Page 1 Medium Voltage Dialog Plus™ Motor Controller Bulletins 1503D, 1560D and 1562D User Manual...
Page 2 In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
Page 3: Table Of Contents
Table of Contents Page Preface Service Procedure ................Product Overview Chapter 1 Manual Objectives ................1-1 Documentation .................. 1-1 Description ..................1-1 1503D – Chassis Mount Retrofit Controller ....... 1-1 1560D – Retrofit Controller............1-1 1562D – Combination Controller ..........1-2 Dialog Plus™...
Page 4 Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual Installation Chapter 2 Page Receiving ................... 2-1 Safety and Codes ................2-1 Unpacking and Inspection ..............2-1 General Precautions................2-2 Transportation and Handling ............. 2-2 Installation Site .................. 2-3 Mounting ..................
Page 5 Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual Programming Chapter 4 Page Overview ................... 4-1 Keypad Description ................4-1 Programming Menu ................4-1 Password .................... 4-5 Search ....................4-5 Parameter Management ..............4-6 Random Access Memory (RAM) ..........4-6 Read-only Memory (ROM) ............
Page 6 Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual Serial Communications Chapter 8 Page Overview ................... 8-1 Logic Control Data ................8-1 Control Wiring .................. 8-1 Control Enable ................... 8-2 SMC Status Data ................8-3 Reference/Feedback ................8-3 Parameter Listing ................
Page 7 Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual Maintenance Chapter 11 Page Safety and Preventative ..............11-1 Periodic Inspection ................11-1 Contamination ................11-1 Vacuum Bottles ................. 11-2 Terminals ................... 11-2 Coils ................... 11-2 Solid-State Devices ..............11-3 Static-Sensitive Items ..............
Page 8 Table of Contents – MV Dialog Plus Medium Voltage Controller User Manual 1560D-UM051D-EN-P – February 2005...
Page 9: Preface
Rockwell Automation Distributor or Sales Office. For MV Dialog Plus 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).
Page 10 Preface 1560D-UM051D-EN-P – February 2005...
Page 11: Product Overview
MV Dialog Plus family of controllers. The family consists of the following Bulletin numbers: 1503D, 1560D and 1562D. Documentation The following Rockwell Automation publications provide pertinent information for the MV Dialog Plus: • MVB-5.0 General Handling Procedures for MV Controllers • 1500-UM055B-EN-P Medium Voltage Controller –...
Page 12: 1562D - Combination Controller
Product Overview Description (cont.) 1562D – Combination Controller A medium voltage solid-state controller that provides isolation and protection for new installations. It includes: • Tin-plated, copper, horizontal power bus (optional) • A continuous, bare copper ground bus • Power electronics •...
Page 13: Starting Modes
Product Overview Starting Modes Soft Start This mode has the most general application. The motor is given an initial torque setting, which is user-adjustable from 0 to 90% of locked-rotor torque. From the initial torque level, the output voltage to the motor is steplessly increased during the acceleration ramp time.
Page 14: Current Limit Start
Product Overview Starting Modes (cont.) Current Limit Start This starting mode provides a fixed, reduced-voltage start that is used when limiting the maximum starting current is necessary. The Current Limit level is user-adjustable from 50% to 600% of the motor's full-load ampere rating, and the current limit time is user-adjustable from 0 to 30 seconds.
Page 15: Dual Ramp Start
Product Overview Dual Ramp Start This starting mode is useful for applications that have varying loads (and therefore varying starting torque requirements). Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings. Percent Percent Voltage...
Page 16: Protection And Diagnostics
Product Overview Protection and Diagnostics The MV Dialog Plus™ controller is capable of providing the following protective and diagnostic features: Overload The MV Dialog Plus controller meets applicable requirements as a motor overload protective device. Thermal memory provides added protection and is maintained even when control power is removed.
Page 17 Product Overview Class 10 Class 10 Class 15 Class 15 Class 20 Class 20 Class 30 Class 30 1000.0 1000.0 10000.0 10000.0 10000.0 10000.0 10000.0 10000.0 100.0 100.0 1000.0 1000.0 1000.0 1000.0 1000.0 1000.0 10.0 10.0 100.0 100.0 100.0 100.0 100.0 100.0 10.0...
Page 18: Stall Protection And Jam Detection
Product Overview Protection and Diagnostics Stall Protection and Jam Detection (cont.) The MV Dialog Plus™ controller provides both stall protection and jam detection for enhanced motor and system protection. • Stall protection is user-adjustable from 0.0 to 10.0 seconds (enabled only after start time expires).
Page 19: Open Gate
Product Overview Open Gate An open-gate fault indicates that improper SCR firing, typically caused by an open SCR gate or driver system, has been detected on one of the power poles. Before the controller shuts down, it will attempt to start the motor a total of three times (or as programmed in Parameter 64).
Page 20: Underload
1-10 Product Overview Protection and Diagnostics Underload (cont.) If a sudden drop in current is detected, motor operation can be halted by utilizing the underload protection of the MV Dialog Plus controller. The MV Dialog Plus controller provides an adjustable underload trip setting from 0 to 99% of the programmed motor full-load current rating.
Page 21: Communication
Product Overview 1-11 Notes: 1. The current sensing capability of the MV Dialog Plus controller requires a Bulletin 825 converter module to maintain the three-phase current, and motor thermal capacity measurements. 2. Current measurement is not available during the slow speed and/or braking operations of the Preset Slow Speed, SMB Smart Motor Brak- ing, and Slow Speed with Braking control options.
Page 22: Programming
An existing controller may be upgraded to another control option by replacing the control module and possibly other components. Consult your nearest Rockwell Automation sales office. Option maneuvers count as a start when determining thermal capacity of the MV Dialog Plus.
Page 23: Pump Control Option
Product Overview 1-13 Percent Percent Voltage Voltage 100% 100% Kickstart Kickstart Coast-to-rest Coast-to-rest Soft Stop Soft Stop Initial Initial Torque Torque Start Start Soft Stop Soft Stop Time (seconds) Time (seconds) Figure 1.12 – Soft Stop Option A T T E N T I O N A T T E N T I O N Soft Stop is not intended to be used as an emergency stop.
Page 24 1-14 Product Overview Control Options (cont.) 3. The Pump Stop option functions only for a centrifugal pump running at greater than approximately 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.
Page 25: Preset Slow Speed Option
Product Overview 1-15 Preset Slow Speed Option This option can be used in applications that require a slow-speed jog for general purpose positioning. Preset Slow Speed provides either 7% of base speed (low) or 15% of base speed (high) settings in the forward direction.
Page 26: Slow Speed With Braking Option
1-16 Product Overview Control Options (cont.) SMB™ Smart Motor Braking Option (cont.) Note: All braking current settings in the range of 1-100% will provide 100% braking current to the motor. A T T E N T I O N A T T E N T I O N SMB Smart Motor Braking is not intended to be used as an emergency stop.
Page 27: Hardware Description
Product Overview 1-17 Hardware Description The following sections contain descriptions of system components and system operation. Each section will be described to give the user an understanding of the MV Dialog Plus to facilitate operation and main- tenance of the system. Refer to Figure 1.17, Typical MV Dialog Plus Power System Diagram.
Page 28: Interface Board
1-18 Product Overview Hardware Description (cont.) Self-Powered Silicon-Controlled Rectifier Gate Driver Board (cont.) The MV Dialog Plus™ has three heatsinks fitted with a thermistor to monitor SCR temperature rise. The circuitry on the gate driver board accepts the thermistor, and drives a fibre-optic cable if the temperature is below the setpoint (85°C).
Page 29: Typical Mv Dialog Plus Power System Diagram
Product Overview 1-19 UTS N/O UTS N/O UTS N/O UTS N/O Figure 1.17 – Typical MV Dialog Plus Power System Diagram (Without Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 30: Functional Description
1-20 Product Overview Functional Description Bulletin 1562D • Basic Control – Standard Module When wired as shown in Figure 1.18, the controller operates as follows: Pressing the "Start" button initiates the start sequence. Relay "CR" closes and applies control power to terminal 16 of the Dialog Plus module. The auxiliary contact #3 (set for "normal") closes, picking up "MC"...
Page 31: Bulletin 1562D • Scanport Control - Standard Module
Product Overview 1-21 Bulletin 1562D • Basic Control – Soft Stop or Pump Control (cont.) If the motor has started, the unit is in the bypass mode, and a trip occurs within the Dialog Plus module or from an external protection relay. “MC” and “MCX”...
Page 32: Bulletin 1560D • Basic Control - Standard Module
1-22 Product Overview Functional Description (cont.) Bulletin 1560D • Basic Control – Standard Module The Bulletin 1560D is intended for addition to an existing motor controller, which provides circuit isolation, motor switching, and overload and overcurrent protection. When wired as shown in Figure 1.22, the controller operates as follows: When a start is initiated in the existing motor controller and the contactor (or breaker) closes, a contact must be supplied to tell the 1560D to start...
Page 33 Product Overview 1-23 Figure 1.18 – Bulletin 1562D Basic Control Circuit • Standard Module 1560D-UM051D-EN-P – February 2005...
Page 34 1-24 Product Overview RECTIFIER RECTIFIER Figure 1.19 – Bulletin 1562D Basic Control Circuit • Soft Stop or Pump Control 1560D-UM051D-EN-P – February 2005...
Page 35 Product Overview 1-25 Figure 1.20 – Bulletin 1562D with SCANport Control • Standard Module 1560D-UM051D-EN-P – February 2005...
Page 36 1-26 Product Overview RECTIFIER RECTIFIER Figure 1.21 – Bulletin 1562D with SCANport Control • Soft Stop or Pump Control 1560D-UM051D-EN-P – February 2005...
Page 37 Product Overview 1-27 Figure 1.22 – Bulletin 1560D Basic Control Circuit • Standard Module 1560D-UM051D-EN-P – February 2005...
Page 38 1-28 Product Overview RECTIFIER RECTIFIER Figure 1.23 – Bulletin 1560D Basic Control Circuit • Soft Stop or Pump Control 1560D-UM051D-EN-P – February 2005...
Page 39: Receiving
Inspect the equipment for physical damage, as stated in the Rockwell Automation Conditions of Sale. Remove all packing material, wedges, or braces from within the controller.
Page 40: General Precautions
Installation General Precautions In addition to the precautions listed throughout this manual, the following statements, which are general to the system, must be read and understood. A T T E N T I O N A T T E N T I O N The controller contains ESD (electrostatic discharge) sensitive parts and assemblies.
Page 41: Installation Site
The 1503D, 1560D and 1562D are designed to be mounted in the vertical position. Standard cabinet drawings with certified dimension drawings can be obtained by contacting your local Rockwell Automation Sales office for the 1560D/1562D. Please refer to OEM documentation for the 1503D.
Page 42: Grounding Practices
Installation Installation Site (cont.) Grounding Practices The purpose of grounding is to: A. Provide safety for Personnel. B. Limit dangerous voltages to ground on exposed parts. C. Facilitate proper overcurrent device operation under ground fault conditions. D. Provide for electrical interference suppression. Important: Generally, grounding should be in accordance with the Canadian Electrical Code (CEC) or National Electrical Code (NEC) and other local codes.
Page 43: Power Connections
Installation Power Connections The controller requires a three-phase supply and an equipment grounding conductor to earth ground. A neutral conductor of the three-phase supply is not necessary and is usually not routed to the controller. Three-phase wiring will connect the controller to the motor. Important: Refer to 1500-UM055B-EN-P for power/ground bus location and cable routing for a Bulletin 1562D.
Page 44 Installation Power Connections (cont.) Phase 1 Module Phase 1 Module Phase 1 Line Connection Phase 1 Line Connection Phase 1 Load Connection Phase 1 Load Connection Phase 2 Module Phase 2 Module Phase 2 Line Connection Phase 2 Line Connection Phase 2 Load Connection Phase 2 Load Connection Phase 3 Line Connection...
Page 45 Installation Phase 1 Module Phase 1 Module Phase 1 Line Terminal Phase 1 Line Terminal Phase 1 Load Terminal Phase 1 Load Terminal Phase 2 Line Terminal Phase 2 Line Terminal Phase 2 Module Phase 2 Module Phase 2 Load Terminal Phase 2 Load Terminal Phase 3 Line Terminal Phase 3 Line Terminal...
Page 46: Power Wiring
Inadequate interlocking could expose personnel to energized parts which could result in severe burns, injury or death. NOTE: Rockwell Automation can assist with the selection of an appro- priate interlocking method, which may include mechanical modifications to the cabinet(s) or key-type lock systems.
Page 47: Installation
Installation Installation Physical Location The controller is designed for limited front access (components may have to be removed) and should be installed with adequate and safe clearance to allow for total door opening. The back of the unit may be placed against a wall and several units may be set end to end.
Page 48: Power Factor Correction Capacitors
2-10 Installation Installation (cont.) Power Factor Correction Capacitors The controller can be installed on a system with power factor correction capacitors. The capacitors must be located on the line side of the controller. This is required to prevent damage to the SCRs in the MV Dialog Plus™ controller.
Page 49 Installation 2-11 Power Bus Power Bus Isolation Switch Isolation Switch Isolation Switch Isolation Switch Fuse Fuse Fuse Fuse Contactor Contactor Isolation Contactor Isolation Contactor di/dt Inductor di/dt Inductor di/dt Inductor di/dt Inductor Capacitor Capacitor PFCC PFCC PFCC PFCC Contactor Contactor (Power Factor (Power Factor Correction Capacitor)
Page 50: Surge Arrestor Protection Devices
2-12 Installation Surge Arrestor Protection Rockwell Automation highly recommends that motor surge capacitors and/or Devices motor surge arresters not be located on the load side of the SMC. The issues that warrant this are: • Motor and system inductance limits the rate at which the current can change through the SMC.
Page 51: Motor Overload Protection
Installation 2-13 Motor Overload Protection Thermal motor overload protection is provided as standard (though it must be programmed) with the MV Dialog Plus™ controller. If the overload trip class is less than the acceleration time of the motor, nuisance tripping may occur.
Page 52: Human Interface Module
2-14 Installation Human Interface Module The Bulletin 1201 human interface modules may be used to program and control the SMC Dialog Plus controller. The human interface modules have two sections: a display panel and a control panel. The display panel duplicates the two-line, 16-character, backlit LCD display and programming keypad on the front of the SMC Dialog Plus controller.
Page 53: Connecting The Human Interface Module To The Controller
Installation 2-15 Connecting the Human Interface Module to the Controller Figure 2.5 shows the connection of the SMC Dialog Plus controller to a human interface module. See Figure 1.20 or 1.21 on page 1-25 or 1-26 for the control wiring diagram that enables start-stop control from a human interface module.
Page 54 2-16 Installation Human Interface Module (cont.) Control Enable To enable motor control from a connected human interface module, follow the procedure below with the connected human interface module's programming keys. Note: Series A and Series B human interface modules require different procedures.
Page 55: Control Enable
Installation 2-17 Series B Human Interface Modules Description Action Display — — STOPPED 0.0 AMPS 1. Press any key to access the Choose CHOOSE MODE Mode function. _ _ _ _ _ 2. Scroll with the Up/Down keys until the CHOOSE MODE Control Logic option is presented.
Page 56: Communication Modules
2-18 Installation Communication Modules The Bulletin 1203 communication module allows the user to connect the SMC Dialog Plus™ controller to various networks and communication protocols. The figure below shows how the controller and the communi- cation module connect. Latching Bulletin 1202 Cable Mechanism Pull back moving part (connector body) to disconnect cable from the SCANport connection.
Page 57: Wiring
Installation 2-19 Wiring Wire in an industrial control application can be divided into three groups: power, control and signal. The following recommendations for physical separation between these groups is provided to reduce the coupling effect. • Different wire groups should cross at 90° inside an enclosure. •...
Page 58: Converter Modules
2-20 Installation Converter Modules The Bulletin 825 converter module provides three-phase current feedback to the SMC Dialog Plus™ controller for metering and overload protection during bypass operation. Cat. No. 825-MCM20 is to be used with current transformers. The current transformer ratio must be programmed in the calibration group for proper current measurement scaling.
Page 59 Installation 2-21 The figure below illustrates the connection of the current transformers to the converter module. Current Transformer Current Transformer Converter Module Converter Module Figure 2.8 – Current Transformer Connection to Converter Module The current transformer (CT) ratio must be programmed in the calibration group for proper current measurement scaling.
Page 60: Control Terminal Designations
2-22 Installation Control Terminal Designations As shown in Figure 2.9, the SMC Dialog Plus™ controller is equipped with 20 control terminals on the front of the controller. Figure 2.9 – SMC Dialog Plus Controller Control Terminals Terminal Number Terminal Number Description Description Control Power Input...
Page 61: Commissioning Procedure
Chapter Commissioning Procedure Preliminary Set-Up A. Ensure the work area is clean and tidy. Pathways to main disconnect and emergency stop push-button must be clear and unobstructed. B. The following test equipment is to be prepared for use: • Test power supply, supplied with each controller •...
Page 62: System Characteristics
Commissioning Procedures 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_______ or Variable Torque _______ Actual Motor Data: __________________________________________ Motor HP: _________________________________________________ Motor Rated Speed: _________________________________________ Motor F.L.A.: ______________________________________________ Motor S.F.: ________________________________________________ Motor L.R.A.: ______________________________________________...
Page 63: Preliminary Check
Commissioning Procedures Preliminary Check A T T E N T I O N A T T E N T I O N Ensure that all sources of power are isolated and locked out before working on installed equipment. Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device.
Page 64: Hi-Pot And Megger Test
Commissioning Procedures Hi-Pot and Megger Test It is recommended that insulation levels be checked before energizing power equipment. This may be done with a High Voltage AC insulation tester (HI-POT) or a Megger. See Publication 1502-5.0 for suggested HI-POT testers, and for test procedures for vacuum contactors. If using a Megger, a 5000 volt type is recommended.
Page 65 Commissioning Procedures Control Fuse (F1): Replace with Control Fuse (F1): Replace with DIP 1: Pulse – Turn ON (slide up) to DIP 1: Pulse – Turn ON (slide up) to Indicated size and type, depending on Indicated size and type, depending on apply test pulses to gate drive circuits.
Page 66: Power Supply Tests
Commissioning Procedures Power Supply Tests A T T E N T I O N A T T E N T I O N Servicing energized industrial control equipment can be hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment.
Page 67 Commissioning Procedures NOTE: Systems with optional Pump Control or Soft Stop include continuous gate drive power supplies (IGDPS); therefore, steps 5 and 10 do not apply. 5. Since the gate driver circuits normally receive power from the snubber circuits when the SMC is operating, an alternate source must be used for testing.
Page 68 Commissioning Procedures Power Supply Tests (cont.) 7. The gate-driver board voltage may be checked by connecting a DC voltmeter to TP2 (+) and TP1 (-) (See Figure 3.3). With the specified power supply connected, the voltage should be 12 ± 2 VDC. 8.
Page 69: Control Function Tests
Commissioning Procedures 10. When each gate driver circuit has been checked, disconnect the power supply and remove it from the cabinet. NOTE: Systems with optional Pump Control or Soft Stop include continuous gate drive power supplies (IGDPS); therefore, step 10 does not apply.
Page 70: Resistance Checks
3-10 Commissioning Procedures Resistance Checks To ensure that resistors and connections have not been damaged during shipment and installation, the following resistance tests should be performed before energizing the starter. 1. Remove all power from the equipment. A T T E N T I O N A T T E N T I O N Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device.
Page 71: Overview
Chapter Programming Overview This chapter provides a basic understanding of the programming keypad built into both the SMC Dialog Plus controller and the optional Bulletin 1201 human interface modules. This chapter also describes programming the controller by modifying the parameters. Keypad Description The keys found on the front of the SMC Dialog Plus controller are described below.
Page 72 Programming Programming Menu (cont.) The SMC Dialog Plus controller does not support EEPROM, Link, Process or Start-up modes. Steps back one level. Control Status and Search are only available when using a Series B Bulletin 1201 human interface module. Password protected. English is currently the only available language.
Page 73 Programming Linear Linear Metering Metering Calibrate Calibrate Basic Basic Advanced Advanced Faults Faults List List Language Language Setup Setup Setup Setup Chapter 6 Chapter 6 Chapter 5 Chapter 5 See page 4-4 See page 4-4 Steps back one level. English is currently the only language available. For further information on parameters, see Appendix A.
Page 74 Programming Programming Menu (cont.) Table 4.A Parameter Linear List Parameter No. Description Parameter No. Description Volts Phase A-B Slow Speed Dir. Volts Phase B-C Slow Accel Current Volts Phase C-A Slow Running Current Current Phase A Braking Current Current Phase B Factory Use Current Phase C Factory Use...
Page 75: Password
After you have completed the programming process, re-enter the Password mode to logout. This will eliminate unauthorized access to the programming system. Note: If you lose or forget the password, contact your nearest Rockwell Automation sales office. You can also call Rockwell Automation Medium Voltage Product Support at 1-519-740-4790 for assistance. Search The Search mode allows the user to view only those parameters that have settings other than the factory default values.
Page 76: Parameter Management
Programming Parameter Management Before you begin programming, it is important to understand how the controller memory is: • structured within the SMC Dialog Plus™ controller • used on power-up and during normal operation Refer to Figure 4.2 and explanations below. Figure 4.2 Memory Block Diagram EEPROM...
Page 77: Using Parameter Management
Programming Using Parameter Management Description Action Display Saving to EEPROM PARAMETER MGMT To ensure that the newly modified STORE IN EE parameters are not lost if control power is removed from the controller, store the values into EEPROM. Recalling from EEPROM Parameters stored in EEPROM can PARAMETER MGMT be manually brought to RAM by...
Page 78: Parameter Modification
Programming Parameter Modification All parameters are modified using the same method. The basic steps to performing parameter modification are described below. Note: Parameter values modified while the motor is operating are not valid until the next start sequence begins. Description Action Display —...
Page 79 Programming Soft Start The following parameters are specifically used to adjust the voltage ramp supplied to the motor. Parameter Option Starting Mode Soft Start, Current Limit This must be programmed for Soft Start. Ramp Time #1 This programs the time period that the controller will ramp 0 to 30 seconds the output voltage up to full voltage from the Initial Torque level programmed.
Page 80: Dual Ramp Start
4-10 Programming Dual Ramp Start The SMC Dialog Plus™ controller provides the user with the ability to select between two Soft Start settings. The parameters below are available in the Advanced Setup programming mode to obtain Dual Ramp control: Parameter Option Advanced Setup —...
Page 81: Basic Setup
Programming 4-11 Basic Setup The Basic Setup programming group provides a limited parameter set, allowing quick start-up with minimal adjustments. If the user is planning to implement some of the advanced features (i.e., Dual Ramp, Unbalance Level, etc.), then the Advanced Setup programming group should be selected.
Page 82: Advanced Setup
4-12 Programming Advanced Setup While the Basic Setup group allows the user to get started with a minimum number of parameters to modify, the Advanced Setup group allows full access to the SMC Dialog Plus™ controller's powerful parameter set. Following is a listing of the additional setup parameters provided. Note: All of the Basic Setup parameters are available in the Advanced Setup group.
Page 83: Example Settings
Programming 4-13 Parameter Option Phase Reversal Off, On Allows the user to enable phase reversal protection. Starts Per Hour Allows the user to limit the number of starts during a one 0-99 (0 is the Off setting) hour period. Restart Attempts Determines the number of attempts the controller will make 0 to 5 to automatically restart the motor after a fault.
Page 84 4-14 Programming 1560D-UM051D-EN-P – February 2005...
Page 85: Calibration
Chapter Calibration Overview The Calibrate programming group allows the user to set parameters to calibrate the controller to the connected motor. It is important to correctly input the data to achieve the best performance from your controller. A T T E N T I O N A T T E N T I O N For overload protection, it is critical that the data be entered as it appears on the motor nameplate.
Page 86 Calibration Motor Data Entry (cont.) Parameter Option Display Motor Code Letter Enter the value from the motor’s nameplate. If the motor nameplate does MOTOR CODE LETTER A – V not provide this, consult the motor manufacturer. See Table 5.A for code letter definitions.
Page 87: Metering
Chapter Metering Overview While the SMC Dialog Plus™ controller operates your motor, it also monitors several different parameters, providing a full function metering package. Viewing Metering Data To access the metering information, follow the procedure below: Description Action Display – –...
Page 88 Metering Viewing Metering Data (cont.) Description Action Display VOLTS PHASE A-B 6. Scroll through the Metering ### VOLTS parameters with the Up/Down keys to access the desired information. VOLTS PHASE B-C ### VOLTS VOLTS PHASE C-A ### VOLTS CURRENT PHASE A ###.# AMPS CURRENT PHASE B ###.# AMPS...
Page 89: Options
Chapter Options Overview The SMC Dialog Plus™ controller offers a variety of unique control options that provide enhanced motor starting and stopping capabilities. (See pages 1-12 to 1-15 for brief descriptions of each option.) Note: Only one option module can reside in a controller. Contact factory before substituting one option module for another.
Page 90 Options Human Interface Module (cont.) Option Action Operation The green start button, when pressed, will commence motor acceleration to full speed. Preset Slow The red stop button, when pressed, will Speed provide a coast stop. The jog button, when pressed, will initiate slow speed motor operation from a “stopped”...
Page 91 Options Programming Parameters The following table outlines the option-specific parameters that are provided with each control option. These parameters are in addition to those already discussed in the Basic Setup, Advanced Setup, Metering, and Calibration groups. Diagrams supporting the options described below are shown later in this chapter.
Page 92: Programming Parameters
Options Programming Parameters Option Parameter Range (cont.) SMC Option This parameter identifies the type of control SMB Smart SMB Braking present and is not user programmable. Motor Braking Braking Current Allows the user to program the intensity of 0–400% of full load current the braking current applied to the motor.
Page 93: Soft Stop Option
Options Soft Stop Option 100% 100% Coast-to-rest Coast-to-rest Motor Speed Motor Speed Start Start Soft Stop Soft Stop Time (seconds) Time (seconds) Push Buttons Push Buttons Start Start Closed Closed Open Open Stop Stop Closed Closed Open Open Soft Stop Soft Stop Closed Closed...
Page 94: Pump Control Option
Options Pump Control Option Coast-to-rest Coast-to-rest 100% 100% Motor Speed Motor Speed Start Start Soft Stop Soft Stop Time (seconds) Time (seconds) Push Buttons Push Buttons Start Start Closed Closed Open Open Stop Stop Closed Closed Open Open Pump Stop Pump Stop Closed Closed...
Page 95: Smb Smart Motor Braking Option
Options SMB Smart Motor Braking Option 100% 100% Smart Motor Braking Smart Motor Braking Coast-to-rest Coast-to-rest Motor Speed Motor Speed Start Start Brake Brake Automatic Zero Speed Automatic Zero Speed Time (seconds) Time (seconds) Shut-off Shut-off Push Buttons Push Buttons Start Start Closed...
Page 96: Preset Slow Speed Option
Options Preset Slow Speed Option 100% 100% 7 or 15% 7 or 15% Motor Speed Motor Speed Slow Slow Start Start Coast Coast Speed Speed Time (seconds) Time (seconds) Push Buttons Push Buttons Start Start Closed Closed Open Open Stop Stop Closed Closed...
Page 97: Slow Speed With Braking Option
Options Slow Speed with Braking Option 100% 100% Braking Braking Motor Speed Motor Speed Slow Slow Start Start Brake Brake Speed Speed Time (seconds) Time (seconds) Push Buttons Push Buttons Start Start Closed Closed Open Open Stop Stop Closed Closed Open Open Slow Speed...
Page 98 7-10 Options 1560D-UM051D-EN-P – February 2005...
Page 99: Serial Communications
Chapter Serial Communications Overview The SMC Dialog Plus™ controller can be started, stopped, and programmed through PLCs or SLCs using an optional Bulletin 1203 communication module. Additionally, parameter data can be read to the logic controller through block transfer. The amount of information that can be transferred from the SMC Dialog Plus controller is determined by the DIP switch settings on the communication module.
Page 100: Control Enable
Serial Communications Control Enable In accordance with factory programming, "STOP" is the only control command active on the SMC Dialog Plus™ controller when the SCANport is utilized. To enable motor control from a PLC or SLC through a Bulletin 1203 communication module, follow the programming procedure below. Description Action Display...
Page 101: Smc Status Data
Serial Communications SMC Status Data The Information in Table 8.B provides the SMC Dialog Plus™ controller status information that can be sent to the logic controller's input image table. Logic Bits Description Definition 1 = Enabled Enabled 0 = Not Enabled 1 = Running Running 0 = Not Running...
Page 102: Display Unit Equivalents
Serial Communications Display Unit Equivalents Some parameter setting options use a text description when viewed from the built-in LCD display or a human interface module. For example, the parameter Starting Mode has the available settings of Soft Start and Current Limit Start.
Page 103 Serial Communications Remote I/O Examples Example #1 – SLC 500 Controller without Block Transfer This example demonstrates discreet control of an SMC Dialog Plus™ controller from an SLC 500 logic controller. Additionally, the SLC controller reads the Current Phase A from the SMC Dialog Plus controller via the analog feedback word.
Page 104: Remote I/O Examples
Serial Communications Remote I/O Examples (cont.) 1203-GD1 Communication Module Switch Settings The following information is provided to explain the required 1203-GD1 communication module switch settings for this example. Refer to the 1203-GD1 manuals for further details related to the switch settings. Example Information Description Switch Setting...
Page 105 Serial Communications G-File Configuration The SLC system uses G-files to configure the R I/O link. G-files are configured through the SLC programming software. The configuration is based on the devices connected to the R I/O link. For this example, the following G-file configuration map for the scanner's I/O image file of the SMC Dialog Plus™...
Page 106 Serial Communications Remote I/O Examples (cont.) I/O Addressing (cont.) SMC Dialog Plus Controller Logic Control Addresses Bit Description I or O Slot Word Address Stop O:1.16/00 Start O:1.16/01 Option Command O:1.16/02 Clear Fault O:1.16/03 SMC Dialog Plus Controller Status Addresses Bit Description I or O Slot...
Page 107 Serial Communications Example # 1 – Ladder Logic Program First Rung: When the Machine START push button is pressed, the SLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog Plus controller will start if no STOP command is being issued by the SLC or any other control device. (The start button is a normally open contact in this example.) Machine START...
Page 108: Example #2 - Slc 500 Controller With Block Transfer
8-10 Serial Communications Remote I/O Examples (cont.) Example #2 – SLC 500 Controller with Block Transfer This example demonstrates a block transfer of the SMC Dialog Plus™ controller's metering group (parameters 1-11) to an SLC 500. Many of the selections shown are example-specific. Some changes by the user may be necessary to apply the concepts of this example to a specific application.
Page 109 Serial Communications 8-11 1203-GD1 Communication Module Switch Settings The following information is provided to explain the required 1203-GD1 communication module switch settings for this example. Refer to the 1203-GD1 manuals for further details related to the switch settings. Example Information Description Switch Setting SW1: Switches 1 &...
Page 110 8-12 Serial Communications Remote I/O Examples (cont.) Software Configuration Settings RIO Configuration Using G-Files – The block transfer operation requires that the G-File of the 1747-SN scanner module be configured. The scanner's G-File settings are based on the devices that you have on the RIO link. It consists of setting logical device starting addresses and the logical device image size of each physical device/adapter with which the scanner communicates.
Page 111 Serial Communications 8-13 Software Configuration Settings (cont.) 3. [F6], MODIFY G-FILE (cont.) Word 2, Primary/Normal Device Logical Image Size – Specifies the logical image size (amount of scanner I/O image) of the devices set in Word 1. As with Word 1, these bits correspond to RIO logical rack and logical group numbers.
Page 112 8-14 Serial Communications Remote I/O Examples (cont.) BT Control Buffer Layout – The following table maps integer files starting at N10:0 with the associated M0 file location as defined in the sample ladder logic program that follows. BT Control Datafile Control Flags Control Flags BT Length...
Page 113 Serial Communications 8-15 Data Path for the BTW – Rung 2:6 of the sample ladder-logic program that follows executes a COP instruction to the M0 file to load the necessary data for the BTW. Address Address 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 Address Address...
Page 114 8-16 Serial Communications Remote I/O Examples (cont.) Data Path for the BTR – Rung 2:5 of the sample ladder logic program that follows executes a COP instruction to copy the data obtained from the BTR to program-defined integer file. Address 0 1 2 3 4 5 6 7 8 9 Address 0 1 2 3 4 5 6 7 8 9...
Page 115 Serial Communications 8-17 Example #2 – Ladder Logic Program Rung 2:0 Rung 2:0 This rung clears the Virtual BT Command word on the first scan. This rung clears the Virtual BT Command word on the first scan. First Scan S : 1 MOVE MOVE Source...
Page 116 8-18 Serial Communications Remote I/O Examples (cont.) Example #2 – Ladder Logic Program (cont.) Rung 2:4 This rung sets up the BT buffer for a BTR and sets the Virtual BT_Enable. User BTR_Avail Virtual Logic BTW = 0 BTR = 1 B3:0 I:1.0 N10:0...
Page 117 Serial Communications 8-19 The information in the data table listed below was obtained from a 150 hp motor, 1800 RPM rated at 480 volts. The motor was operating continuously for a period of 72 hours. Parameter Parameter Display Parameter Parameter Display Description Number...
Page 118 8-20 Serial Communications Remote I/O Examples (cont.) Example #3 – PLC 5/20, 5/40, 5/60 and 5/80 This example demonstrates PLC control of an SMC Dialog Plus™ Controller with the Pump Control option. Use of the Option Command bit to initiate the pump stop maneuver is also shown. Finally, the SMC fault bit is monitored as a conditional logic input for the block transfer of the associated fault code stored in the SMC Dialog Plus controller's Parameter 19, Fault Buffer #1.
Page 119 Serial Communications 8-21 1203-GD1 Communication Module Switch Settings The following information is provided to explain the required 1203-GD1 communication module switch settings for this example. Refer to the 1203-GD1 manuals for further details related to the switch settings. Example Information Description Switch Setting SW1: Switches 1 &...
Page 120 8-22 Serial Communications Remote I/O Examples (cont.) I/O Addressing The 1203-GD1 communcation module uses one-slot addressing. Based on the module switch settings as described above, the discrete I/O can be mapped to the PLC I/O Image as shown below. PLC I/O Group Number Output Image Input Image Block Transfer...
Page 121 Serial Communications 8-23 Communication Module Block Transfer Status Word Addresses Bit Description I or O Rack Group Address Block Transfer Ready I:020/10 (BT_READY) Block Transfer Write in Progress I:020/11 (BTW_IN_PROG) Block Transfer Read Available I:020/12 (BTR_AVAIL) Block Transfer Wait I:020/13 (BT_WAIT) Block Transfer Error I:020/14...
Page 122 8-24 Serial Communications Remote I/O Examples (cont.) Block Transfer Instructions Block transfer operations with the 1203-GD1 communication module require coordinated block transfer write (BTW) and block transfer read (BTR) instructions to achieve successful data transmissions. BLOCK TRNSFR WRITE BLOCK TRNSFR READ ——...
Page 123 Serial Communications 8-25 Block Transfer Datafiles The tables below provide the necessary data file configuration for a parameter value read of the SMC Dialog Plus™ controller's Fault Buffer #1. BTW Datafile: Message Length PLC Decimal Value Parameter Number Address N10:10 This is a fixed value, associated with the Parameter Value Read function.
Page 124 8-26 Serial Communications Remote I/O Examples (cont.) Example #3 – Ladder Logic Program First Rung: When the Machine START push button is pressed, the PLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog First Rung: When the Machine START push button is pressed, the PLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog Plus controller will start if no STOP command is being issued by the PLC or any other control device.
Page 125 Serial Communications 8-27 DeviceNet Examples Example #1 • SLC 500 Controller with Explicit Messaging This example demonstrates discreet control of the SMC Dialog Plus controller in addition to use of the explicit messaging function for transferring parameter data to an SLC500. The DeviceNet Manager (revision 3.001) software is used in this example for network and node configuration.
Page 126: Devicenet Examples
8-28 Serial Communications DeviceNet Examples (cont.) 1203-GK5 Communication Module Switch Settings The following information is provided to explain the required 1203-GK5 communication module switch settings for this example. Refer to the 1203-GK5 manual for further details related to the switch settings. Example Information Description Switch Settings...
Page 127 Serial Communications 8-29 1203-GK5 Communication Module Switch Settings (cont.) I/O Mapping The SMC Dialog Plus controller's first two words of data are pre-configured in the 1203-GK5 Communication module as follows: Word Output Data Input Data Logic Command Logic Status Reference Feedback The SMC Dialog Plus Controller does not utilize this feature;...
Page 128 8-30 Serial Communications DeviceNet Examples (cont.) I/O Mapping (cont.) Double-click the Master (node 0) on the DeviceNet network; the following screen will appear: Select the Edit Scan List option by clicking on the button; the following screen will appear: Notice that the SMC Dialog Plus controller (node 13) has an “active” status.
Page 129 Serial Communications 8-31 I/O Mapping (cont.) You will also notice that “Yes” is listed twice under the Mapped column. The left-side Yes indicates that input data is mapped from the SMC Dialog Plus controller to the SLC-500. The right-side Yes indicates that output data from the SLC-500 is mapped to the SMC Dialog Plus controller.
Page 130 8-32 Serial Communications DeviceNet Examples (cont.) I/O Mapping (cont.) This indicates that the SLC-500's output data associated with the SMC Dialog Plus controller is mapped to words 7 and 8. Given this data table mapping, following are the individual logic command and status bit addresses for the SMC Dialog Plus controller: SMC Dialog Plus Controller Logic Command Addresses Bit Description...
Page 131: Explicit Messaging
Serial Communications 8-33 Explicit Messaging The 1747-SDN scanner module uses the M0 and M1 file areas for data transfer. Words 224 through 256 must be used to execute the Explicit Message Request and Response functions. The minimum data size for an Explicit Message Request is 6 words and the maximum is 32 words.
Page 132 8-34 Serial Communications DeviceNet Examples (cont.) Explicit Messaging (cont.) Size: This identifies the size of the transaction body in bytes. The transaction body begins at word 3. The maximum size is 58 bytes. The Size data size is one byte. Service: This code specifies the type of request being delivered.
Page 133 Serial Communications 8-35 Sequence of Events Use the following sequence of events as a guide for establishing explicit messages in your SLC ladder logic: 1. Put the Explicit Message Request data into an integer (N) file of the SLC-500 processor. 2.
Page 134 8-36 Serial Communications Setting Up the Data File (cont.) TXID Command Port Size Service MAC ID Class Instance Attribute File N11:0 0l 01 00 2E 32 0D 0093 0000 0000 0001 0001 0002 0001 Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder...
Page 135: Example Ladder Logic Program
Serial Communications 8-37 Example Ladder Logic Program Rung 0: The 1747-SDN scanner module will map output data from its scanner output table (MO) and discrete outputs to each node only when Rung 0: The 1747-SDN scanner module will map output data from its scanner output table (MO) and discrete outputs to each node only when it’s in the “run mode”.
Page 136 8-38 Serial Communications Example Ladder Logic Program (cont.) Rung 3: When the FAULT RESET command is initiated at the RSView station, the SLC processor sets the output bit mapped to the SMC Dialog Plus Rung 3: When the FAULT RESET command is initiated at the RSView station, the SLC processor sets the output bit mapped to the SMC Dialog Plus controller’s logic control word clear faults bit.
Page 137: Overview
Chapter Diagnostics Overview This chapter describes the fault diagnostics of the MV Dialog Plus™ controller. Further, this section describes the conditions that cause various faults to occur. Protection Programming Many of the protective features available with the SMC Dialog Plus controller can be enabled and adjusted through the programming parameters provided.
Page 138: Fault Buffer
Diagnostics Fault Buffer The SMC Dialog Plus™ controller stores the five most recent faults in memory. Display the fault buffer by selecting the Faults group and scrolling through the fault buffer parameters. The information is stored as fault codes. To determine what faults have occurred, use the fault code cross-reference below.
Page 139: Fault Auxiliary Contact
Diagnostics Fault Auxiliary Contact The auxiliary contact is located at terminals 29 and 30. This contact can be programmed as either Normal or Fault. Note that the state this contact takes upon power-up (normally open or normally closed) can be programmed. These parameters can be found in either Basic Setup, Advanced Setup, or the Linear List groups when modifying parameters in the Program mode.
Page 140 Diagnostics Fault Definitions (cont.) Voltage Unbalance Voltage unbalance is detected by monitoring the three-phase supply voltages. The formula used to calculate the percentage voltage unbalance is as follows: = 100 (V : Percent voltage unbalance : Maximum voltage deviation from the average voltage : Average voltage The controller will shut down when the calculated voltage unbalance reaches the user-programmed trip percentages.
Page 141 Diagnostics Open Gate (Start A,B,C firing fault) Open gate indicates that an abnormal condition that causes faulty firing (i.e., open SCR gate or driver system) has been sensed during the start sequence. The SMC Dialog Plus™ controller will attempt to start the motor a total of three times before the controller shuts down.
Page 142 Diagnostics Fault Definitions (cont.) MPU or System Fault These faults indicate an internal fault or that an unexpected condition was encountered in the internal hardware or software. Reset the module by cycling control power. If the fault persists, replace the control module. 1560D-UM051D-EN-P –...
Page 143: Troubleshooting
Consult the factory prior to applying these options. For MV Dialog Plus 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).
Page 144: Fault Identification
10-2 Troubleshooting General Notes and Warnings Important: In the case of the 1503D, refer to applicable documentation (cont.) from OEM for troubleshooting and repair. This manual should be utilized in conjunction with the OEM supplied documentation, and is suitable for commissioning, programming, calibration, metering, serial communications, diagnostics, troubleshooting, and maintenance of a standard solid-state controller.
Page 145: Fault Display Explanation
Troubleshooting 10-3 Table 10.A Fault Display Explanation Display Fault Code Possible Causes Possible Solutions Power Loss • check for open line (eg. blown line fuse) F1, F2, F3 • missing supply phase (as indicated) (with phase indication) • check voltage feedback circuits •...
Page 146 10-4 Troubleshooting Fault Identification (cont.) Table 10.A Fault Display Explanation (cont.) Display Fault Code Possible Causes Possible Solutions • broken motor shaft • repair or replace motor Underload • broken belts, gears, machine • check machine, repair if necessary • pump cavitation •...
Page 147 Troubleshooting 10-5 Table 10.B Motor Will Not Start – No Output Voltage to the Motor Display Possible Causes Possible Solutions Fault displayed • See fault description • See Table 10.A addressing fault conditions • Control voltage is absent • Check control wiring and correct if necessary Display is blank •...
Page 148 10-6 Troubleshooting Fault Identification (cont.) Table 10.E Miscellaneous Situations Display Possible Causes Possible Solutions Motor current and • Motor • Verify type of motor as a standard squirrel cage voltage fluctuates with induction motor steady load • Erratic load • Check load conditions •...
Page 149: Control Module Removal
If the lubricant is missing, apply a thin film of the recommended contact lubricant. The Rockwell Automation approved contact lubricant is NYOGEL 759G, manufactured by William F. Nye., Specialty Lubricants, New Bedford, MA 02742 U.S.A. To install control module, follow the reverse order for removal.
Page 150: Voltage Feedback Circuit Tests
10-8 Troubleshooting Voltage Feedback Circuit The most straightforward means of checking the feedback circuits is to Tests perform the "snubber and resistor testing" procedure, found on page 10-24. Another possible test involves measuring the feedback voltages at the interface board (see Figure 1.17). This can only be done with line voltage applied.
Page 151: Igdps Boards
Troubleshooting 10-9 IGDPS Boards MV SMC units provided with optional stop capabilities (soft stop or pump control) utilize isolated gate drive power supply (IGDPS) boards. These boards provide a continuous source of power to the gate drive boards. The IGDPS boards are fed from a 50 V DC power supply provided with the MV SMC.
Page 152: Igdps Board Leds
10-10 Troubleshooting IGDPS Board LEDs A green LED is provided inside each of the six (6) output module boxes (channels) to indicate the presence of a healthy output voltage (20 V DC). • LED ON: Output Healthy • LED OFF: Output Voltage is below 18 V DC If the IGDPS is healthy, then all six (6) LEDs will be illuminated.
Page 153: Circuit Board Replacement
Troubleshooting 10-11 Circuit Board Replacement The replacement of printed circuit boards is straightforward, however, there are a number of precautions which must be considered when handling the boards. Some circuit boards may contain CMOS components A T T E N T I O N A T T E N T I O N which can be destroyed by static charges generated by friction of materials made with synthetic fibres.
Page 154: Power Circuit Troubleshooting
10-12 Troubleshooting Power Circuit Thyristor Testing Troubleshooting If a power semiconductor is suspected of malfunctioning, it may be checked as follows: 1. Remove all power from the equipment. A T T E N T I O N A T T E N T I O N To avoid shock hazard, ensure the main power has been disconnected before working on the controller, motor or control devices.
Page 155: Scr Replacement Procedure
Troubleshooting 10-13 SCR Replacement Procedure Important: Refer to OEM documentation for SCR stack location in 1503D. A. Remove SCR Stack from Unit For all types of SMCs, the stack requiring new SCRs must first be removed from the unit as follows: 1.
Page 156 10-14 Troubleshooting Power Circuit SCR Replacement Procedure (cont.) Troubleshooting (cont.) 7. Pull module out slowly, and slide onto a platform lift, or lift the module out of the cabinet. A T T E N T I O N A T T E N T I O N The heatsink assembly is heavy (approx.
Page 157 Troubleshooting 10-15 SCR Replacement Procedure (cont.) B. Replace SCRs (cont.) 2. Loosen the clamp by rotating the centre nut below the indicator washer at the top end of the clamp. Refer to Figures 10.4, 10.8 and 10.15. As the centre nut is rotated, the entire spring assembly is retracted from the top heatsink.
Page 158 10-16 Troubleshooting Power Circuit SCR Replacement Procedure (cont.) Troubleshooting (cont.) C. Install Refurbished Stack 1. Inspect all connections on the module. Inspect wire insulation and components for damage. 2. Install the module in the cabinet. Watch for power cables and fibre-optic cables as module is slid into place.
Page 159 Troubleshooting 10-17 Voltage Voltage Feedback Feedback Board Board Bulletin 1562D, phase A module shown extracted from cabinet. Low voltage panel can swing out for access to Phase A module. Figure 10.1 – Low Voltage Panel & Power Cell Detail (1562D) • 180/360A, 2400 V to 4160 V Important: For 1503D, refer to OEM documentation for location of printed circuit boards and power stacks.
Page 160 10-18 Troubleshooting Heatsink 1 Heatsink 1 SCR 1 SCR 1 Heatsink 1 Heatsink 1 SCR 1 SCR 1 Heatsink 2A Heatsink 2A Heatsink 2B Heatsink 2B Heatsink 2 Heatsink 2 SCR 2 SCR 2 Heatsink 3 Heatsink 3 Heatsink 3 Heatsink 3 SCR 2 SCR 2...
Page 161 Troubleshooting 10-19 NOTE: The following steps pertain to the 180/360A NOTE: The following steps pertain to the 180/360A power stack assembly with four heatsinks. The power stack assembly with four heatsinks. The process is similar for a power stack assembly with process is similar for a power stack assembly with only three heatsinks.
Page 162 10-20 Troubleshooting Heatsink 1 Heatsink 1 SCR 1 SCR 1 Heatsink 2 Heatsink 2 SCR 2 SCR 2 Heatsink 3 Heatsink 3 SCR 3 SCR 3 Heatsink 4 Heatsink 4 SCR 4 SCR 4 Heatsink 5 Heatsink 5 Figure 10.7 – 3300/4160 Volt Heatsink Assembly, 180/360 A (5 Heatsinks) (Do not loosen) (Do not loosen) Centre Nut...
Page 163 Troubleshooting 10-21 To Remove SCR4: To Remove SCR4: • Remove shorting bar hardware • Remove shorting bar hardware • Pry Heatsinks 4 and 5 apart • Pry Heatsinks 4 and 5 apart • Extract SCR • Extract SCR Shorting Bar Hardware Shorting Bar Hardware To Insert New SCR: To Insert New SCR:...
Page 164 10-22 Troubleshooting Gate Driver Boards Gate Driver Boards Line Connection Line Connection Load Connections Load Connections Figure 10.11 – 6900V Module, 180/360 A Board Mounting Frame Board Mounting Frame Line Connection Line Connection Load Connection Load Connection Figure 10.12 – 6900V Module with Gate Driver Boards Removed, 180/360 A 1560D-UM051D-EN-P –...
Page 165 Troubleshooting 10-23 Module retaining hardware locations (4) Module retaining hardware locations (4) Line Connection Line Connection Load Connection Load Connection Figure 10.13 – 6900V Module with Boards and Frame Removed, 180/360 A 1560D-UM051D-EN-P – February 2005...
Page 166 10-24 Troubleshooting SCR 3 SCR 3 SCR 4 SCR 4 SCR 5 SCR 5 SCR 2 SCR 2 SCR 6 SCR 6 SCR 1 SCR 1 SCR1, SCR2 and SCR5 are a matched set. SCR1, SCR2 and SCR5 are a matched set. SCR3, SCR4 and SCR6 are a matched set.
Page 167 Troubleshooting 10-25 SCR5 SCR5 Heatsink 6 Heatsink 6 Heatsink 3 Heatsink 3 SCR2 SCR2 SCR1 SCR1 Locating Pin Locating Pin Heatsink 2 Heatsink 2 To Remove SCR1: To Remove SCR1: • Remove shorting bar hardware • Remove shorting bar hardware •...
Page 168 10-26 Troubleshooting Snubber Resistors Snubber Resistors Heatsink Assembly Heatsink Assembly Sharing Resistors Sharing Resistors Snubber Capacitors Snubber Capacitors Gate Driver Board Gate Driver Board Figure 10.18 – 3300 and 4160V Heatsink Module, 600A Snubber Resistors Snubber Resistors Heatsink Assembly Heatsink Assembly Snubber Capacitor Snubber Capacitor Sharing Resistors...
Page 169: Snubber And Resistor Circuit Testing
Troubleshooting 10-27 Snubber and Resistor Circuit If the resistance checks from the Thyristor testing section were abnormal Testing and the thyristors checked out OK, there may be a problem in the snubber or resistor circuits. 1. Remove all power from the equipment. A T T E N T I O N A T T E N T I O N To avoid shock hazard, ensure main power has been...
Page 170 10-28 Troubleshooting Snubber and Resistor Circuit The feedback voltages given are based on the stated system voltage. If the Testing (cont.) actual system voltage is different, the feedback voltages will be scaled by the actual system voltage divided by the value in the chart on page 10-8. For example, if the actual system voltage is 2337 volts, the feedback voltage should be (2337 / 2400) x (191 to 211), or 186 to 205 volts.
Page 171: Snubber Resistor Replacement
A small container of compound will be supplied with the replacement resistor; however, if more is required, it can be ordered from Rockwell Automation by part number RU-6052. When installing the mounting screws, alternately tighten each screw gradually to ensure uniform pressure distribution over the mounting surface.
Page 172 10-30 Troubleshooting Figure 10.20 – 1500/2400 Volt Module Wiring (180/360 A) (Without Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 173 Troubleshooting 10-31 Figure 10.21 – 1500/2400 Volt Module Wiring (600A) (Without Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 174 10-32 Troubleshooting Figure 10.22 – 1500/2400 Volt Module Wiring (180/360 A) (With Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 175 Troubleshooting 10-33 Figure 10.23 – 1500/2400 Volt Module Wiring (600A) (With Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 176 10-34 Troubleshooting Figure 10.24 – 3300/4160 Volt Module Wiring (180/360 A) (Without Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 177 Troubleshooting 10-35 Figure 10.25 – 3300/4160 Volt Module Wiring (600 A) (Without Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 178 10-36 Troubleshooting Figure 10.26 – 3300/4160 Volt Module Wiring (180/360 A) (With Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 179 Troubleshooting 10-37 Figure 10.27 – 3300/4160 Volt Module Wiring (600 A) (With Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 180 10-38 Troubleshooting Figure 10.28 – 6900 Volt Module Wiring (180/360/600 A) (Without Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 181 Troubleshooting 10-39 Figure 10.29 – 6900 Volt Module Wiring (180/360/600 A) (With Optional Pump Control or Soft Stop) 1560D-UM051D-EN-P – February 2005...
Page 182 10-40 Troubleshooting 1560D-UM051D-EN-P – February 2005...
Page 183: Safety And Preventative
Chapter Maintenance Safety and Preventative The Maintenance Technician should become familiar with the layout and be aware of the basic system parameters. Only qualified technicians should be allowed to work with this equipment under competent supervision. General housekeeping is the key to maintaining power electronic and electrical equipment.
Page 184: Vacuum Bottles
11-2 Maintenance Periodic Inspection (cont.) A T T E N T I O N A T T E N T I O N 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 185: Solid-State Devices
Maintenance 11-3 Solid-State Devices Solid-state devices require little more than a periodic visual inspection. Printed circuit boards should be inspected to determine whether all cables are properly seated in their connectors. Board locking tabs should also be in place. Necessary replacements should be made only at the PC board or plug-in component level.
Page 186: Keep Good Maintenance Records
11-4 Maintenance Periodic Inspection (cont.) "Keep Good Maintenance Records" This rule will be most helpful in locating possible intermittent problems by pointing to a particular area of recurring trouble within the overall system. Furthermore, good maintenance records will help reduce major, costly shutdowns by demanding the use of proper test equipment and an appropriate inventory of spare parts.
Page 187: Parameter Information
Appendix Parameter Information Table A.1 Parameter List Parameter Display Scale Default User Group Parameter Description Minimum Maximum Number Units Factor Setting Setting Voltage Phase A-B Volts – – – – Voltage Phase B-C Volts – – – – Voltage Phase C-A Volts –...
Page 188 Parameter Information Table A.1 Parameter List (cont.) Parameter Display Scale Default User Group Parameter Description Minimum Maximum Number Units Factor Setting Setting Control Options Soft Stop Soft Stop Time Seconds Pump Control Soft Start, Current Limit Starting Mode – – Soft Start and Pump Start Pump Stop Time...
Page 189 Parameter Information Table A.1. Parameter List (cont) Parameter Scale Default User Group Parameter Description Display Units Minimum Maximum Number Factor Setting Setting Dual Ramp – – No, Yes Ramp Time #2 Seconds Initial Torque #2 % LRT Undervoltage Level % Line Voltage Undervoltage Delay Seconds Overvoltage Level...
Page 190 Parameter Information Table A.1 Parameter List (cont.) Parameter Scale Default User Group Parameter Description Display Units Minimum Maximum Number Factor Setting Setting Overload Class – – Off, 10, 15, 20 and 30 Overload Reset – – Manual – Auto Manual Motor HP Rating 6,553.5 Motor kW Rating...
Page 191 Parameter Information Table A.2 Parameter Text/Display Unit Cross-Reference Parameter Number Description Setting Text Display Unit Standard Soft Stop Pump Control SMC Option Preset Slow Speed Smart Motor Braking Accu-Stop Slow Speed with Braking ETM Reset Ready Parameter Default Init. Management Recall from EE Store in EE Clear Fault...
Page 192: Parameter Text/Display Unit Cross-Reference
Parameter Information Table A.2 Parameter Text/Display Unit Cross-Reference (cont.) Parameter Number Description Setting Text Display Unit Motor Code Letter None Converter Rating 50:5 75:5 100:5 150:5 200:5 250:5 CT Ratio 300:5 400:5 500:5 600:5 700:5 800:5 1000:5 1200:5 Manual Overload Reset Auto 1560D-UM051D-EN-P –...
Page 193: Spare Parts
Appendix Spare Parts Table B.1 Bulletin 1503D • 1000-1500 Volt, 180/360 Amp, 6-device Qty per controller Description Part Number 180 A Individual SCR, 5STP04D5200 (matching not required) 80156-815-61-R 360 A Individual SCR, 5STP08G6500 (matching not required) 80156-894-71-R Common Components 80165-898-52 Gate Driver Board (2 devices) 80165-898-55 IGDPS Board...
Page 194 Spare Parts Table B.2 Bulletin 1503D, 1560D, 1562D • 2300 Volt, 180/360 Amp, 6-device Qty per controller Description Part Number 180 A Individual SCR, DCR820 or 5STP03D6500 (matching not required) 80156-893-71-R 360 A Individual SCR, DCR1020 or 5STP03D6500 (matching not required) 80156-894-71-R Common Components Gate Driver Board (2 devices)
Page 195 Heatsink Assembly 600A with Thermistor 80187-326-51 Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly be replaced. Contact the Rockwell Automation factory. SCR Gate Driver Board (2 devices) 80165-898-52 Gate Driver Board (2 devices)
Page 196 Spare Parts Table B.4 Bulletin 1503D, 1560D, 1562D • 3300 Volt, 180/360 Amp, 12-device Qty per controller Description Part Number 180 A SCR, DCR820 or 5STP03D6500 (matched set of 2) 80156-893-72-R 360 A SCR, DCR1020 or 5STP08G6500 (matched set of 2) 80156-894-72-R Common Components Gate Driver Board (4 devices)
Page 197 Heatsink Assembly 600A with Thermistor 80187-309-51 Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly be replaced. Contact the Rockwell Automation factory. SCR Gate Driver Board (4 devices) 80165-858-52 Gate Driver Board (4 devices)
Page 198 Spare Parts Table B.6 Bulletin 1503D, 1560D, 1562D • 4160 Volt, 180/360 Amp, 12-device Qty per controller Description Part Number 180 A SCR, DCR820 or 5STP03D6500 (matched set of 2) 80156-893-72-R 360 A SCR, DCR1020 or 5STP08G6500 (matched set of 2) 80156-894-72-R Common Components Gate Driver Board (4 devices)
Page 199 Heatsink Assembly 600A with Thermistor 80187-309-51 Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly be replaced. Contact the Rockwell Automation factory. SCR Gate Driver Board (4 devices) 80165-858-52 Gate Driver Board (4 devices)
Page 200 Spare Parts Table B.8 Bulletin 1503D, 1560D, 1562D • 5500/6900 Volt, 180/360 Amp, 18-device Qty per controller Description Part Number 180 A 180A : Matched Set 3 SCRs DCR820 or 5STP03D6500 80156-893-73-R 360 A 360A : Matched Set 3 SCRs DCR1020 or 5STP08G6500 80156-894-73-R Common Components SCR Gate Driver Board...
Page 201 Part Number Heatsink Assembly 600A with Thermistor 80187-285-51 Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly be replaced. Contact the Rockwell Automation factory. SCR Gate Driver Board 80165-898-52 (2 devices)
Page 202: Accessories
B-10 Spare Parts Table B.10 Accessories Qty per controller Description Part Number Control Module (Standard) 80187-194-01 Control Module (Soft Stop) 80187-194-02 Control Module (Pump Control) 80187-194-03 Control Module (Slow Speed) 80187-194-04 Control Module (Smart Motor Brake) 80187-194-05 Control Module (Slow Speed with Brake) 80187-194-06 Converter Module 825-MCM20...
Page 203 Appendix Accessories Table C.1 Accessories Description Description/Used With Catalog Number IP30 (Type 1) Door Mount Bezel Kit 1201-DMA IP30 (Type 1) Programmer Only 1201-HAP IP65 (Type 4/12) Programmer Only 1201-HJP Human Interface Module IP30 (Type 1) Analog Control Panel 1201-HA1 IP30 (Type 1) Digital Control Panel 1201-HA2 IP65 (Type 4/12) Digital Control Panel...
Page 204 Accessories 1560D-UM051D-EN-P – February 2005...
Page 206 Europe/Middle East/Africa: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433...

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