Allen-Bradley 7760 User Manual
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Allen-Bradley 7760 User Manual

Allen-Bradley 7760 User Manual

Medium voltage onegear smc flex motor controller 10...15 kv
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User Manual
Original Instructions
Medium Voltage OneGear SMC Flex Motor Controller
(10...15 kV)
Catalog Numbers 7760, 7761, 7762, 7763

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Summary of Contents for Allen-Bradley 7760

  • Page 1 User Manual Original Instructions Medium Voltage OneGear SMC Flex Motor Controller (10…15 kV) Catalog Numbers 7760, 7761, 7762, 7763...
  • Page 2 Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

  • Page 3: Table Of Contents

    7760 – Retrofit Controller ........
  • Page 4 Bulletin 7763 – Basic Control – Controlled Start only ..44 Bulletin 7760 – Basic Control – Controlled Start Only..44 Chapter 2 Commissioning Procedure Preliminary Setup .
  • Page 5 Configuring Datalinks ..........97 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 6 ..............141 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 7 ..............143 Index Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 8 Table of Contents Notes: Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 9 This manual contains new and updated information. New and Updated This table contains the changes made to this revision. Information Topic Page Changed to 81020-761-51-R, and Match Designator to W Changed to 81020-295-51-R, and Match Designator to W Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 10 Summary of Changes Notes: Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 11: Preface

    For MV SMC Flex technical support on start-up or existing installations, contact your Rockwell Automation representative. You can also call 1-519-740-4790 for assistance Monday through Friday from 9:00 a.m. to 5:00 p.m. (Eastern time zone). Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 12 Preface Notes: Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 13: Product Overview

    The manual contains material that allows you to operate, maintain, and troubleshoot the OneGear™ MV SMC™ Flex family of controllers. The family consists of the following Bulletin numbers: 7760, 7761, 7762, and 7763. This user manual pertains to units with firmware release 6.003 or later.

  • Page 14: 7760 - Retrofit Controller

    • Fiber-optic connection from SMC Flex control module to gate driver board on PowerBrick • Provision for bottom fed line and load connections • Earthing switch (optional) Figure 1 - Typical OneGear Single-Line Diagram, Bulletin 7760 (10…14.4 kV) (Vacuum Breaker) Bypass Controller Power Converter Cable Connection Unit...

  • Page 15: 7761 - Combination Controller

    • Provision for bottom fed line and load connections Figure 2 - Typical OneGear Single-Line Diagram, Bulletin 7761 (10…14.4 kV) SMC Flex Control Module R, S, T U, V, W Output Customer Supplied Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 16: 7762 - Combination Controller (Vacuum Contactor)

    Bypass Controller Start Controller Power Converter R, S, T R, S, T R, S, T SMC Flex Control Module Optional Optional SMC Flex Converter Control Section Module Optional Earthing Switch U, V, W Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 17: 7763 - Combination Controller (Vacuum Breaker)

    Bypass Controller Start Controller Power Converter R, S, T R, S, T R, S, T SMC Flex Control Module optional Optional SMC Flex Control SMC Flex Module Optional Earthing Switch U, V, W Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 18: Power Factor Correction Capacitors

    Figure 6, and Figure 7. The same concept applies to Bulletin 7761. Figure 5 - Typical OneGear Single-Line Diagram Bulletin 7760 (10…14.4 kV) with two optional Power Factor Correction Capacitor positions (Vacuum Breaker) Power Converter Cable Connection Point Optional PFCC...
  • Page 19 Power Converter Start Controller Optional PFCC R, S, T R, S, T R, S, T R, S, T SMC Flex Control Module Breaker Breaker Fused Contactor Optional Earthing PFCC Switch U, V, W Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 20: Proposal For Implementation Of Power Factor Correction Capacitors

    6. If a coast stop is initiated, the Flex opens the contact between 20 to 34; KG3 opens M and command KG4 to open CC. CC holds B until CC drops out. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 21: Smc Flex Control Module

    (1) Requires motor tachometer. (2) This option utilizes gating patterns that result in motor and line currents which produce noise and vibration in the motor and/or distribution transformer. This must be considered before applying this option. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 22: Starting Modes

    Figure 8 - Soft Start Percent Voltage 100% Initial Torque Start Time (Seconds) Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 23: Selectable Kickstart

    Figure 10 - Current Limit Start Percent Full Load Current Start Time (seconds) Kickstart is also available with Current Limit Start, Dual Ramp Start, and Linear Acceleration. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 24: Dual Ramp Start

    Full Voltage Start This starting mode is used for applications which require across-the-line starting. The output voltage to the motor will reach full voltage within 1/4 second. Table 3 - Full Voltage Start Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 25: Preset Slow Speed

    Slow speed running is not intended for continuous operation due to reduced IMPORTANT motor cooling. The two starts per hour limitation also applies to slow speed operation. This option employs a cycle-skipping scheme, which produces limited torque. Applications must be checked with the factory. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 26: Linear Speed Acceleration And Deceleration

    Linear Deceleration is not intended to be used as an emergency stop. Such IMPORTANT usage can result in severe injury or death. See the applicable standards for emergency stop requirements. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 27: Soft Stop

    Soft Stop is not intended to be used as an emergency stop. Such usage can IMPORTANT result in severe injury or death. See the applicable standards for emergency stop requirements. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 28: Protection And Diagnostics

    3. The trip rating is 117% of the programmed FLC. Figure 14 Figure 15 provide the overload trip curves for the available trip classes. Separate protection relay c/w instantaneous overcurrent protection is required when used with vacuum breakers. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 29 Class 30 Class 30 Auto Reset Times Class 10 = 90 s Class 15 = 135 s Class 20 = 180 s Class 30= 270 s 100% 1000% Percent Full Load Current Setting Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 30: Underload

    The alarm modification information is displayed through the LCD, HIM, Communication (if applicable), and alarm contact closing. Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 31: Unbalance

    • Jam detection allows you to determine the jam level (up to 1000% of the full-load current rating of the motor) and the delay time (up to 99.0 seconds) for application flexibility. Figure 16 - Stall Protection Percent Full Load Current Programmed Start Time Stall Time (seconds) Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 32: Ground Fault

    It is adjustable from 0.1…25 seconds. Parameter 73, Gnd Flt Level, allows the installer to define the ground fault current at which the MV SMC Flex trips. It is adjustable from 1.0…5.0 A. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 33: Thermistor/Ptc Protection

    Maximum Voltage at PTC Terminals (RPTC - 4 k ) < 7.5V Maximum Voltage at PTC Terminals (RPTC = open) Maximum Number of Sensors Maximum Cold Resistance of PTC Sensor Chain 1500 Ω Response Time 800 ms Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 34: Ptc Trip

    An open gate is detected when the module sends a gate signal to the SCRs but does not detect that they turned on. SCR turn-on is detected when the voltage across the leg (L-T) collapses. The Open Gate detection is active during starting or stopping only. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 35: Line Faults

    An overtemperature condition could indicate high ambient temperature, overloading, or excessive cycling. After the power module temperature is reduced to allowable levels, the fault can be cleared (see Maintenance on page 115 instructions). Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 36: Metering

    Network NC, they can be controlled over a Network. See Table 34 which defines the Logic Command Word (Control). For MV applications, some of the I/O are assigned to specific functions. See page 38 for additional details. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 37: Communication

    LCD. Parameters are organized in a three-level menu structure, using a text format for straightforward programming. Figure 20 - Built-in Keypad and LCD Port 5 – DPI Communications Port 2 Ports 2 and 3 when two HIMs are connected with a splitter Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 38: Status Indication

    Contract) • The Aux #1 contact is always programmed Up-to-speed for 7762 and 7763 applications, or External Bypass (N.O.) for 7760 applications to control the bypass circuit breaker/contactor. • The Aux #2 contact is typically programmed for fault indication (it can be configured for N.O./N.C.).

  • Page 39: Control Options

    2/3 of the motor rated horsepower. 4. Pump applications with input and/or output valves that are closed during starting and/or stopping may not benefit from the Pump Control option. Consult the factory for applications with valves. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 40: Braking Control Options

    Each section will be described to give the user an understanding of the MV SMC Flex to facilitate operation and maintenance of the system. See Figure 23 Figure 24, Typical MV SMC Flex Power System. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 41: Power Module

    If the heatsink temperature rises above a set value, a signal is sent to the SMC Flex to stop gating the SCRs and initiate a temperature fault. For a detailed layout of this circuit board, see Figure 27 Chapter Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 42 Figure 23 - Typical OneGear SMC Flex Power System – Bulletin 7763 BYPASS CONTROLLER -BC1 -BC2 -BC3 POWER CONVERTER START CONTROLLER -BC1 -BC2 -BC3 RR1/2 RR1/2 -RS 1 -RS n RS1/2/3 RS1/2/3 OV S OV S TEST TEST TEST TEST -GP1 -GP2 -GP2...
  • Page 43 Figure 24 - Typical OneGear SMC Flex Power System – Bulletin 7760 BYPASS CONTROLLER POWER CONVERTER EXISTING CONTROLLER CABLE CONNECTION UNIT -BC1 -BC2 -BC3 RR1/2 RR1/2 -RS 1 -RS n RS1/2/3 RS1/2/3 OV S OV S TEST TEST TEST TEST...

  • Page 44: Functional Description

    When a start is initiated in the existing motor controller and the contactor (or breaker) closes, a contact must be supplied to tell the 7760 to start also. A "-KG1" contact applies control voltage to terminal 17 of the SMC Flex module.
  • Page 45 Current Loop Current Sensor -BC4 Miniature Circuit Breaker or Control Fuse -KG1 Start/Stop Signal Control Relay -KG2 Bypass Controller Pilot Control Relay Start Controller Pilot Control Relay -KG3 Current Loop Transformer -TT1 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 46 Chapter 1 Product Overview Figure 26 - Typical OneGear SMC Flex Control Circuit (without Stop Control) – Bulletin 7760 Control Power 230V 115V -TT1 To SMC Flex Interface -BC4 Board - TB6 Start/Stop Signal from ØA ØB ØC existing controller...

  • Page 47: Commissioning Procedure

    2. Prepare the following test equipment for use: • Test power supply, with each controller • Multimeters • Hi-Pot Tester (recommended) or Megger • Oscilloscope with memory (optional) 3. Complete the drawing package and parts list. 4. Specification of project. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 48: System Characteristics

    Fan ___Pump___Conveyor___Compressor___Mixer___ Other________________________________________ Constant Torque_______ or Variable Torque _________ Actual Motor Data: ____________________________________________ Motor HP: ___________________________________________________ Motor Rated Speed: ____________________________________________ Motor F.L.A.: _________________________________________________ Motor S.F.: ___________________________________________________ Motor L.R.A.: ________________________________________________ Frequency: ___________________________________________________ Phases: ______________________________________________________ Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 49: Important Commissioning Checks

    • Verify Power System Grounding (Earthing). • Check if there are any Power Factor Correction Capacitors. For correct installation requirements of these capacitors, see publication 7760-IN001. • Check if surge capacitors or surge arrestors are installed at the motor. Open the motor junction box and verify. These components must be disconnected from the circuit.

  • Page 50: Programming

    • Complete device resistance checks per installation instructions. See publication 7760-IN001. • Complete Power Supply Tests. See publication 7760-IN001. • Program the module with correct parameter settings. • Start the unit and record (if available) scope waveforms (line voltage, motor voltage and motor current).
  • Page 51 Reconnect the system as it existed before this section. Perform the power supply and resistance checks in the following sections. ATTENTION: Failure to reconnect all wires and cables correctly may result in equipment damage, personal injury, or death. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 52 2. VCOM is the common connection for Current and Voltage feedback test points. Do not connect J2 (VCOM) to earth ground; do not connect ICOM and VCOM together, either directly or through test probes, meter or scope common. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 53: Resistance Checks And Power Supply Tests

    SCR Power trucks. 5. The fiber optic cables are removed at the fiber optic board end and gently coil the cable bundle on the power truck to be racked out. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 54 A red LED beside the switch, and the three yellow LEDs on the left side of the interface board should be lit. They may appear dim, depending on ambient light conditions. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 55 (i.e., SW2 toggled up) and the Portable Test Power Supply should be connected to J1. The pulse should appear as shown in Figure 31 Figure Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 56 Directing the light to a fingertip or another object is sufficient to determine correct performance. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 57 25. Finally make the power connections with the flexible links to the Bus and torque to 20 lb•ft (27 N•m). Do not drop any hardware during the process of re-connecting the links. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 58: Control Function Tests

    SMC Flex front panel display. (see Parameter 106 – MV Ratio in Table 52 on page 131) Table 6 - Input Voltage Ranges Module-rated Voltage Voltage Range MV Ratio 12,000 10,000...12,000 14,400 12,001...15,000 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 59: Start-Up

    5. If an earthing switch is provided, it must be opened before the apparatus can be inserted to the service position. 6. The controller is ready to power the motor. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 60 Chapter 2 Commissioning Procedure Notes: Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 61: Programming

    Parameters are organized in a three-level menu structure for straightforward programming. Figure 33 details the programming menu structure and the three- level hierarchy. To change parameters, the controller must be in the STOP mode, and the control voltage must be present. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 62 Linear List GROUP MENU Parameter menu Continued in Figure 34 The SMC Flex controller does not support EEPROM, Link, Process, or Start-up modes. Steps back one level. Shown if password protection is configured. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 63 Braking Current For further information on parameters, see Appendix B. Slow Speed Sel For further information on parameter management, see page Slow Speed Dir Slow Accel Cur Slow Running Cur Stopping Current Parameter Mgt Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 64 Bypass Delay Pump Pedestal PTC Enable Fault 1 Braking Current Phase Reversal Fault 2 Braking Time Starts Per Hour Fault 3 Load Type Restart Attempts Fault 4 High Eff Brake Restart Delay Fault 5 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 65: Password

    8. Press the Enter key after you have completed modifying the password. (1) To complete the programming process, reenter the Main Menu mode to log out. This eliminates unauthorized access to the programming system. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 66: Parameter Management

    Program mode. At any time, you can restore defaults by accessing the memory storage menu. Table 10 - SMC Flex Controller ROM Reset Procedure Description Action Display Recalling Defaults: After parameter values have been modified, factory default settings can still be re-initialized. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 67: Electrically Erasable Programmable Read-Only Memory (Eeprom)

    5. Press Enter to select the Set Up group. 6. Scroll to Basic Set Up and press Enter. 7. Scroll to the Starting Mode parameter by using the Up/Down keys, and press Enter. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 68: Soft Start

    This must be programmed for Soft Start. Current Limit Ramp Time Programs the time period that the controller will ramp the output 0...30 s voltage up to full voltage from the initial Torque level programmed. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 69: Dual Ramp Start

    (3) For ramp times greater than 30 s, set “Ramp Time 2” to zero and program “Start Time 2E” (parameter 130) for the new time. Do not exceed the thermal capacity of the controller. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 70: Full Voltage Start

    (3) Consult factory if settings over 30 seconds are required. The base rating of the MV SMC-Flex is two starts (or one start/stop combination) per hour, 30 seconds maximum for each operation. A stopping operation counts as a start for purposes of thermal capacity calculations. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 71: Preset Slow Speed

    Current Limit The current limit level that is applied for the Ramp time selected. 50…600% FLC Level Kickstart Time A boost current is provided to the motor for the programmed time 0.0…2.0 s period. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 72 A 'Stop' command opens the line contactor first and allow the motor to coast, regardless of the programmed 'Stop Mode' . For Pump Option modules, the Option 2 input defaults to 'Emergency Run' for MV applications. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 73: Motor Protection

    (1) The delay time must be set to a value greater than zero when Undervoltage, Overvoltage, and Unbalance are enabled. (2) For Jam and Underload detection to function, the Motor FLC must be programmed in the Motor Protection group. See page Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 74: Example Settings

    With Motor FLC programmed for 90 A and the Underload level programmed for 60%, the trip value is 54 A. (1) The average value of the three phase-to-phase voltages is utilized. (2) The largest value of the three phase currents is utilized. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 75: Motor Information

    (3) See the SMC Flex controller nameplate for maximum ratings. Exceeding these could result in damage to the controller. (4) This is not to indicate how the motor windings are configured. Do not select “Delta” for MV applications. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 76 Chapter 3 Programming Notes: Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 77: Metering

    2. Scroll with the Up/Down keys until the Parameter option is shown. 3. To access the Parameter option, press the Enter — key. 4. Scroll with the Up/Down keys until the Monitoring option is displayed. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 78 Figure 34 on page 63 for details on the metering functions. The metering values that are displayed on the controller can be modified to show you desired values by accessing Main Menu / Preferences. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 79: Options

    The red stop button, when pressed, provides a coast stop. The jog button is not active for Preset Slow Speed. Preset Slow Speed Slow Speed cannot be operated via the HIM. Pump Control Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 80 (1) Braking Control is not offered for standard use in MV applications. Consult factory for further assistance. ATTENTION: The Bulletin 20-HIM interface module’s stop push button is not intended to be used as an emergency stop. See the applicable standards for emergency stop requirements. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 81: Programming Parameters

    (1) Braking Control is not offered for standard use in MV applications. Consult factory for further assistance. (2) All braking/stopping current settings in the range of 1…100% provide 100% braking current to the motor. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 82: Control Wiring

    When the motor is stopped, it will coast. If the supply is restored, the alarm symbol is cleared and the module performs the programmed sequence. Control Wiring Chapter 1 for typical control wiring examples that are used with various control schemes. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 83: Overview

    Press ESC to get to another programming/diagnostic list. The controller remains in a faulted state. Resetting a fault does not correct the cause of the fault condition. Corrective IMPORTANT action must be taken before resetting the fault. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 84: Clear Fault

    Line Loss C Coms Loss P2 Shorted SCR A Coms Loss P3 Shorted SCR B Coms Loss P5 Shorted SCR C Network P2 Open Gate A Network P3 Open Gate B Network P5 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 85: Fault And Alarm Auxiliary Indication

    PTC trips, the controller trips and indicates a Motor PTC fault. Open Bypass Power Pole bypass contacts are monitored for proper operation. In the event of a contact failure, the controller indicates an Open Bypass fault. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 86: Overload Class

    SCR conduction is not continuous, a fault is indicated. (1) Phase loss, overvoltage, and undervoltage protection are disabled during braking operation. (2) Jam detection and underload protection are disabled during slow speed and braking operation. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 87: Communication

    3 available by installing a splitter on port 2. Port 5 is supported by connecting one of the modules that are listed in Table 26 to the internal DPI comm card connection. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 88: Human Interface Module

    Bulletin 20-HIM Rev3.002 or later must be used with the SMC Flex. Extension cables are available up to a maximum of 10 m (32.8 ft). A maximum of two HIM modules can be installed. The control panel provides the operator interface to the controller. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 89: Connecting The Human Interface Module To The Controller

    HIM Modules. SMC Flex does not support scanport devices. Figure 25 on page 45 Figure 26 on page 46 for the control wiring diagram that enables start-stop control from a human interface module. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 90: Him Control Enable

    1. Disconnect the HIM and allow to power down. 2. Reconnect the HIM. On Initializing screen, the bottom right corner of LCD shows Port X. Note this port number. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 91 Only the DPI communication card on port 5 is enabled One HIM on port 2 and the DPI communication card on port 5 are enabled Two HIMs on ports 2 and 3 and the DPI communication card on port 5 are enabled Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 92: Control Enable

    (2) The reference word is not used with the SMC Flex; however, the space must be reserved. The total size that is produced or consumed varies, depending on the communication card being used. For more information, see the user manual for the communication card. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 93: Variable Input/Output Configuration

    I/O data sizes. Table 32 - Variable Input/Output Configuration Data Links Logical Status/ Reference/ Rx Size Tx Size Command (16 b) Feedback (16 b) To configure Datalinks, see Configuring Datalinks on page Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 94: Smc Flex Bit Identification

    0 – Not Ready 1 – Input Active Option 1 Input 0 – Input Inactive 1 – Input Active Option 2 Input 0 – Input Inactive — — Bits 12 to 15 – Not Used Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 95: Reference/Feedback

    The SMC Flex does not offer the analog Reference feature. The analog Feedback Reference/Feedback feature is supported and provides Parameter1, Current in Phase A, automatically as the feedback word. Parameter Information A complete listing of the SMC Flex parameters is located on page 131. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 96: Scale Factors For Plc Communication

    This relationship is identical for other similar parameters that are located in Appendix B. Table 35 - Display Text Unit Equivalents Text Descriptor Numerical Equivalent Disabled Class 10 Class 15 Class 20 Class 30 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 97: Configuring Datalinks

    The latest version of firmware and instructions for the SMC Flex can be obtained from www.ab.com. The MV SMC Flex must use firmware release 6.003 or later. This manual pertains to units with firmware release 6.003 or later. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 98 Chapter 7 Communication Notes: Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 99: Troubleshooting

    For MV SMC Flex technical support on start-up or existing installations, contact your Rockwell Automation representative. You can also call 1-519-740-4790 for assistance Monday through Friday from 9:00 a.m. to 5:00 p.m. (EST). For after hours technical support, call pager no. 519-654-5616. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 100 Open Gate (with phase indication) 7, 8, and 9 • Open gate circuitry • Perform power supply tests (Chapter • Loose gate lead • Check gate lead connections to the gate driver boards and fiber optics Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 101 • Check for open line (for example, blown line fuse) indication) • Loss of feedback • Check CT connections, replace Interface board HAL_ID • Faulty interface • Check ribbon cable connections between interface board and control module • Replace interface board Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 102 • Check for binding or external loading and correct • Inadequate Current Limit setting • Check motor • Failed control module • Adjust the Current Limit Level to a higher setting • Replace control module Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 103 • Time setting • Verify the programmed stopping time and correct if necessary (1) Various faults can occur if Parameter #15 is set to "Delta". It must be set to "Line" for all MV applications. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 104: Control Module Removal

    5. Carefully rotate the module to the left, and unplug the five ribbon cables from the interface board. ATTENTION: When removing the control module, make sure to hold the module in place as the screws are removed, to avoid strain on the ribbon cables. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 105: Voltage Feedback Circuit Test

    VSB. Cut the cable ties and remove the wires from the assembly. b. Install the wires on the new assembly in the same positions and secure them with cable ties at the ends of the wire guide channels. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 106 Failure to replace all six covers with nylon hardware before energizing may result in personal injury, property damage or economic loss. Figure 42 - 14.4 kV Sensing Board Insulation Shrouds Insulation Shroud Nylon Screw goes here VSB channel Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 107 7. For personnel and equipment safety, reconnect both grounding connections to the sensing board. Figure 43 - Sensing Board with mounting hardware placement Mounting Hardware Mounting Hardware Mounting Hardware Mounting Hardware Wire Guide Channels Cable Ties High Voltage Wires Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 108: Current Loop Power Supply

    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. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 109: Power Circuit

    Variations may also be noted based on the devices used in different ratings of PowerBricks. The key is to look for notable differences between individual PowerBricks or power poles. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 110 Overvoltage Sense Connection 6. If the resistance values are out of range, the PowerBrick must be removed from the power pole cart assembly. Refer to PowerBrick removal procedure in the Installation Manual (publication 7760-IN001_-EN-P). Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 111 If the snubber components are suspect, repair or replace the PowerBrick. Refer to Appendix C for replacements parts. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 112 Figure 47. Check DC resistance values per step 5 above. 11. Replace the PowerBrick in the power pole assembly. Figure 47 - PowerBrick Component Wiring Diagram SCR2 SCR1 Thermistor Sharing Resistors Snubber Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 113: Voltage Sensing Board Testing

    Measure across R2, R4, R6, R10, R12, R14, R18, R20 and R22 located at the bottom of each leg of the module. The resistance should be 11.3 kohm. (The two ground connections must be connected to ground, or to each other if the module has been removed.) Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 114: Power Resistor Replacement

    When replacing the ceramic wire-wound type resistors, use caution when handling the parts. The resistor element is under a thin coating on the ceramic tube, and it may be damaged if dropped, struck or scraped. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 115: Maintenance

    ATTENTION: Allen-Bradley magnetic starters, contactors, and relays are designed to operate without lubrication – do not lubricate these devices since oil or grease on the pole face (mating surfaces) of the operating magnet may cause the device to stick in the “ON”...

  • Page 116: Vacuum Bottles

    Installation and Maintenance of Solid State Control”. ATTENTION: Use of other than factory-recommended test equipment for solid- state controls may result in damage to the control or test equipment, or unintended actuation of the controlled equipment. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 117: Static-Sensitive Items

    ELECTRICAL EQUIPMENT MAINTENANCE”, published by the National Fire Protection Association. Power Components Keep power components clean and free of dirt and obstructions. This practice avoids tracking and heat build-up, increasing the life of the device. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 118: Control Components - Electronic

    Contact the factory for any environmental information on any material in the product or with questions regarding environmental impact. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 119: Disposal

    (steel, copper, plastic, wire, and so forth). Send these materials to local recycling facilities. In addition, all disposal precautions that are mentioned here must also be taken for those particular materials. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 120: Rockwell Automation Publication 7760-Um001F-En-P - March

    Chapter 9 Maintenance Notes: Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 121: 7760, 7761, 7762, And 7763 Smc

    Appendix 7760, 7761, 7762, and 7763 SMC Flex Specifications Table 42 - Electrical Ratings (Bulletin 7761) Electrical Ratings Power Circuit Method of Connection Motor in delta or star; SCRs between windings and supply Number of Poles Equipment that is designed for three phase loads only...

  • Page 122: Appendix A

    Appendix A 7760, 7761, 7762, and 7763 SMC Flex Specifications Electrical Ratings Safety: 92/59/EEC (Directive) Ref:BSEN 61010-1:1993 BSEN 60204-1:1997 Approvals IEC 62271-1 IEC 62271-200 IEC 60146-1-1 IEC 60947-4-2 Short Circuit Protection Protect the power electronics unit by current-limiting fuses or a fast-acting circuit breaker. The standard 12 kV combination controller includes appropriate fusing (coordinated with motor).

  • Page 123: Appendix A

    7760, 7761, 7762, and 7763 SMC Flex Specifications Appendix A Electrical Ratings Tachometer Input (Control Module) Voltage 0…5V DC; 4.5V DC=100% speed Current 1.0 mA (1) Excludes power electronics (2) For stop maneuvers, the gate driver boards are pre-charged with a current loop power supply (75 VA).

  • Page 124: Appendix A

    Appendix A 7760, 7761, 7762, and 7763 SMC Flex Specifications Table 46 - Power Bus Specifications Attribute Value Main Power Bus Bus Bar Material Tin-plated insulated copper Optional Power Bus Plating Silver Continuous Current Rating at 40 °C 1250, 2000 A (104 °F)

  • Page 125: Appendix A

    7760, 7761, 7762, and 7763 SMC Flex Specifications Appendix A Table 47 - Medium Voltage Spring Actuated Vacuum Circuit Breaker: 10…12 kV Attribute Value Voltage Ratings Maximum Rated Voltage 12 kV Basic Impulse Level (B.I.L.) Withstand– Phase to Ground, Phase to Phase (kV)

  • Page 126: Appendix A

    Appendix A 7760, 7761, 7762, and 7763 SMC Flex Specifications Table 48 - Medium Voltage Spring Actuated Vacuum Circuit Breaker: 12.5…15 kV Attribute Value Voltage Ratings Maximum Rated Voltage 17.5 kV Basic Impulse Level (B.I.L.) Withstand– Phase to Ground, Phase to Phase (kV) Rated Insulation Voltage 17.5 kV...

  • Page 127: Appendix A

    7760, 7761, 7762, and 7763 SMC Flex Specifications Appendix A Table 49 - Medium Voltage Magnetically Actuated Vacuum Circuit Breaker: 10…12 kV Attribute Value Voltage Ratings Maximum Rated Voltage 12 kV Basic Impulse Level (B.I.L.) Withstand– Phase to Ground, Phase to Phase (kV)

  • Page 128: Appendix A

    Appendix A 7760, 7761, 7762, and 7763 SMC Flex Specifications Table 50 - Medium Voltage Magnetically Actuated Vacuum Circuit Breaker: 12.5…15 kV Attribute Value Voltage Ratings Maximum Rated Voltage 17.5 kV Basic Impulse Level (B.I.L.) Withstand– Phase to Ground, Phase to Phase (kV) Rated Insulation Voltage 17.5 kV...

  • Page 129: Appendix A

    7760, 7761, 7762, and 7763 SMC Flex Specifications Appendix A Table 51 - Medium Voltage Vacuum Contactor: 10 to 12 kV Attribute Value Voltage Ratings Maximum Rated Voltage 12 kV Rated insulation voltage 12 kV Impulse withstand voltage 75 kV...
  • Page 130 Appendix A 7760, 7761, 7762, and 7763 SMC Flex Specifications Notes: Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 131: Parameter Information

    Do not set to Basic Set Up Motor Connection Line/Delta Line attached motor (WYE or DELTA). A fault controlled “Delta” means of disconnecting the line should always be use in the DELTA mode. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 132: Appendix B

    When using the current limit starting mode for profile #2, this parameter allows the user to adjust Dual Ramp Cur Limit Level 2 %FLC 50…600 the current level applied to the motor during the start maneuver. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 133: Appendix B

    2 – Hi Friction work sufficiently. Adjusting this parameter should 3 – Ramp 89 really only be used when some type of problem during braking is being encountered. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 134 OL Trip Enable/ maneuvers. Motor Thermal Usage (%MTU) Linear List Enable Disable continues to increment during these maneuvers. 1= Enable Setting this parameter to disable can result in motor overheating or potential damage. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 135: Appendix B

    Allows the user to set a percentage of line to line Voltages that will cause an Alarm when the voltage Unbalance Unbalance A Lvl 0…25 falls above this value. A zero value is the “off” setting. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 136: Appendix B

    Allows the user to enable the SMC-Flex to auto- restart for up-to 5 attempts, other than an SCR Restart Restart Attempts 0…5 overtemp or motor overload fault. The start signal must remain active for a restart to occur. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 137: Appendix B

    CT Ratio 1…1500 current transformer is used for Medium Voltage applications. (example, for 150:5, set 150) Sets the proper feedback scaling when used for Motor Data MV Ratio 1…10000 Table 6 Medium Voltage applications. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 138: Appendix B

    0 = Disable Linear List Timed Start Disable an early up-to-speed detection. The default is set to before adjusting 1=Enable “Disabled”, so that the SMC can determine when the this parameter. motor is at speed. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 139: Appendix B

    (pump control) parameter without specifically talking with Technical Support. An internal on-delay timer. Ensures that a Linear List Start Delay 0…30 subsequent start can not be initiated for a preset amount of time. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 140: Appendix B

    Elapsed Time 2 Hours 0.0/3000.0 be reset by the user. It increments exactly as the Elapsed Time but cannot be reset. (1) Pump option modules default to “Pump Stop”. (2) Brake option modules only. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 141: Spare Parts

    81020-752-86-R Complete Rollout Assembly 10…12 kV 580 A 81020-761-85-R (with power bricks, gate driver boards, and CT loop) Complete Rollout Assembly 12.4…14.4 kV 81020-295-85-R (with power bricks, gate driver boards, and CT loop) Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 142 Frequency to voltage converter to Tachometer feedback 80026-427-02-R 0…100 kHz 80026-433-01-R Power Supply for frequency to voltage converter (1) Optional equipment. 7703E – For OEM products, refer to OEM-supplied documentation for specific spare parts list. Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...

  • Page 143: Accessories

    Remote Door Mounted P66 (Type 4/12) Programmer Only 20-COMM-R Remote I/O 20-COMM-S RS 485 (DF-1) 20-COMM-D DeviceNet 20-COMM-C ControlNet 20-COMM-E EtherNet/IP Communication Modules 20-COMM-P Profibus® 20-COMM-I InterBus 20-COMM-L LonWorks 20-COMM-Q ControlNet (Fiber) 20-COMM-H RS485 HVAC Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 144 Appendix D Accessories Notes: Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 145 7762 – Combination 16 7763 – Combination 17 Hardware Current Limit Start Current Loop Gate Driver (CLGD) Board Programming 68 overview 41 Current Limit Start starting mode description 40 overview 23 Interface Board Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 146 Static-Sensitive Items 117 Full Voltage 24 Terminals 116 Linear Speed Acceleration and Decelera- Vacuum Bottles 116 tion 26 Metering Preset Slow Speed 25 overview 36 Selectable Kickstart 23 viewing data 77 Soft Start 22 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 147 Read-only Memory (EEPROM) 67 Electrical Ratings (Bullet 7761) 121 Random Access Memory (RAM) 66 Environmental Ratings 123 Read-Only Memory (ROM) 66 Medium Voltage Magnetically Actuated Parameter Menu Vacuum Circuit Breaker 10 to 12 kV 127 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 148 Static-Sensitive Items Maintenance 117 Status Indication overview 38 Stop Control Programming 70 Terminals Maintenance 116 tests Control Function 58 Hi-Pot and Megger 50 Resistance and Power Supply 53 Thermistor Protection and Diagnostics overview 33 Rockwell Automation Publication 7760-UM001F-EN-P - March 2016...
  • Page 150 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Accu-Stop, Allen-Bradley, DPI, OneGear, PowerBrick, PowerFlex, Rockwell Automation, Rockwell Software, RSNetWorx, SMB, and SMC are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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