M.V. DEVELOPMENT

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February 2004

MV SMC
-
Flex

Product Overview

2

Why Use MV SMC
-
Flex Motor Controllers?

Major Reasons


Help minimize
downtime / operating
costs


Help provide cost
savings by minimizing
the effects of



High inrush currents


High starting torque


3

MV SMC
-
Flex Minimizes Downtime/Operating Cost


Problem:


Belts, gears and machinery can be damaged by across
-
the
-
line starting










MV SMC
-
Flex Solution:



Lengthens system life by reducing

mechanical stress during starting by using Soft Start


Helps eliminate the need for maintenance people to repair the process


No need to replace damaged parts


Minimal production loss

Breakdown Torque

180%

100%

100%

0

Percentage

of Full Load

Torque

Percentage of Full Speed

High torque can cause

physical damage to the

mechanical system.

4

MV SMC
-
Flex Minimizes Downtime/Operating Cost


Problem:


Materials can be

damaged by sudden

starts and stops




MV SMC
-
Flex

Solution:


Soft Start minimizes

damage by reducing

high starting torque


Soft Stop reduces damage by minimizing load shifting or spillage
during stop


Higher yield during production

5

MV SMC
-
Flex Provides Cost Savings by

Minimizing Inrush Currents


Problem:


Power company restrictions on incoming line current, or you pay
the penalty


Weak power lines cannot handle

high inrush currents, causing brown

outs or excessive line disturbances,

which in turn cause other processes

to shut down



MV SMC
-
Flex Solution:


Current Limit starting minimizes the amount of inrush current,
meeting power company restrictions


Process shut down and brown outs are minimized by reducing the
amount of current drawn during starting

600%

100%

100%

0

Percentage

of Full Load

Current

Percentage of Full Speed

6


Three MV SMC
-
Flex Offerings:


Bulletin 1562E, a complete motor control solution


Bulletin 1560E, a retrofit solution, that builds on an
existing full voltage controller


Bulletin 1503E, component kits for use by OEMs


The MV SMC
-
Flex represents a continuing
legacy of product enhancement, since the initial
MV SMC shipments in 1993


Part of the Centerline family of MV controllers


CSA, UL and CE Approved

MV SMC
-
Flex

Overview

7

MV SMC
-
Flex

Overview

Retrofit


1560E

Combination


1562E

M
M
Main Contactor

Isolation

Switch &
Power Fuse

Bypass

Contactor

Bypass

Contactor

Current
Transformers

Current
Transformers

SCR Power Stack
Assembly

8

MV SMC
-
Flex

Overview


Efficient 1562E design


enclosure choices


NEMA 1, 1A, 12 & 3R


IP 10, 21, 52, and 34


power electronics and by
-
pass
contactor in top section


isolation switch, power fuses and
main contactor in bottom section


two large low voltage panels


SMC
-
Flex controller (top)


Main LV control (bottom)

Bulletin 1562E

9


Uses SMC
-
Flex control module (the
same as low voltage products)


New interface board with inherent
safety, using fiber optic isolation


Human Interface Modules (HIMs) &
communication interfaces are also
used with the LV SMC
-
Flex and
PowerFlex drives (DPI
-
based)


Power circuit enhancements

MV SMC
-
Flex

Overview

Bulletin 1562E

10

MV SMC
-
Flex

Power Ratings
-

HP

0
1000
2000
3000
4000
5000
6000
7000
8000
HP
200 Amp
400 Amp
600 Amp
2400 V
3300 V
4160 V
6900 V

2,400
-

6,900 Volts


200 / 400 / 600 Amp


50 / 60 Hz

11

MV SMC
-
Flex

Power Ratings

Voltage

Maximum Output Ratings


HP (kW)

200 Amp Unit

400 Amp Unit

600 Amp Unit

2,400

800
(600)

1,500 (1100)

2,750 (2050)

3,300

1,000

(750)

2,250 (1700)

4,000 (3000)

4,160

1,250

(950)

2,750 (2050)

4,500 (3350)

6,900

2,500

(1900)

4,500 (3350)

7,500 (5600)

12

MV SMC
-
Flex

Dimensions

Bulletin

Voltage

Rating

Width

Depth

Height

Weight

in.

mm

in.

mm

in.

mm

lb.

kg

1560E

2400

3300

4160

200 A

26

660

36

914

91

2311

800

363

400 A

26

660

36

914

91

2311

800

363

600 A

44

1117

36

914

91

2311

1,300

590

6900

200 A

36

914

36

914

91

2311

1,220

554

400 A

36

914

36

914

91

2311

1,220

554

600 A

44

1117

36

914

91

2311

1,300

590

1562E

2400

3300

4160

200 A

36

914

36

914

91

2311

1,400

636

400 A

36

914

36

914

91

2311

1,400

636

600 A

80

2032

36

914

91

2311

2,325

1056

6900

200 A

62

1575

36

914

91

2311

2,325

1056

400 A

62

1575

36

914

91

2311

2,325

1056

600 A

100

2540

36

914

91

2311

4,000

1812

13

MV SMC
-
Flex

Power Stacks


Rockwell Automation design


designed specifically for MV
soft starter duty


efficient compact design


200 Amp
-

aluminum


400 / 600 Amp
-

copper

14

MV SMC
-
Flex

Control Module Overview


Soft Start
-

with Selectable Kickstart


Soft Stop


Current Limit Start
-

with Selectable
Kickstart


Linear Speed Acceleration
-

with
Selectable Kickstart


Linear Speed Deceleration


Dual Ramp
-

with Selectable
Kickstart


Full Voltage


Preset Slow Speed


Pump Control (Optional)

15

MV SMC
-
Flex

Starting Mode
-

Soft Start


Adjustable Ramp Time:

0 to 30 seconds


Adjustable Initial Torque:

0 to 90% LRT


Selectable Kickstart:


0.0 to 2.0 seconds


Adjustable Kickstart Level:

0 to 90% LRT

16

MV SMC
-
Flex

Stopping Mode
-

Soft Stop


Soft Stop extends stopping time to minimize
load shifting or spillage


Adjustable Soft Stop time: 0 to 30 seconds

17

MV SMC
-
Flex

Starting Mode
-

Current Limit


Current Adjustment:


50 to 600% FLA


Current Limit Time:


0 to 30 seconds


Selectable Kickstart:


0.0 to 2.0 seconds


Adjustable Kickstart Level:

0 to 90% LRT

18

MV SMC
-
Flex

Starting/Stoping Mode
-

Linear Acceleration & Deceleration


Linear Speed Control uses
closed
-
loop feedback to
accelerate / decelerate the
motor at a constant rate


0 to 30 second start time


0 to 30 second stop time


Applications Include:


Overland conveyor


Tunnel conveyor


Feed conveyor for rock crusher


Requires the use of a
tachometer (customer supplied)

19

MV SMC
-
Flex

Starting Mode
-

Dual Ramp Start


Provides two Start profiles with separate

ramp times and initial torque settings


Adjustable ramp time:

0 to 30 seconds


Adjustable initial torque:

5 to 90% LRT


Selectable Kickstart:


0.0 to 2.0 seconds


Adjustable Kickstart Level:

0 to 90% LRT

20

MV SMC
-
Flex

Starting Mode
-

Full Voltage


High duty cycle


Full inrush current and locked rotor torque are
achieved


Applications requiring across
-
the
-
line starting

21

MV SMC
-
Flex

Starting Mode
-

Preset Slow Speed



Preset Slow Speed furnishes two jog
speeds to facilitate process set
-
up and
alignment


Forward Speeds: 7 or 15% of rated speed


Reverse Speeds: 10 or 20% of rated speed

22

MV SMC
-
Flex

Pump Control (Optional)


The SMC Flex controller’s unique, interactive Pump Control
reduces fluid surges in pumping systems


Adjustable Pump Start time:

0 to 30 seconds


Adjustable Pump Stop time:

0 to 30 seconds


Selectable Kickstart:


0.0 to 2.0 seconds


Adjustable Kickstart Level:

0 to 90% LRT

23

MV SMC
-
Flex

Pump Control



Designed specifically for centrifugal pumps (not to
be used for positive displacement pumps)


Reduces surges caused by uncontrolled
acceleration and deceleration of centrifugal pumps.


Can eliminate the need for specialized flow control
valves


Provides closed loop acceleration and deceleration
motor control
-
without the use of sensors or
feedback devices


Performance not matched by any competitor


Pump Control benefits for your applications

Torque

Speed

Pump System

Full Speed

Across the Line Start

Full

Load

MV SMC
-
Flex

Starting Mode
-

Pump Control

Torque

Speed

Pump System

Full Speed

Across the Line Start


Full

Load

Soft Start

MV SMC
-
Flex

Starting Mode
-

Pump Control

Torque

Speed

Pump System

Full Speed

DOL

Start

Full

Load

Pump Start

MV SMC
-
Flex

Starting Mode
-

Pump Control

Flow

Time

Pump

Control

Soft

Start

DOL

100%

MV SMC
-
Flex

Starting Mode
-

Pump Control

Flow

Time

Pump

Control

Soft

Stop

DOL

100%

MV SMC
-
Flex

Stopping Mode
-

Pump Control

29

MV SMC
-
Flex

Protection & Diagnostics


Electronic Motor Overload Protection


Stall Detection


Jam Detection


Ground Fault Protection


Thermistor Input (PTC)


Diagnostics and Warnings


Monitoring


Configurable Auxiliary Contacts

30

MV SMC
-
Flex

Stall Detection


Utilizes a programmable time delay


Adjustable up to 10 seconds


Enabled with a setting above zero

TIME

FLA

600%

Ramp

Stall

31

MV SMC
-
Flex

Jam Protection


Enabled by programming the Jam Trip Level


Jam trip level adjustable up to 999% FLA


Utilizes a programmable delay time


Delay time adjustable up to 99 seconds


Operational only during the at speed condition

FLA

TIME

Running

Jam

100%

32

MV SMC
-
Flex

Ground Fault Protection


Class I protection


No high current inhibit function


100:1 zero sequence CT required (825
-
CBCT or
equivalent)


Equipment Protection Only


Not intended as a Ground Fault Circuit
-
Interrupter for
personnel protection


Adjustments


Inhibit time adjustable:


0
-

250 seconds


Trip delay adjustable:


2
-

25 seconds


Trip level adjustable:


1.0
-

5.0 amperes


Warning level adjustable:


1.0
-

5.0 amperes


33

MV SMC
-
Flex

Thermistor Input (PTC)


The SMC
-
Flex controller offers enhanced motor
protection with additional circuitry to monitor motor
stator
-
embedded positive temperature coefficient
(PTC) thermistors


PTC Characteristic

per IEC 34
-
11
-
2

Resistance Ohms (
W
)

34

MV SMC
-
Flex

Fault Diagnostics


Overtemperature


Stall Detection


Open SCR Gate


Shorted SCR Gate


Overload


Underload


Excessive Starts per
Hour


Thermistor (PTC)


Current Unbalance


Line Fault


Power Loss


Voltage Unbalance


Phase Reversal


Undervoltage


Overvoltage


Jam Detection


Communication Fault


Ground Fault

35

MV SMC
-
Flex

Fault Alarms


Alarm Settings Can Be Programmed for:


Thermal Overload




Ground Fault


Jam


Underload


Thermistor (PTC)


Over Voltage


Under Voltage


Alarm Settings Can Be Used to Provide Advance
Notification of Impending Trips


Allows for corrective action to avoid downtime!!

36

MV SMC
-
Flex

Monitoring


Eliminate the mystery of your motor’s operation by
applying the SMC
-
Flex controller with its built
-
in
metering capabilities


Three
-
phase currents


Three
-
phase voltages


Three
-
phase power (MW, MWh)


Power factor of the running motor


Motor thermal capacity usage


Elapsed time of motor operation


Motor speed (with optional use of tachometer)


37

MV SMC
-
Flex

Configurable Auxiliary Contacts


One Normally Open Auxiliary Contact


Programmed for Up
-
To
-
Speed for MV applications


One Fault Auxiliary Contact


Programmable for Normally Open or Normally Closed


One Alarm Auxiliary Contact


Programmable for Normally Open or Normally Closed


One Normal Auxiliary Contact


Programmable for Normally Open or Normally Closed

38

MV SMC
-
Flex

Human Interface Modules (HIMs)


Built
-
in


Easy parameter access
speeds commissioning and
maintenance


External (Optional)


Handheld


On Panel


-
A2

-
A3

-
A4

39

MV SMC
-
Flex

HIM Communications


Built
-
in LCD display is easy to use


data presented clearly


pop
-
up menus and messages

for better alerts / access


Change Languages Quickly


2 keystrokes for any language


Languages


English, French, Spanish, Italian,
German, Portuguese, Chinese

Main Menu:
Diagnostics
Parameter
Device Select
0.00
F-> Stopped Ready A
Hz.
F Stopped Auto
- Fault -

F05
Overvoltage
Time Since Fault
1:10:07
Fault Pop Up

40

MV SMC
-
Flex

Optional Communication Modules


The SMC Flex uses the same
Communication Modules and Human
Interface Modules (HIMs) as the PowerFlex
drives family (DPI communication)


DPI communication modules


DeviceNet™


ControlNet


EtherNet/IP


Remote I/O


RS 485
-
DF1


ProfiBUS
-
DP

ControlNet

41

MV SMC
-
Flex

Typical Communication Architecture

Typical DeviceNet Unit Architecture

SMC
-
Flex

825P

DSA

42

MV SMC
-
Flex

Communications, Programming & Monitoring


Using the MV SMC
-
Flex communication capabilities
provides enhanced control & monitoring


Parameter settings


Fault Diagnostics


Metering


Start
-
stop control via network (DeviceNet,

ControlNet, Ethernet)


Use DriveTools software to program

and monitor the MV SMC
-
Flex


IntelliCENTER compatibility


System status & detailed

unit information



43

MV SMC
-
Flex

Standard Units for Quick Shipment


Bulletin 1560E and 1562E units are
available for the following reduced factory
lead
-
times:


200 to 400 Amps, 2400 to 4160 V


15 to 20 business days


Includes standard options


Motor protection relays (825P, E3/E3+)


Pump control module


IntelliVAC™ solid
-
state contactor control


Communication


44

MV SMC
-
Flex

Summary


Minimizes stress on mechanical drive and
power systems



Safe & Reliable design



Flexible control and communication



Enhanced performance, to meet the challenge
of a wide variety of applications