the calculated current is estimated based on time and current settings This parameter reports the three phase...

Page 123: ...alculations is 10 of the true electromechanical torque Table 28 Metering Parameters Associated with Torque Parameter Number Name Description Min Max Value DefaultValue Access Units 5 Current Average 0 15 000 0 R Amps 6 Current Phase A 7 Current Phase B 8 Current Phase C Parameter Number Name Description Min Max Value DefaultValue Access Units 1 Voltage P P Average 0 15 000 0 R Volts 2 Volts Phase ...

Page 124: ...ses a rolling window algorithm where the previous n periods are averaged TIP For Reactive Energy Parameter 278 and 279 the system will keep a positive energy which only integrates power when it is positive negative energy which only integrates power when it is negative and net energy which always integrates Table 29 Metering Parameters Associated with Power Parameter Number Name Description Min Ma...

Page 125: ...ers on page 122 Elapsed Time 2 is similar to Elapsed Time Elapsed Time 2 differs in that you cannot reset it and will count up to 50 000 hours and then hold that value it will not roll over Table 31 Metering Parameters Associated with Elapsed Time 283 Apparent Power A 1000 000 0 000 R MVA 284 Apparent Power B 285 Apparent Power C 286 Apparent Power 287 Apparent Energy MVAH 288 Apparent Demand MVA ...

Page 126: ...00 Table 33 Metering Parameters Associated with Motor Speed Actual StartTime The SMC 50 control module logs the start time of the last five motor starts and stores that information in Parameters 24 through 28 The start time data is stored in a first in first out method so the record of the last five starts is always maintained Table 34 Metering Parameters Associated with Actual Start Time TIP When...

Page 127: ...ents current through controller Power Pole 1 In addition the average THD is calculated for both Line Voltage and Phase Current The controller algorithm uses a round robin approach to gather the six signals by sampling one signal and then calculating the THD value for that signal In other words each power cycle current and voltage THD are calculated for a phase then for the next phase and so on Par...

Page 128: ...module provides a calculated Current Imbalance value The Current Imbalance calculation is equal to the largest deviation of the three RMS phase current signals from the average RMS phase current divided by the average Note that the controller Power Pole Current is used for the Current Imbalance calculation Table 39 Metering Parameters Associated with Current Imbalance Parameter Number Name Descrip...

Page 129: ...alculation is equal to the largest deviation of the three RMS phase voltage signals from the average RMS phase voltage divided by the average Note that the phase to neutral voltage is used in the calculation for voltage unbalance Table 40 Metering Parameters Associated with Voltage Unbalance Parameter Number Name Description Min MaxValue Default Value Access Units 296 Voltage Unbalance 0 100 0 R ...

Page 130: ...130 Rockwell Automation Publication 1560F UM001A EN P June 2019 Chapter 5 Metering Notes ...

Page 131: ...Table 41 20 HIM A6 Control Button Functionality Standard Control IMPORTANT You must enable the logic mask port before you initiate control commands except for Stop which always initiate a Coast to Stop command SeeControl Enable on page 137 for instructions ATTENTION The Bulletin 20 HIM A6 LCD module s stop push button is not intended to be used as an emergency stop See applicable standards for eme...

Page 132: ...red stop button provides a coast stop and or reset a fault Displays the Control Screen with the Jog button The jog button initiatesa pumpstop maneuver IMPORTANT To navigate from the Control Screen to another HIM menu screen you must press the ESC soft key This deactivates the Control Screen and displays the previous screen Label Name Function ESC Escape Reverts back to the previous screen PROPERTI...

Page 133: ...M A6 user manual 20HIM UM001 Label Name Function JOG Stop Option for controller REF NA HELP Displays Rockwell Automation Drive sTechnical Support direct phone number website address and email address REV NA EDIT REF NA FWD NA REMOVE HIM AllowsHIM removalwithoutcausing a faultifthe HIMisnot the last controlling device TheREMOVE HIM label is notavailable when the HIM has a manual control of the host...

Page 134: ...134 Rockwell Automation Publication 1560F UM001A EN P June 2019 Chapter 6 Optional HIM Operation Notes ...

Page 135: ...ication module being used Table 45 shows a list of available modules Table 45 Communication Card Selection by ProtocolType Communication Ports The SMC 50 control module supports four DPI ports for communication Port 1 is for the front mounted bezel Human Interface Module HIM Ports 2 and 3 are supported through the serial connection on the top of the device and are typically used to interface with ...

Page 136: ...at enables start stop control from a HIM Figure 47 SMC 50 Control Module with a HIM Table 46 Description of Ports TIP TheSMC 50controlleronlysupportstheuseofDPIcommunicationmodules and DPI 20 HIM A6 Modules DPI Port Number Source 1 Front Mounted HIM HIM Bezel 2 Remote DPI top of SMC 50 control module 3 Remote DPI top of SMC 50 control module with splitter 4 1 1 When using a 20 COMM x network commu...

Page 137: ...controller s DPI ports 1 2 3 or 4 To enable motor control from either of the four ports using a connected 20 HIM A6 the following steps must be performed from the SMC 50 control module standard power up screen 1 Press the key Use the right or left arrow key on the keypad to display the 00 DEV PARAM folder screen 2 Select highlight the File Group 3 Press the enter key The Port 00 Param File Group s...

Page 138: ...port then press EDIT Table 47 Logic Mask and Logic Mask Active Parameter Specifications Parameter Bit Number DPI Assignment Access Units default Number Name 148 Logic Mask 0 NA 1 2 3 4 5 15 NA Port 0 NA Port 1 Port 2 Port 3 Port 4 Port 5 15 NA R W Bit 0 disabled Bit 1 enabled 149 Logic Mask Act R Bit 0 disabled Bit 1 enabled Follows Logic Mask PROPERTIES AUTO Stopped 0 Amps Allen Bradley ESC Port ...

Page 139: ... additional information The I O message size depends on how many DataLinks are enabled The following table summarizes the I O data sizes IMPORTANT The Logic Mask must be set to 0 or the REMOVE HIM key is depressed via the HIM controller screen see Chapter 6 before you disconnect the HIMfromtheSMC 50controlmodule Ifnot theunitwillfaultona Exp Removed The Logic Mask Active Parameter 149 is a read on...

Page 140: ...ower NOT applied 1 Running Powerappliedtomotor gatingSCRsor bypass closed Power NOT applied to motor 2 Phasing ABC phasing CBA phasing 3 Phasing Active Three phase is valid No valid three phase detected 4 Starting Accel Performing a start maneuver Not performing a start maneuver 5 Stopping Decel Performing a stop maneuver coast to stop not included Not performing a stop maneuver 6 Alarm Alarm pres...

Page 141: ...alue should be divided by 100 The correctly read value is 0 85 WriteExample Motor FLC Parameter 78 The example value which is to be written to the SMC 50 control module is 75 A Because this value has one decimal place the value should be multiplied by 10 The correctly written value is 750 Bit Number Control Description 1 0 0 Stop Coast Inhibit No action 1 Start Start No action 2 Stop Option Stop M...

Page 142: ... control module supports a 32 bit DataLink allowing you to configure the device to return up to eight additional pieces of information without the need for an explicit message Criteria for Using DataLink Each set of DataLink parameters in an SMC 50 can be used by only one adapter If more than one adapter is connected multiple adapters must not try to use the same DataLink Parameter settings conten...

Page 143: ...dule can be obtained from http ab rockwellautomation com Motor Control LV Soft Starters SMC 50 resources Parameter Number Description Min Max Default Access Units 153 Data In A1 0 Max Parameter Number 1 1 The data transferred via the DataLink function is the setting content s of the parameter number as entered by you here R W 154 A2 155 B1 156 B2 157 C1 158 C2 159 D1 160 D2 161 Data Out A1 162 A2 ...

Page 144: ...144 Rockwell Automation Publication 1560F UM001A EN P June 2019 Chapter 7 Communications Notes ...

Page 145: ...The HOLD TO TEST PUSH TO RESET button lets you reset an alarm fault test for a fault condition and initiate the tuning mode Table 55 Function Initiation of theHOLD TO TEST PUSHTO RESET Button Status LED Color Device Mode SMC 50 Control Module Status Green Running Running without an alarm Green Amber Running Running with an alarm Green Flashing Ready Ready no inhibit and no fault without an alarm A...

Page 146: ...SMC 50 IMPORTANT Resetting a fault does not correct the cause of the fault condition You must take corrective action before you reset the fault The fault display remains active as long as control power is applied If you cycle control power the fault is cleared the control module re initializes and the display shows a status of Stopped unless the Fault condition still exists You can press Esc to ge...

Page 147: ...er left of the display 2 From the 00 DEV PARAM folder screen select File Group then press ENTER number 5 from the keypad The Port 00 Param File Group screen appears 3 Use the down arrow key to select highlight FILE Motor Protection then press ENTER number 5 from the keypad 4 Use the down arrow key to select GROUP History then press ENTER number from the keypad TIP Make sure that the Advanced acces...

Page 148: ...Diagnostic folder To do so perform the following steps 1 From the SMC 50 control module standard power up screen press the Folders key at the lower left of the display 2 Using the right or left arrow key display the DIAGNOSTIC folder 3 Using the up or down arrow key select either Faults or Alarms then press ENTER In this example Faults is used TIP In step 5 Fault 61 is displayed For Fault Alarm co...

Page 149: ...on then press ENTER The date and time that the Fault or Alarm occurred is displayed TIP The Fault Alarm buffers are available using Connected Components Workbench software via the Explore and Device properties drop down menu Ensure 0 SMC 50 controller is selected from the list of Devices PROPERTIES AUTO Stopped 0 Amps Allen Bradley ESC CLR Port 00 Faults 01 61 IO Config 02 7028 Exp 03 9026 Exp Rem...

Page 150: ...M Hours 50 M X C 9 PM Starts 51 M X SCR Overtemp 10 3 D X Power Quality A 52 M X Open Bypass A 11 2 D X B 53 M X B 12 C 54 M X C 13 Power QualityTHDV 55 M X No Load 14 2 M X Power QualityTHD I 56 M X Open Load A 15 2 M X Config Change 57 D X B 16 Ground Fault 58 M X C 17 Motor PTC 59 M X Voltage Unbal 18 3 M X Power Pole PTC 60 3 D X Overvoltage 19 M X I O Config 61 D X Undervoltage 20 M X Test Fa...

Page 151: ...isting Fault and Alarm Code Overview Fault Alarm Code Name F A Code Time Delay Avail F A Bit Enable Restart Enable Description F A Fault and Alarm A Alarm F Fault Line Loss A 1 N Y Y F A Loss of line power for Phase A B or C B 2 C 3 Shorted SCR A 4 N N N A A During prestart checks motor stopped not running the SMC 50 control module monitors for current flow in each individual phase NOTE InWye conf...

Page 152: ...This F A condition is not active during starting or stopping Stall 24 Y Y Y F A Condition exists and a Fault Alarm is generated if the SMC 50 control module senses that the motor is NOT Up to Speed UTS at the endofthe programmedstarting ramptimeplusthetimeprogrammed in the Stall Delay time Phase Reversal 25 N Y Y F A Fault Alarm is indicated when the incoming power to the SMC 50 control module is ...

Page 153: ...lt is always enabled TB Input 1 38 N N N A F Occurs when the Control Input is configured to generate a Fault and the input condition N O or N C is satisfied 2 39 3 40 4 41 Current Imbal 42 Y Y Y F A Exists when the calculated imbalance level is equal to or greater than the user defined Fault Alarm level Under Power Real 43 Y Y Y F A Occurs when the Real Power fallsbelowtheuser definedfault alarm l...

Page 154: ...tart This fault is also generatedwhentheinputconfigurationchangesfromonethat cannot start the motor to one that can It will also be generated when a parameterischangedfromaninputthatcanstopthemotortoonethat cannot This fault is always enabled Test Fault 62 N N N A F Occurs when the Push to Reset Hold to Test push button on the SMC 50 control module is pushed for 3 seconds but 10 seconds Under PF L...

Page 155: ...uffer for Start Event tracking Stop Option 73 N A N A N A Stop Option Event tracking Coast 74 N A N A N A Coast Event tracking ClearFault 75 N A N A N A Clear Fault Event tracking Fault 76 N A N A N A Fault Event tracking Parm Change 77 N A N A N A Parameter Change Event tracking Reserved 78 9 9 N N N Future Use System Faults 100 199 N N N A A general Fault Alarm typically associated with the SMC ...

Page 156: ...156 Rockwell Automation Publication 1560F UM001A EN P June 2019 Chapter 8 Diagnostics Notes ...

Page 157: ... circuit even when the controller is off To avoid shock hazard disconnect main power before working on the controller motor and control devices for example Start Stop push buttons Procedures that require parts of the equipment to be energized during troubleshooting testing etc must be performed by properly qualified personnel using appropriate local safety work practices and precautionary measures...

Page 158: ... Controller duty cycle exceeded Ambient temperature limit exceeded Failed thermistor Check for proper controller ventilation Check application appropriate duty cycle Wait for controller to cool or provide external cooling if ambient temperatureis high Replace power module or control module as needed Open Bypass 11 12 13 In All Modes Control voltage is low Inoperable power module bypass Check contr...

Page 159: ...port Update the control module firmware Replace defective module Expansion x028 2 In All Modes Expansion module is loose or removed Expansion module is defective Expansion module is inserted into an incompatible control module port number Controller firmware is not compatible with the expansion module Reseat and or replace loose removed module and tighten module screws Replace defective expansion ...

Page 160: ...plication Repair replace the condition causing the high MVAR power draw Modify the programmed fault alarm parameters to better suit the application Disable the fault alarm feature Und PwrApp 1 47 Running Abnormally reduced apparent MVA power draw by the motor Programmed settings are incorrect for the application Repair replace the condition causing the reduced MVA power draw Modify the programmed ...

Page 161: ...damaged To reset theTest fault press the Push to Reset Hold toTest push button for less than two seconds NOTE Only use the Push to Reset push button when absolutely necessary Attempt to dislodge the push button or replace the control module if necessary Und PF Lag 63 In All Modes A lagging PF is abnormally under the typical value less inductance or more capacitance has been introduced to the power...

Page 162: ...ot provide To understand what is an abnormal running operation you need to determine a normal or typical value usually established during system startup 2 X indicates a port number in which the expansion module resides in the SMC 50 control module 3 If controller based motor overload is disabled external motor overload protection should be used Table 58 Fault Display Explanation Continued Display ...

Page 163: ...it setting Increase kickstart time or turn off Motor stops too quickly with Soft Stop option Time setting Verify the programmed stopping time and correct if necessary Motor stops too slowly with Soft Stop option Stopping time setting Misapplication Verify the programmed stopping time and correct if necessary The Soft Stop option is intended to extendthestoppingtimeforloadsthat stop suddenly when p...

Page 164: ...hen the control power is not applied to the SMC 50 the operation of the RTC is maintained by an off the shelf Lithium CR2032 coin cell battery The battery must be replaced if the SMC 50 s low battery alarm is activated To replace the battery 1 Perform the steps that are required to remove the control module See the control module installation instructions publication 150 IN078 2 Locate the battery...

Page 165: ...onmental codes 4 With the positive symbol of the new battery facing upward properly seat the battery into place 5 Perform the steps that are required to replace the control module See the control module installation instructions publication 150 IN078 6 Reprogram reset the clock Remove and replace battery with postive symbol facing upward Bottom Side of SMC 50 ...

Page 166: ...ol circuit to close the line contactor without applying a start signal to the SMC 50 module In this case the three line voltages Line A Line B Line C measured with respect to ground should be approximately 1 volt rms It is important that the level in each phase is the same as the other phases within 1 If any voltage is well outside this range there may be a problem either with the system voltage o...

Page 167: ...Replace with the new assembly securing with all 4 nuts and washers See Figure 50 7 Replace ring lugs on terminals Plug in ribbon cable making sure that it is positioned properly and fitting is secure locking mechanism is engaged 8 For personnel and equipment safety ensure both grounding connections are reconnected to the sensing board Figure 50 Sensing Board with mounting hardware placement SHOCK ...

Page 168: ...ply 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 Figure 51 Current Loop Power Supply The current loop power supply provides a current of 50 AC to each SCR power module phase assembly If this current is not detected and fed back to the interface boards stop maneuvers will not func...

Page 169: ...ing the hardware or pressing down onto nylon stand offs Connect all wires cables and connectors Ensure that all switch and or jumper settings on the new board are identical to those on the old board and correct for the application ATTENTION Some circuitboards maycontain CMOS components which can be destroyed by static charges generated by friction of materials made with synthetic fibres Use of dam...

Page 170: ...as 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 Location of Probes 1000V 1300V 1500V 2300V 3300V 4160V 5500V 6900V CathodetoCathode KΩ 1 1 Measured between terminals Cathode on CLGO Boards upper two or between two wi...

Page 171: ...ill 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 8 Place the module on a flat surface see Figure 55 Figure 58 and Figure 64 When tilting the module ensure that wires are not damaged TIP This procedure applies to 180 A and 360 A units 5000V only IMPORTANT Refer to OEM documentation for SCR stac...

Page 172: ...sinks together as you proceed down the stack Make sure the SCRs are positioned and oriented properly Refer to Figure 55 Figure 58 and Figure 64 6 Ensure that the SCRs are properly seated on the locating pins in the heatsinks and rotate each SCR so that the leads are oriented toward the front right side of the assembly 7 Advance the center nut until the spring assembly engages the top heatsink Make...

Page 173: ... 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 fiber 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 lb ft 4 Install gate driver board ensuring that the locking tabs on the nylon circuit board ...

Page 174: ...174 Rockwell Automation Publication 1560F UM001A EN P June 2019 Chapter 9 Troubleshooting Figure 52 Upper Low Voltage Panel and Power Cell Detail 1562F 2400 4160V 180 360A ...

Page 175: ...hase 1000 1300 1500 2400V 180 360A Figure 54 Heatsink Clamp Heatsink 1 Heatsink 3 Heatsink 2 SCR 2 SCR 1 Do not loosen Gap Center Nut Locking Nut Do not adjust IndicatingWasher 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 ...

Page 176: ...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 SCR 2 SCR 1 Shoring Bar Hardware Heatsink 1 Heatsink 3 Heatsink 2 Locating P...

Page 177: ...p SCR 1 Heatsink 1 SCR 2 SCR 3 SCR 4 Heatsink 2 Heatsink 3 Heatsink 4 Heatsink 5 Note SCR 1 and SCR 3 are a matched set SCR 2 and SCR 4 are a matched set Do not loosen Gap Center Nut Locking Nut Do not adjust IndicatingWasher 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 ...

Page 178: ...in 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 SCRs matched pair SCR 2 Note You must replace both SCRs of a matched set SCR 4 SCR 2 Shoring Bar Hard...

Page 179: ...apter 9 Figure 59 Power Module Assembly one phase 5500 6900V 180 360A Figure 60 Power Module Assembly one phase with Gate Driver Boards Removed 5500 6900V 180 360A Gate Driver Boards Line connection Load connection Load connection Board Mounting Frame Line connection Load connection ...

Page 180: ...k Assembly 180 360A Positioned on bench for SCR replacement Module retaining hardware locations 4 Heatsink 7 Heatsink 6 Heatsink 5 Note SCR 1 SCR 2 and SCR 5 are a matched set SCR 3 SCR 4 and SCR 6 are a matched set Spacer block must be flat Minimum Height 30 mm 1 25 in MaximumWidth 200 mm 8 0 in Minimum Length 400 mm 16 0 in Heatsink 1 Heatsink 2 Heatsink 3 Heatsink 4 SCR 6 SCR 5 SCR 4 SCR 3 SCR ...

Page 181: ...red To Remove SCR 1 Remove shorting bar hardware Pry Heatsinks 1 and 2 apart Extract SCR To Insert New SCR Apply thin film of electrical joint compound to surfaces of SCR Install SCR so that 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 Proce...

Page 182: ...300V 600A Figure 66 Power Module Assembly one phase 3300 4160V 600A Gate Driver Boards Line connection Load connection Heatsink Assembly Gate Driver Snubber Circuit and Sharing Resistor Frame Assembly Line connection Load connection Heatsink Assembly Gate Driver Snubber Circuit and Sharing Resistor Frame Assembly Gate Driver Boards ...

Page 183: ...UM001A EN P June 2019 183 Troubleshooting Chapter 9 Figure 67 Power Module Assembly 1 Phase 5500 6900V 600A Line connection Load connection Heatsink Assembly Gate Driver Snubber Circuit and Sharing Resistor Frame Assembly Gate Driver Boards ...

Page 184: ... 2 or 3 Replace any out of spec components See Appendix H 3 If the snubbers and sharing resistors are within tolerances check the resistance of the voltage sensing module refer to Figure 68 Remove the ribbon connector from J1 by pressing down on the locking tabs then gently pulling the connector out Take note of which tap the white high voltage wires are connected to then remove them L1 T1 L2 T2 L...

Page 185: ...R 2 R 2 2 T12 T14 T V S 6 T V S 7 T V S 8 J1 T V S 5 T V S 4 T V S 3 T V S 2 T V S 1 R 4 R 2 5 T11 T10 T9 T8 R 2 0 6 5 4 3 2 1 kV RATED VOLTAGE USA IN MADE VOLTAGE FEEDBACK GND2 GND1 PART R E B M U N R E B M U N SERIAL 24 23 2 1 R 3 7 PB To Interface Board Ground Connections Measure 11 3 kΩ V rated Tap 1 3 5 Tap 2 4 6 1 5 kV 1 9 M 2 8 M 2 5 kV 3 7 M 5 6 M 4 8 kV 6 6 M 10 0 M 7 2 kV 11 2 M 16 9 M V...

Page 186: ...ight Make sure all barriers and mechanical parts are in place and secured 5 Repeat Thyristor SCR resistance checks page 170 and Power Supply Tests page 77 Snubber Resistor Replacement When replacing the ceramic wire wound type snubber resistors use caution when handling the parts The resistor element is under a thin coating on the ceramic tube and it may be damaged if dropped struck or scraped ATT...

Page 187: ...l 1500 2400V Module Wiring 180 360 A _ _ _ LEGEND RR SHARING RESISTOR RS SNUBBER RESISTOR CS SNUBBER CAPACITOR HS HEATSINKS G GATE LEAD WHITE C CATHODE LEAD RED THERMISTOR GATE DRIVER BOARDS THERMISTOR T GD1 S1 C1 C OV S C1 G1 RS CS GD2 S2 C2 C OV S C2 G2 RR1 C1 OV1 C2 OV2 HS1 HS2 G1 C1 LINE G2 C2 HS3 LOAD ...

Page 188: ...cal 1500 2400V Module Wiring 600 A _ _ _ LEGEND RR SHARING RESISTOR RS SNUBBER RESISTOR CS SNUBBER CAPACITOR HS HEATSINKS G GATE LEAD WHITE C CATHODE LEAD RED THERMISTOR GATE DRIVER BOARDS THERMISTOR T GD1 S1 C1 C OV S C1 G1 RS CS GD2 S2 C2 C OV S C2 G2 RR1 C1 OV1 C2 OV2 HS1 HS2 G1 C1 LINE G2 C2 HS3 LOAD ...

Page 189: ...R SHARING RESISTOR RS SNUBBER RESISTOR CS SNUBBER CAPACITOR HS HEATSINKS G GATE LEAD WHITE C CATHODE LEAD RED THERMISTOR GATE DRIVER BOARDS THERMISTOR T GD1 S1 C1 C OV S C1 G1 RS1 CS1 RR1 C1 OV1 C4 OV4 HS1 HS2 G1 C1 LINE G2 C2 HS3 LOAD OV1 GD2 S2 C2 C OV S C2 G2 OV2 C2 GD3 S3 C3 C OV S C3 G3 OV3 GD4 S4 C4 C OV S C4 G4 OV4 CS2 RS2 RR2 C2 OV2 OV3 G3 C3 HS4 HS5 G4 C4 ...

Page 190: ...PACITOR HS HEATSINKS G GATE LEAD WHITE C CATHODE LEAD RED THERMISTOR GATE DRIVER BOARDS THERMISTOR OV1 GD1 S1 C1 C OV S C1 G1 RR2 C2 OV2 OV4 HS1 HS2 G1 C1 LINE G2 C2 HS3 LOAD GD3 RS2 C3 OV S3 C3 G3 OV3 CS2 GD4 S4 C4 C OV S C4 G4 OV4 RR1 C3 OV3 G3 C3 HS4 G4 C4 HS5 G5 C5 HS6 G6 C6 HS7 OV2 GD2 S2 C2 OV S C2 G2 T C S C RS1 CS1 GD5 S5 C5 C OV S C5 G5 OV5 C5 GD6 S6 C6 C OV S C6 G6 OV6 RS2 CS3 RS3 OV1 C1...

Page 191: ...Fault and or Alarm condition is activated and the parameter counter stops decrementing After the preventive maintenance is complete you can reset the Fault and or Alarm You must reload the Time to PM to the value configured and stored in the PM Hours Parameter 126 through the Meter Reset Parameter 16 via the HIM or network connection Enable the PM Hours Fault by using the PM Hours bit in the Motor...

Page 192: ... PM Starts bit in the Motor Alarm Enable Parameter 231 Table 65 Starts Protection Parameter List Safety and Preventative Maintenance The Maintenance Technician should become familiar with the layout and be aware of the basic system parameters Only qualified technicians should be allowed to work with this equipment under competent supervision General housekeeping is the key to maintaining power ele...

Page 193: ...pecified in their individual instructions If in doubt consult the nearest Rockwell Automation sales office for information Vacuum Bottles The contacts in a vacuum bottle cannot be seen or examined directly They rely on the high vacuum to operate properly and to interrupt current Visually inspect the wear of the main contacts with the contacts closed When any part of the wear indicator located on t...

Page 194: ...ce Necessary replacements should be made only at the PC board or plug in component level Solvents should not be used on printed circuit boards Where blowers are used air filters if supplied should be cleaned or changed periodically depending on the specific environmental conditions encountered For additional information see NEMA Standards Publication No ICS 1 1 1987 entitled Safety Guidelines for ...

Page 195: ...per test equipment and an appropriate inventory of spare parts For additional information see NFPA 70B RECOMMENDED PRACTICE FOR ELECTRICAL EQUIPMENT MAINTENANCE published by the National Fire Protection Association Power Components Power components should be kept clean and free of dirt and obstructions This will avoid tracking and heat buildup thereby increasing the life of the device Control Comp...

Page 196: ... today in the industry In the interim the following precautionary information is provided for your protection and for the protection of the environment Please contact the factory for any environmental information on any material in the product or with any general questions regarding environmental impact Capacitor Dielectric Fluid The fluids used in the snubber capacitors are generally considered v...

Page 197: ... local regulations and must not be disposed of with general landfill refuse In Case Of Fire This product is highly protected against arcing faults and therefore it is very unlikely it would be the cause of a fire In addition the materials used are self extinguishing i e they will not burn without a sustained external flame If however the product is subjected to a sustained fire from some other sou...

Page 198: ...198 Rockwell Automation Publication 1560F UM001A EN P June 2019 Chapter 10 Maintenance Notes ...

Page 199: ...he SMC Power section to the load R 6 Current Phase A Amps 0 15000 0 DisplaystheCurrentflowingthroughthePhaseApowerpoleof the SMC Power section to the load R 7 Current Phase B Amps 0 15000 0 DisplaystheCurrentflowingthroughthePhaseBpowerpole of the SMC Power section to the load R 8 Current Phase C Amps 0 15000 0 Displays the Current flowing through the Phase Cpower pole of the SMC Power section to ...

Page 200: ...to PM Hrs 0 10000 0 Displays the estimated time to a preventive maintenance event if enabled The scheduled time for a PM event is set by the user viathePMHoursparameter 126 Thisvaluecanberesetbythe user after an event via the meter reset parameter 16 R 22 Starts to PM 0 50000 0 Displays the estimated number of starts to a PM event if enabled The scheduled number of starts for a PM event is set by ...

Page 201: ...e voltage R 36 THDVb 0 1000 0 Measures theTHD of the applied Phase B line voltage R 37 THDVc 0 1000 0 Measures theTHD of the applied Phase C line voltage R 38 THDVave 0 1000 0 Displays the calculated average of the three voltageTHD measurements R 39 THD Ia 0 1000 0 Measures theTHD of the applied Phase A current R 40 THD Ib 0 1000 0 Measures theTHD of the applied Phase B current R 41 THD Ic 0 1000 ...

Page 202: ...ontactor Enabled 0 Start Isolate Contactor Disabled bit 10 1 Bypass Contactor Enabled 0 Bypass Contactor Disabled bit 11 1 indicates that the SMC is eady to accept a Start command The device is not faulted or in the process of stopping starting or jogging bit 12 13 0 always bit 14 Control Module Input 1 Status 1 Input Closed bit 15 Control Module Input 2 Status 1 Input Closed R 44 Motor Config 0 2...

Page 203: ...is applied to the motor for this programmed time R W 55 Kickstart Level LRT 0 90 0 Gives the user the ability to adjust the amount of current boost applied to the motor during the kickstart period R W 56 Input 1 0 14 4 Disable Start Coast Stop Option Start Coast Start Stop Reserved Reserved Dual Ramp OL Select Fault Fault NC Clear Fault Emerg Run Reserved Allows the user to select the operation of...

Page 204: ... Mode 2 0 5 2 FullVoltage Current Limit Soft Start Linear Speed Torque Ramp Pump Start Allows the user to program an alternate starting mode for the SMC 50 that suits the application FullVoltage Apply full voltage to the motor at start CurrentLimit Apply limitedcurrent fora programmed period of time Soft start Slowly increase current to load over a programmed period of time LinearSpeed Increasecur...

Page 205: ... trip class of internal solid state overload Overload fault and alarms are enabled and disabled in the Starter Fault En and Starter Alarm parameters R W 76 Overload Class 2 5 30 10 Allows user to set the internal solid state overload to an alternate trip class ThisTrip Class is used when an input configured as overload select is asserted R W 77 Service Factor 0 01 1 99 1 15 Parameter to enter the ...

Page 206: ...ime period set in MWatts Ov F Dly parameter an MWatts Ov fault will be signaled The MWatts Ov bit in the Motor Fault En parameter must be set to signal a fault R W 91 MWatts Ov F Dly Secs 0 1 99 0 1 The time period that Real Power must exceed MWatts Ov F Lvl to signal a fault The MWatts Ov bit in the Motor Fault En parameter must be set to signal fault R W 92 MWatts Ov A Lvl MW 0 1000 0 000 If the...

Page 207: ...ree phase line voltage exceed this level for the time period set in the Overvolt A Dly parameter an Overvolt alarm will be signaled The Overvolt bit in the Starter Alarm parameter must be set to signal an alarm R W 105 Overvolt A Dly Secs 0 1 99 3 0 The time period that the average three phase voltage must exceed the Overvolt A Level to signal an alarmThe Overvolt bit in the Starter alarm En param...

Page 208: ...in the Motor Alarm En parameter must be set to signal a alarm R W 118 THDV F Lvl 0 1000 1000 If the average total harmonic distortion THD on the line voltage exceeds theTHDV F Lvl for the time period set inTHDV F Dly a fault will be signaled TheTHDV bit must be set in the Starter Fault En parameter to signal a fault R W 119 THDV F Dly Secs 0 1 99 0 1 The time period that the averageTHD on the line...

Page 209: ...tage frequency that can be applied to the SMC 50beforecausingaFreqLowFLvlfault TheFreqLowbitin the Starter Fault En parameter must be set to signal a fault R W 131 Freq High A Lvl Hz 45 66 63 The highest line voltage frequency that can be applied to the SMC 50 before causing a Freq High F Lvl alarm The Freq High bit in the Starter Alarm parameter must be set to signal an alarm R W 132 Freq Low A L...

Page 210: ...entry in the fault buffer The oldest fault displayed in the fault buffer R W 143 Alarm 1 0 10000 0 First entry in the alarm buffer and is the most recent alarm to have occurred R W 144 Alarm 2 0 10000 0 Second entry in the alarm buffer R W 145 Alarm 3 0 10000 0 Third entry in the alarm buffer R W 146 Alarm 4 0 10000 0 Fourth entry in the alarm buffer R W 147 Alarm 5 0 10000 0 Fifth entry in the al...

Page 211: ...k Cfg parameter setup by the local user if someone changes it over the network bit 1 port 1 on board HIM bit 2 port 2 DPI port on control module bit 3 port 3 DPI port on control module with splitter bit 4 port 4 Internal Comm module bit 5 15 reserved R 152 Port Mask Act 0 65535 0 Displays which DPI ports are active on the control module and will accept operational commands from bit 1 port 1 on boa...

Page 212: ...ter number of the parameter that will be read to during Datalink communications A value of 0 indicates that it is disabled R W 163 Data Out B1 0 159999 0 ThisistheachannelOUTDatalinkindex holdingtheparameter number of the parameter that will be read to during Datalink communications A value of 0 indicates that it is disabled R W 164 Data Out B2 0 159999 0 ThisistheachannelOUTDatalinkindex holdingt...

Page 213: ...it is not active DeviceLogix Aux1 is controlled by DeviceLogix program AuxControl WhenanauxiliaryisconfiguredforAuxControl a bit within the parameter Aux Control controls the state of that auxiliary Network 1 With an auxiliary configured as Network 1 it is controlled over the Local Area Network LAN as Relay 1 Network 2 With an auxiliary configured as Network 2 it is controlled over the LAN as Rela...

Page 214: ...y Network 1 With an auxiliary configured as Network 1 it is controlled over the Local Area Network LAN as Relay 1 Network 2 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 2 Network 3 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 3 Network 4 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 4 R W 177...

Page 215: ...mplete its entire time ramp period This ability can help to avoid conditions where an up to speed is sensed before the motor is actually up to speed Disable Complete starting mode when up to speed detected Enable Complete starting mode when ramp time expires R W 184 V Shutoff Level 0 100 25 Provides the ability to manually adjust the threshold for the controller s voltage notch shutoff detection l...

Page 216: ...rithm This parameter is not typically modified and it is recommended that RATechnical Support be contacted for assistance before attempting to do so R W 192 Bypass Delay Secs 2 10 2 During the coast to stop the bypass contactor will be hold by this number after the Main Contactor open R W 194 ForcedTuning 0 1 1 FALSE TRUE Enables the controller s tuning algorithms to analyze the load and supplyand...

Page 217: ...ally modified and it is recommended that RATechnical Support be contacted for assistance before attempting to do so R W 208 Phase Shift 30 360 360 0 Timing parameters used in speed measurement algorithms These parameters are not typically modified and it is recommended that RATechnical Support be contacted for assistance before attempting to do so R W 209 Phase Shift 40 360 360 0 Timing parameters...

Page 218: ...on Port 9 R 224 Line Frequency Hz 0 100 0 Displays the line frequency of the three phase voltage applied to the SMC 50 at terminals L1 L2 and L3 R 225 Freq High F Dly Secs 0 1 99 0 1 Allows the user to configure the time period that the supplied line voltage frequency must exceed Freq High F Lvl parameter value before causing a Freq High fault The Freq High bit must be set in the Starter Fault En ...

Page 219: ...ulehasitsownassociatedParameter Mgmt parameter Ready Waiting for command to set factory defaults Factory Default Command for SMC to set all Control Module Writable Parameters to factory default values This command does not impact Option Module parameters R W 230 Motor Fault En BitValue 0 1 Overload Underload MWatts Over Mwatts Under MVAR Over MVAR Under MVAR Over MVAR Under MVAUnder MVAOver Curr I...

Page 220: ...ignaled R W 233 MVAR Ov F Dly Secs 0 1 99 0 1 Allows the user to enter a time value for the MVAR Over Fault delay If the current actual value of Consumed Reactive Power MVAR is greater than the MVAR OV F Lvl for a time period greater than that defined by MVAR Ov F Dly a MVAR Ov Fault will be signaled R W 234 MVAR Ov A Lvl MVAR 0 1000 0 000 Allows the user to enter a value for the Consumed Reactive...

Page 221: ...atime periodgreater than that defined by MVA Ov F Dly a MVA Ov Fault will be signaled R W 241 MVA Ov F Dly Secs 0 1 99 0 1 Allows the user to enter a time value for the Apparent Power Over Fault Delay MVA Ov F Dly If the current actual value of Apparent Power MVA is greater than the MVA Ov F Lvl for a time period greater than that defined by MVA Ov F Dly a MVA Ov Fault will be signaled R W 242 MVA...

Page 222: ... than that defined by Lead PF Ov A Dly a Lead PD Ov alarm will be signaled R W 251 Lead PF Ov A Dly Secs 0 1 99 0 1 Allows the user to enter a time value for the Leading Power FactorOverAlarmDelay LeadPFOvADly Ifthecurrentactual PowerFactorvalueisleadingmorethantheLeadPFOvALvlfor a period greater than that defined by Lead PF Ov A Dly a Lead PD Ov alarm will be signaled R W 252 Lead PF Un F Lvl 0 1...

Page 223: ...agging Power Factor Under Fault Level Lag PF Un F Lvl If the current actual Power Factor value lags less than the Lag PF Un F Lvl for a time period greater than that defined by Lag PF Un F Dly a Lag PF Un Fault will be signaled R W 261 Lag PF Un F Dly Secs 0 1 99 0 1 Allows the user to enter a time value for the Lagging Power Factor Under Fault Delay Lag PF Un F Dly If the current actual Power Fac...

Page 224: ...tage Pn Ave Volts 0 9000 0 Displays the average of the sum of the three phase voltages to neutral R 266 Voltage Phase A N Volts 0 9000 0 Displays Phase A L1 to neutral voltage R 267 Voltage Phase B N Volts 0 9000 0 Displays Phase B L2 to neutral voltage R 268 Voltage Phase C N Volts 0 9000 0 Displays Phase C L3 to neutral voltage R 269 Real Power A MW 1000 1000 0 000 DisplaystheRealPowerofthePhase...

Page 225: ...DisplaystheApparentEnergywhichisequalto ApparentPower xTime R 288 Apparent Demand MVA 1000 1000 0 000 Displays the total amount of Apparent Energy which is equal to MVAH x demand period produced or consumed by the load R 289 Max Apparent Dmd MVA 1000 1000 0 000 Displaysthemaximumapparentdemandrecordedsinceenergy meters were reset R 290 Demand Period Mins 1 255 1 Enables the user to enter the time ...

Page 226: ...d Reactive Power is less than the MVAR UnF Lvl for a period greater than that defined by MVAR Un F Dly a MVAR Un Fault will be signaled R W 302 MVAR Un F Dly Secs 0 1 99 0 1 Enables the user to enter a time value for the Generated Reactive Power Under Fault Delay MVAR Un F Dly If the current actual value for Generated Reactive Power is less than the MVAR Un F Lvl for a period greater than that def...

Page 227: ...SM4Option Module Input 3 Bit9 DisplaysstatusofControlModulePort8 150 SM4Option Module Input 4 Bit 10 Displays status of Control Module Port 9 150 SM4 Option Module Input 1 Bit 11 Displays status of Control Module Port 9 150 SM4 Option Module Input 2 Bit 12 Displays status of Control Module Port 9 150 SM4 Option Module Input 3 Bit 13 Displays status of Control Module Port 9 150 SM4 Option Module In...

Page 228: ...neutralvoltageduringthe motor start run and stop cycle The value resets to 0 when the motor starts R 316 Vc Peak Volts 0 15000 0 The peakvalue of the Phase Cline to neutralvoltageduring the motor start run and stop cycle The value resets to 0 when the motor starts R 317 Ia Peak Amps 0 15000 0 The peak value of the Phase A current during the motor start run and stop cycle The value resets to 0 when...

Page 229: ...occurs The value is overwritten if a subsequent fault occurs Bit 0 1 Ready 0 Not Ready Bit 1 1 Power Applied to Motor Gating SCRs or Bypass closed 0 Power not applied Bit 2 1 ABC Phasing 0 CBA Phasing Bit 3 1 3 phase is valid 0 No valid 3 phase Bit 4 1 Performing a Start Maneuver 0 Not Performing Bit 5 1 Performing a Stop Maneuver coast to stop not included 0 Not Performing Bit 6 1 Alarm Present 0...

Page 230: ...neral purpose datalink used to select another parameter within the SMC 50 as an input to the DeviceLogix Engine R W 341 DLX DL Input 5 0 159999 1 General purpose datalink used to select another parameter within the SMC 50 as an input to the DeviceLogix Engine R W 342 DLX DL Input 6 0 159999 1 General purpose datalink used to select another parameter within the SMC 50 as an input to the DeviceLogix...

Page 231: ...nsion Port 7 Analog Input 1 from 150 SM3 option module in Expansion Port 8 Analog Input 2 from 150 SM3 option module in Expansion Port 8 Analog Input 1 from 150 SM3 option module in Expansion Port 9 Analog Input 2 from 150 SM3 option module in Expansion Port 9 DeviceLogix Output 1 DeviceLogix Output 2 R W 349 OutputV Ref 1 100 1 N A Parameter that can be set from 1 to 100 output voltage for Resist...

Page 232: ...les user to configure the turns ratio for the GFCT being used R W SM2 06 GF Gnd Flt Level Amps 0 5 2 50 Enablestheusertoconfigurethelevel value ofgroundcurrent primary current of GFCT that determines a ground fault condition R W SM2 07 GF Gnd Flt Delay Secs 0 1 250 0 5 Setsthetimelimitthatthegroundfaultlevelmustbeexceeded before signalling a fault R W SM2 08 GF Gnd Flt A Level Amps 0 5 2 50 Sets t...

Page 233: ...ure determination of the phase shift between external CT and the internal current measuring circuitry R SM2 18 GF Phase Shift C Deg 12 5 12 5 0 Displayed result of the SMC 50 tuning feature determination of the phase shift between external CT and the internal current measuring circuitry R SM2 19 GF Parameter Mgmt 0 1 0 Ready Factory Default Ready Waiting for command to set defaults FactoryDefault ...

Page 234: ... Start Coast Start Stop Reserved Dual Ramp OL Select Fault Fault NC Clear Fault Emerg Run Reserved Allows the user to select the operation of InputTerminal A1 Option Input 1 on the 150 SM4 Digital I O Option Module Disable Disable the input ignores any assertion to Input 1 Terminal A1 Start InitiatesastartassetupbythestartparametersatInput 1 Terminal A1 High Coast Initiates a coast stop no current...

Page 235: ...r to run in emergency run mode if asserted from Input 1 Terminal A2 does not start motor High R W SM4 04 DIO Input 3 0 13 0 Disable Start Coast Stop Option Start Coast Start Stop Reserved Dual Ramp OL Select Fault Fault NC Clear Fault Emerg Run Reserved Allows the user to select the operation of InputTerminal A3 Option Input 3 on the 150 SM4 Digital I O Option Module Disable Disable the input igno...

Page 236: ...nitiates a stop maneuver as set up by the stopping parameters at Input 1 Low Start Coast if Input 1 0 Stops motor 1 Initiates a start as set up by the start parameters Start Stop if Input 1 0 Initiates a stop maneuver as set up bystoppingparameters 1 Initiatesastartassetupbythestart parameters Dual Ramp if Input 1 0 Use starting mode 1 1 Use starting mode 2 OL Select if Input 1 0 Use Motor Overloa...

Page 237: ...ary configured as Network 1 it is controlled over the Local Area Network LAN as Relay 1 Network 2 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 2 Network 3 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 3 Network 4 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 4 R W SM4 07 DIO Aux1 Invert 0 1 0 ...

Page 238: ...ary configured as Network 1 it is controlled over the Local Area Network LAN as Relay 1 Network 2 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 2 Network 3 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 3 Network 4 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 4 R W SM4 11 DIO Aux2 Invert 0 1 0 ...

Page 239: ...as Network 2 it is controlled over the LAN as Relay 2 Network 3 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 3 Network 4 With an auxiliary configured as Network 2 it is controlled over the LAN as Relay 4 R W SM4 15 DIO Aux3 Invert 0 1 0 Disable Enable Enables the user to invert the logic of the Aux3 output When disabled it is a normally open relay output contact...

Page 240: ...240 Rockwell Automation Publication 1560F UM001A EN P June 2019 Appendix A Parameter Information Notes ...

Page 241: ...y Cycle 3 600A rated current Table 70 Duty Cycles 1 3 Duty Cycle 1 Multiple of Rated Current 3 4 5 ON time in seconds 50 30 15 OFF time in seconds 300 300 300 Number of Consecutive ON OFF operations 2 2 2 RestTime in hours 1 1 1 Repeat above steps for number of sequences 1 1 1 Duty Cycle 2 Multiple of Rated Current 3 4 5 ON time in seconds 40 24 12 OFF time in seconds 300 300 300 Number of Consecu...

Page 242: ...242 Rockwell Automation Publication 1560F UM001A EN P June 2019 Appendix B Controller Duty Cycle Ratings Notes ...

Page 243: ...e AUX1 Ext Bypass auxiliary contacts closing relay BC which closes the bypass contactor The motor then runs at full line voltage When the Stop button is pressed the CR relay opens terminal A2 of 150 SM4 Digital I O card that is inserted in SMC 50 module If terminal A2 is programmed to be Coast to Stop the Aux2 Normal contact opens dropping out the main contactor allowing the motor to stop The Aux1...

Page 244: ...eme shown in Figure 75 allows the SMC 50 to be controlled using Programming Interface Control Refer to SMC 50 Control Module Bit Identification on page 140 for Logic Command Word bits assignment for DPI control This interface includes provisions for a Local mode of control as well With the Local Off Remote selector switch in the Remote position terminal A2 and A3 of the 150 SM4 DigitaL I O card wi...

Page 245: ...t condition sensed by the SMC 50 module If possible it is better to have the SMC 50 module control the main contactor directly In this case the control circuit would look like and function like the descriptions above for the Bulletin 1562F Bulletin 1560F Programming Interface Control The control scheme shown in Figure 76 allows the SMC 50 to be controlled using Programming Interface Control Refer ...

Page 246: ...IN CONTACTOR M R CLT H1 H3 H2 H4 X1 X2 115V 0 6V RECTIFIER RECTIFIER Y BLK HC MOV B Y MOV CC Y BLK HC B Y MOV CC BE ME M N M C D M N D C B MOV B M A MOV ME MC MC ME ME ME REC MOV 1 B B A REC MOV 2 BE BE BE BE BC BC 1 2 1 2 3 4 5 6 7 8 9 10 11 12 L1 L2 GND Aux1 Aux2 COM Enable Input 1 DC Input 2 DC 24V DC A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Aux A1 Input A1 Input A2 Input A3 Input A4 COM Aux A2 A...

Page 247: ...V RECTIFIER RECTIFIER Y BLK HC MOV B Y MOV CC Y BLK HC B Y MOV CC BE ME M N M C D M N D C B MOV B M A MOV ME MC MC ME ME ME REC MOV 1 B B A REC MOV 2 BE BE BE BE BC BC BYPASS CONTACTOR B MAIN CONTACTOR M 1 2 1 2 3 4 5 6 7 8 9 10 11 12 L1 L2 GND Aux1 Aux2 COM Enable Input 1 DC Input 2 DC 24V DC A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Aux A1 Input A1 Input A2 Input A3 Input A4 COM Aux A2 Aux A3 NC SL...

Page 248: ... ØC TO SMCLEXIB TB6 R CLT H1 H3 H2 H4 X1 X2 115V 0 6V RECTIFIER Y BLK HC MOV B Y MOV CC BE M N D C B MOV B B A REC MOV 2 BE BE BE BE BC BC BYPASS CONTACTOR B 1 2 3 4 5 6 7 8 9 10 11 12 L1 L2 GND Aux1 Aux2 COM Enable Input 1 DC Input 2 DC 24V DC A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Aux A1 Input A1 Input A2 Input A3 Input A4 COM Aux A2 Aux A3 NC SLOT 7 150 SM4 SLOT 8 SLOT 9 DPI COMM SMC 50 EXT BYP...

Page 249: ...6 R CLT H1 H3 H2 H4 X1 X2 115V 0 6V RECTIFIER Y BLK HC MOV B Y MOV CC BE M N D C B MOV B B A REC MOV 2 BE BE BE BE BC BC BYPASS CONTACTOR B 1 2 3 4 5 6 7 8 9 10 11 12 L1 L2 GND Aux1 Aux2 COM Enable Input 1 DC Input 2 DC 24V DC A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Aux A1 Input A1 Input A2 Input A3 Input A4 COM Aux A2 Aux A3 NC SLOT 7 150 SM4 SLOT 8 SLOT 9 DPI COMM SMC 50 EXT BYPASS NORMAL START S...

Page 250: ...250 Rockwell Automation Publication 1560F UM001A EN P June 2019 Appendix C 1560F and 1562F Relay Control Notes ...

Page 251: ...To ensure Arc resistant integrity it is important to ensure that the following rules are followed The pressure relief vent maynotbe tampered with and itis not to be used as a step No alterations can be made to the ArcShield structure All covers plates and hardware removed for installation or maintenance purposes must be re installed and properly secured Failure to do so voids the arc resistant int...

Page 252: ...esistant enclosure Unit plenums are secured to the top of the unit structure and to adjacent plenums creating a continuous conduit for release of the arc flash energy Refer to Appendix E for plenum installation instructions Each plenum based ArcShield line up includes a plenum exhaust piece that extends beyond either the left or right ends of the line up The other end of the plenums is capped with...

Page 253: ...rmitted to escape with plenum extensions see Figure 79 Figure 80 and Figure 81 2 Plenum duct to outside of control room see Figure 79 and Figure 80 Plan the location where the plenum will exhaust Ensure that There is no access to personnel while equipment is energized Area is free of flammable material or vapors Ensure that adequate space is provided around the plenum exhaust as outlined in Figure...

Page 254: ...ension s to Internal Controlled Access Area Top View Figure 80 Plenum Exit Left with Extensions to Internal Controlled Access Area FrontView Minimum H 3 5 m 138 inches Minimum L 1 2 m 47 inches MinimumVolume of space required for safe pressure relief X Y H 11 m 390 cubic feet Personnel Access Barriers X L Y Personnel Access Barriers L H ...

Page 255: ...e 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 Chain link fencing is a suitable barrier material Equipment that consists of more than 4 vertical sections bolted togethe...

Page 256: ...chimney installation instructions Each ArcShield line up includes a chimney exhaust section that extends vertically directly above the enclosure Chimney Exhaust Considerations 1 From the outlet of the chimney there needs to be a minimum clear distance of 1 7m from the top of the chimney to the ceiling and 1m 39 in on each side 2 No obstructions for example piping can be in path of the exhaust with...

Page 257: ...is force will be in the direction opposite to where the relief vent exits The amount of bracing will depend on how the plenum is supported at its exit as well as the distance from the end of the cabinets to the exit vent A flange is available for installing hangers for supporting the weight of the plenum The plenum extension has holes for mechanical support Weight per unit length of Rockwell suppl...

Page 258: ... the 0 7 m 26 inch wide cabinet 36 in wide Plenum Fastened directly over the 0 9 m 36 inch wide cabinet DANGER DANGER ARC FLASH HAZARD PRESSURE RELIEF EXIT AREAS TO BE INACCESSIBLE TO PERSONNEL WHILE EQUIPMENT ENERGIZED FREE OF OBSTRUCTIONS REFER TO USER MANUAL SEVERE INJURY OR DEATH MAY RESULT HAZARDD ARCÉLECTRIQUE SORTIE DE L ÉVENT RÉGION ÊTRE INACCESSIBLEAUXPERSONNEL PENDANT QUE L ÉQUIPEMENT ES...

Page 259: ... exit direction Also shown is an optional vertical top direction exhaust extension see Figure 98 18 in long Extension Connected to the last Plenum on the exhaust end of the line up 26 in long Extension Connected to the last Plenum on the exhaust end of the line up 36 in long Extension Connected to the last Plenum on the exhaust end of the line up Screen Cover Plate Fastened at the opening of the l...

Page 260: ...n 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 87 The Plenums are designed to fit over the fastener heads at the corners of the Relief vent The corner fasteners are required to secure the Relief vent during installation Front Duct Section Components Figure 86 Typic...

Page 261: ... in Cabinet Preparation above are replaced to attach the Plenum to the top of the enclosure Use hand tools only Figure 88 Plenum Placement STEP 2 Alignment of Side by Side Plenums Plenums mounted side by side must be fastened together through the aligning holes using 5 16 inch supplied hardware see Figure 89 Use recommended torque value for 1 4 20 fasteners TIP Use silicone caulking generously to ...

Page 262: ... enclosure and to the Plenum directly beside it before the front duct sections are re attached see Figure 85 Figure 90 Sequence of Final Assembly 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 90 Left side IMPORTANT Any unused holes must be filled with thread forming screws i e Lifting Lug holes All Gaps mus...

Page 263: ... are to be attached using 5 16 inch hardware in the following sequence Step 5A See Figure 94 Step 5B See Figure 95 Step 5C See Figure 96 Figure 91 Top Plate Figure 92 Bottom Plate Figure 93 Front Closing Plate TopPlate Bottom Plate Front Closing Plate IMPORTANT Do not re install the front duct section of the last Plenum on the exhaust side of the Line up at this time refer to STEP 6 Mounting Exten...

Page 264: ...oved This allows access to fastener holes in order to mount the Extension Elbow components see Figure 97 Figure 94 90 Elbow Section Assembly Step 5A Front View Figure 95 90 Elbow Section Assembly Step 5B FrontView 36 Extensions 2 piece 90 deg Elbow Section Screen Cover Plate The Extension components are attached to the Elbow Section using 5 16 inch Hardware Figure 96illustrateswhattheExtension Elb...

Page 265: ...eplaced and fastened through the holes on the outside flanges STEP 7 Additional Mounting Support The Extension Elbow Assembly must have additional mounting support 90 Elbow Section Approximate weight 64 kg 142 lb 36 in Extension Assembly Approximate weight 51 kg 112 lb Figure 98 shows an example of how the Extension Elbow Sections can be supported by suspension from a high ceiling Points A B and C...

Page 266: ...ns Figure 98 Completed Assembly for optional vertical exit Plenum Right hand exit A B C TIP Duringanarcfault theplenumwillbesubjectedtoabriefhighpressureshock wave The Extension Elbow assembly may experience dynamic loading It is important to account for dynamic loading when selecting supporting means and materials ...

Page 267: ...se instructions Recommended Torque Values 1 4 20 Thread Fasteners 7 5 N m 6 lb ft 5 16 18 Thread Fasteners 14 N m 11 lb ft Figure 99 Chimney Exhaust Label DANGER DANGER ARC FLASH HAZARD PRESSURE RELIEF EXIT AREAS TO BE INACCESSIBLE TO PERSONNEL WHILE EQUIPMENT ENERGIZED FREE OF OBSTRUCTIONS REFER TO USER MANUAL SEVERE INJURY OR DEATH MAY RESULT HAZARDD ARCÉLECTRIQUE SORTIE DE L ÉVENT RÉGION ÊTRE I...

Page 268: ...00 Chimneys of varying widths are mounted directly over the MV enclosures of the corresponding width Figure 100 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 102 Figure 101 ReliefVent Fasteners top view Figure 102 Relief Vent ReliefVent Remove ...

Page 269: ...elief vent during installation Chimney Placement on Structure Once the Chimney has been lifted in place directly over the relief vent shown in Figure 102 all 1 4 20 fasteners removed in Cabinet Preparation on page 268 are replaced to attach the chimney to the top of the enclosure Figure 103 Chimney Placement TIP Usesiliconecaulkinggenerously tofill anyairgapsonce the chimney has been securely moun...

Page 270: ...270 Rockwell Automation Publication 1560F UM001A EN P June 2019 Appendix F ArcShield Chimney Installation Instructions Notes ...

Page 271: ... continues execution independent of the controller s state such as starting running fault Thereisnodataretention in DeviceLogix duringapower cycle Timer and counter accumulators calculationresults latchedbits etc arecleared Controlling the operating modes starting stopping etc through DeviceLogix requires you to set bit 14 of the Logic Mask parameter 148 Parameters See parameters 335 346 in Table ...

Page 272: ...Logix Editor navigation and programming basics are not covered in this manual Refer to the DeviceLogix user manual publication RA UM003 for additional information Macro Blocks You can create up to five Macro Blocks and you can use each five times The selections are empty until you create a Macro Block You also create the icon text associated with each Macro Block Bit and Analog I O Points The Devi...

Page 273: ...into the corresponding expansion port is functioning and Ready PX input 1 PX input 4 Status of the Boolean inputs from the expansion cards See the Expansion Card Mapping table below 15 Network Boolean Inputs Running Phase Rotation Phase Detection Starting Stopping Alarm Fault At Speed Start Bypass Ready These Boolean inputs correspond to the statuses listed in Table 50 on page 140 Network Bit 1 Ne...

Page 274: ... PX Aux3 Auxiliary Relays 1 3 available on the Digital I O 150 SM4 Expansion Card 1 7 Network Boolean Outputs Coast Start Stop CLR Fault Emergency Run Motor Heater These outputs canbe used tocontrolthe controllerinthe samewayaPLCcancontrolthecontroller SeeTable 51on page 141 for a definition of these control bits Analog Inputs Name Description 22 Network Analog Inputs Volt PP Ave Average Phase to ...

Page 275: ...g network devices SMC 50 Control Module DeviceLogix Input Datalinks P337 P342 The SMC 50 control module provides parameters directly to DeviceLogix as analog inputs Additional parameters from the host and expansion cards can be made available through the DeviceLogix Datalink inputs The value of the parameter linked to by the datalink is made available to DeviceLogix For example configuring a datal...

Page 276: ...ters to make those values available to DeviceLogix as shown in Table 78 Table 78 DeviceLogix Datalink Parameters Figure 104 Function Block Programming Inputs Outputs Input 1 Input 2 Output Selection Selector Switch Output 0 0 0 Volt PP Ave 0 1 1 Volt Phase A B 1 0 2 Volt Phase B C 1 1 3 Volt Phase C A Parameter No Parameter Value Description 337 DLX DL Input 1 Port 0 Volts Phase A B Value for Sele...

Page 277: ...ensor is ON Type Location of I O Name Description Inputs Port 8 Input 2 Critical High Levelsensor Indicatesacriticallyhighlevel Itisnormallyabackupto theHighLevelsensorandisalsousedtodetectwhether the High Level sensor is faulty Port 8 Input 3 High Level sensor Indicates thewellisatahighlevel andit istime tostart pumping using the controller Port 8 Input 4 Low Level sensor When OFF it is used to i...

Page 278: ...arameter Configuration Port Parameter No Parameter Value Description 0 148 14 Host Parameter 148 Bit 14 Logic Mask Set bit 14 Allow DeviceLogix to control the motor 8 6 Port 8 Parameter 6 Aux 1 Config Device Logix Auxiliary 1 is used to control the Sensor Failure pilotlight InorderforDeviceLogixtocontrolthe Auxiliaryit must be configuredto Device Logix 8 10 Port 8 Parameter 10 Aux 2 Config Device ...

Page 279: ...Rockwell Automation Publication 1560F UM001A EN P June 2019 279 Using DeviceLogix Appendix G Figure 106 Function Block Programming ...

Page 280: ...280 Rockwell Automation Publication 1560F UM001A EN P June 2019 Appendix G Using DeviceLogix Notes ...

Page 281: ...Rated Voltage max Part Number 180 Amp 360 Amp 600 Amp 1 1 Due to stringent torquing specifications for 600A power stacks individual SCRs are not replaceable It is mandatory that the entire power stack be replaced 1500 80187 513 53 80187 513 52 80187 522 51 2500 80187 513 51 80187 513 52 80187 522 51 4800 80187 514 51 80187 514 52 80187 523 51 7200 80187 521 51 80187 521 52 80187 524 51 Snubber Cap...

Page 282: ...gurations The current loop total length must equal 21 ft for proper operation Current loop cable assembly 5 ft 80018 246 55 6 ft 80018 246 51 7 ft 80018 246 52 8 ft 80018 246 53 9 ft 80018 246 54 1 per controller Current loop sense CT 80022 163 01 1 per controller Ribbon cable fromVSB to Interface Board 80026 146 56 3 per controller Ribbon cable from Control Module to Interface Board 6 pin 80174 2...

Page 283: ...for specific spare parts list 1560 1562F are Allen Bradley manufactured starters 3 For spare parts for starter and contactor components refer to Additional Resources on page 11 Qty per controller Description Part Number 1 Control Module Standard PN 281287 1 HIM Bezel Mounted 350325 A06 1 SMC 50 Digital I O Module PN 71481 1 SMC 50 Ground Fault PTC Module PN 71480 Fuse Extractor 80144 491 02 ...

Page 284: ...284 Rockwell Automation Publication 1560F UM001A EN P June 2019 Appendix H Spare Parts Notes ...

Page 285: ...escription UsedWith Catalog Number HIM Remote Door Mounted IP66 Type 4 12 Programmer Only 20 HIM C6S 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 20 COMM P INTERBUS 2 20 COMM I LonWorks 20 COMM L ControlNet Fiber 20 COMM Q RS485 HVAC 20 COMM H ...

Page 286: ...286 Rockwell Automation Publication 1560F UM001A EN P June 2019 Appendix I Accessories Notes ...

Page 287: ...ist 151 alarm indication 155 ArcShield chimney 256 chimney installation 267 chimney installation instructions 267 design 251 overview 251 plenum 252 plenum bracing 257 plenum installation instructions 257 auxiliary relay alarm indication 155 output fault 155 B bit identification 140 bit inputs 273 C CEC 49 52 60 change password 86 chimney exhaust considerations 256 information 256 installation 267...

Page 288: ...elements 271 functional descriptions 42 G gate driver board test power application 78 ground bus bar 61 ground fault 29 grounding 52 H handling 50 hardware description 38 heatsink clamp detail 175 HIM basic configuration 112 connect to SMC 50 136 control buttons 131 control screen 132 function keys 84 keypad 136 mounting locations 84 soft key 85 Hi Pot 72 I I O 34 communication 139 data sizes 140 ...

Page 289: ...257 exhaust considerations 253 power circuit resistance measurements 81 power connections 53 power factor correction capacitors 62 power stacks spare parts 281 power supply tests 77 power wiring 60 preliminary check 71 programming 36 83 protection features 24 PTC protection 30 sensor characteristics 30 PTC power pole 32 pump start parameters 102 pump stop 23 timing diagram 23 pwoer module 38 R RAM...

Page 290: ...agram coast to stop 21 linear speed deceleration 22 pump stop 23 soft stop 21 torque start parameters 100 torque values 53 chimney installation 267 plenum 257 total harmonic distortion 32 transportation 50 troubleshooting 157 circuit board replacement 169 control module removal 164 current loop power supply 168 fault display explanation 158 flowchart 157 158 power circuit 170 resistor circuit test...

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Page 292: ...support engineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Brochures and Technical Data http www rockwellautomation com global literature library overview page Product Compatibility and Download Center PCDC Get help determining how products interact check features and capabilities and find associated firmware http www rockw...

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