Page 1 User Manual Original Instructions CENTERLINE Medium Voltage SMC-50 Motor Controller Bulletin Numbers 1503E, 1560F, and 1562F...
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
1562F – Combination Controller ......14 SMC-50™ Control Module ....... . . 14 Starting Modes.
Page 4 Table of Contents Programming ..........36 Status Indication .
Page 5 SMC-50 Module ........
Page 6 Variable Input/Output Configuration ..... 139 SMC-50 Control Module—Bit Identification ....140 Reference/Feedback .
Page 7 Table of Contents Scale Factors for PLC Communication ......141 Display Text Unit Equivalents ....... . 142 Configuring DataLink™...
Page 8 Table of Contents Final Check Out ......... 195 Keep Good Maintenance Records.
Page 9 DeviceLogix Scratchpad Registers......275 SMC-50 Control Module DeviceLogix Input Datalinks (P337…P342) ..........275 Program Examples .
Page 10 Table of Contents Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 11: Preface
Preface Manual Objectives This manual is intended for use by personnel familiar with Medium Voltage and solid-state power equipment. The manual contains material which will allow the user to operate, maintain and troubleshoot the SMC™-50 family of controllers. The family consists of the following Bulletin numbers: 1503E, 1560F and 1562F. This manual applies only to this series of products.
Page 12 Preface Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 13: Product Overview
Chapter Product Overview Overview The SMC-50 is a solid-state, three-phase, AC line controller. It is designed to provide microprocessor-controlled starting and stopping of standard three-phase, squirrel-cage induction motors, using the same control module as the Allen- Bradley Bulletin 150 SMC-50.
Page 14: 1562F - Combination Controller
• Motor overload protection (included in SMC-50 control module) - available in Arc Resistant enclosures SMC-50™ Control Module The SMC-50 control module offers a full range of starting and stopping modes as standard: • Soft Start with Selectable Kickstart • Soft Stop •...
Page 15: Starting Modes
Product Overview Chapter 1 Starting Modes Starting Mode Page Soft Start Sensorless Linear Speed Acceleration Torque Control Start Current Limit Start Selectable Kickstart Pump Control Mode Dual Ramp Start Emergency Bypass Run (Full Voltage Start) TIP For any of the following starting modes, the motor only accelerates in the programmed time if that time and the current limit setting is appropriate for the connected load.
Page 16: Sensorless Linear Speed Acceleration
Chapter 1 Product Overview Sensorless Linear Speed Acceleration With this type of starting mode, the motor acceleration is at a constant rate. The controller accelerates the motor in a linear fashion from the off (0 speed) condition to full speed condition in the time configured in the user-defined ramp time.
Page 17: Torque Control Start
Product Overview Chapter 1 Torque Control Start This method provides a torque ramp from a user-adjustable, initial motor starting torque to a user-adjustable, maximum torque over the defined starting ramp time. The torque control mode provides a more linear starting ramp than a soft start, potentially resulting in less stress on mechanical components and a more time controlled ramp.
Page 18: Selectable Kickstart
This mode also reduces pump cavitations, increasing pump life. To provide these benefits, the SMC-50 module’s microprocessor generates a motor starting curve which follows the starting characteristics of a centrifugal pump and monitors operation during start to ensure reliable pump starts.
Page 19 Product Overview Chapter 1 6. Motor overload and/or upstream breaker settings may have to be adjusted to allow the starting or stopping current to flow for extended periods. ATTENTION: Pump stopping is not intended to be used as an emergency stop. Refer to the applicable standard for emergency stop requirements.
Page 20: Dual Ramp Start
Chapter 1 Product Overview Dual Ramp Start This method is useful on applications with varying loads, starting torque, and start time requirements. Dual Ramp Start gives you the ability to select between two separate start profiles via any programmable auxiliary input. Each start profile can use any of the available starting modes.
Page 21: Stopping Modes
Product Overview Chapter 1 Stopping Modes The SMC-50 Smart Motor Controller provides the following Stopping Modes of operation as standard. Stopping Mode Page Coast Soft Stop Linear Speed Deceleration Pump Stop TIP Except for Coast stop, all other optional stopping modes will increase the stopping time of the motor.
Page 22: Linear Speed Deceleration
Chapter 1 Product Overview Figure 10 - Soft Stop Timing Diagram 100% Stop Time Soft Stop Time (seconds) Linear Speed Deceleration Configuring the motor stop mode to Linear Speed Deceleration mode commands the motor to stop from full speed to zero speed following a linear ramp based on the user-configured stop time.
Page 23: Pump Stop
Product Overview Chapter 1 Pump Stop Just as starting a centrifugal pump at full voltage causes fluid hammer and check valve slam, stopping a centrifugal pump that is running at full speed can also produce the same results. The SMC- 50 module's Pump Stop mode generates a motor stop curve, which follows the stop characteristics of a centrifugal pump.
Page 24: Motor And Starter Protection Features
The SMC-50 module has a separate Fault Buffer and Alarm Buffer to maintain a Fault/Alarm history. In addition to the fault/alarm code and description, a time and date stamp is provided by the SMC-50 controller's Real Time Clock (RTC).
Page 25: Overload Protection
Service Factor 0.01…1.99 If the SMC-50 is used to control a multi-speed motor, or more than one motor, the Overload Class parameter must be programmed to “OFF” and separate overload relays must be supplied for each speed/motor. The trip rating is 118% of the programmed FLC.
Page 26 Chapter 1 Product Overview Figure 13 - Overload Trip Curves Class 5 Class 10 Class 15 10000 10000 10000 1000 2 3 4 5 10 3 4 5 2 3 4 5 Multiples of FLC Multiples of FLC Multiples of FLC Class 20 Class 30 Class 25...
Page 27: Underload Protection
Product Overview Chapter 1 Underload Protection Utilizing the underload protection of the SMC-50 module, motor operation can be halted if a sudden drop in current is sensed. The SMC-50 control module provides an adjustable underload trip setting from 0…99% of the programmed motor full load current rating. Trip delay time can be adjusted from 0…99 seconds.
Page 28: Voltage Unbalance Protection
Product Overview Voltage Unbalance Protection The SMC-50 module is able to detect an unbalance in line voltages. Motor operation can be halted if the unbalance is greater than the desired range. The SMC-50 module provides an adjustable unbalance setting from 1…25% of the line voltages.
Page 29: Ground Fault
The SMC-50 module can provide ground fault indication when used with the 150-SM2 Option Module and an external core balance current transformer.
Page 30: Thermistor/Ptc Protection
Chapter 1 Product Overview Thermistor/PTC Protection The optional 150-SM2 module lets the SMC-50 control module interface with motor PTC sensors. It is common for motor manufacturers to embed PTC thermistor sensors in motor stator windings to provide temperature monitoring of the motor windings. Because PTC thermistor sensors react to the actual motor winding temperature, enhanced motor protection can be provided to address conditions like obstructed motor cooling and high ambient temperature.
Page 31: Open Gate
Phase reversal protection can be toggled either ON or OFF. The SMC-50 control module can individually identify and provide a Fault and or Alarm if a power line loss occurs on any phase. TIP Phase A, B, or C loss = Fault Code 1, 2, or 3 respectively. There are no line loss Fault Parameters to configure.
Page 32: Excessive Starts/Hour
Chapter 1 Product Overview Excessive Starts/Hour The SMC-50 module allows the user to program the desired number of starts per hour (up to 99). This helps eliminate motor stress caused by repeated starting over a short time period. TIP Refer to...
Page 33: Metering
• Power Factor—The value of the power factor is provided for each phase and as a total of all three. • Peak Starting Current—The SMC-50 control module stores the peak average RMS motor current consumed for the last 5 start cycles.
Page 34: Inputs And Outputs
An overload fault occurs when this value reaches 100%. Inputs and Outputs The SMC-50 control module has the ability to accept up to two (2) inputs and two (2) outputs controlled over a network. The two inputs are +24V DC rated (Input #1, terminal 10 and Input #2, terminal 11).
Page 35: Communication Interface
(shown without cover) Port 4 Device Peripheral Interface (DPI) Protocol The SMC-50 soft starter communicates in the same manner as the drive products using the DPI protocol. This enables almost any DPI-supported Human Interface Module (HIM), PC software (such as Connected Components Workbench™...
Page 36: Programming
Chapter 1 Product Overview Programming Figure 19 shows how to connect a HIM and DPI device to the SMC-50 control module. Table 3 provides a description of each port. TIP The SMC-50 control module only supports the use of DPI communication modules and DPI 20-HIM-A6 Modules.
Page 37: Status Indication
The contact state changes when the external braking command is active and opens when it is not active Aux. Control: The contact state changes when an auxiliary output is configured for Aux. Control. Figure 20 - Control Terminals - SMC-50 Control Module Aux 1 Aux 2...
Page 38: Hardware Description
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 SMC-50 to facilitate operation and maintenance of the system. Refer to Figure 22 Figure 23, Typical SMC-50 Power System.
Page 39: Interface Board
The interface board also receives temperature feedback from the gate-driver board via fiber-optic cable(s). If the heatsink temperature rises above a set value, a signal is sent to the SMC-50 to stop gating the SCRs and initiate a temperature fault.
Page 40 Chapter 1 Product Overview Figure 22 - Typical SMC-50 Power System • Bulletin 1562F (3300/4160V shown) CT INPUTS POWER GATE TRANSMITTERS POWER PHASE A PHASE B PHASE C TEMP. Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 41 Product Overview Chapter 1 Figure 23 - Typical SMC-50 Power System • Bulletin 1560F (3300/4160V shown) POWER CT INPUTS GATE TRANSMITTERS POWER PHASE A PHASE B PHASE C TEMP. Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 42: Functional Description
This holds the bypass contactor closed for several seconds as set in Par 192 of SMC-50 module to protect the power electronics from any voltage transients due to opening the motor circuits. If terminal A2 is programmed to be Stop Option, the SMC-50 module will initiate the option stop.
Page 43: Bulletin 1562F • Programming Interface Control
If the motor has started, the unit is in the bypass mode, and a trip occurs within the SMC-50 module or from an external protection relay; “Aux #2” will open the line contactor immediately, and “Aux #1” will remain closed for the number of programmed seconds to protect the power electronics from any voltage transients due to opening the motor circuits.
Page 44: Bulletin 1560F • Standard Control
(or breaker) in the event of a fault condition sensed by the SMC-50 module. If possible, it is better to have the SMC-50 module control the main contactor directly. In this case, the control circuit would look like, and function like, the descriptions above for the Bulletin 1562F.
Page 45 Product Overview Chapter 1 Figure 24 - Typical Bulletin 1562F IntelliVAC Control Circuit 115V M-IV 0.6V TO SMCLEXIB MAIN CONTACTOR (M) -TB6 ESTOP ØA ØB ØC B-IV BYPASS CONTACTOR (B) M-IV B-IV START STOP CONTROL RELAY (CR) M-IV MODULE MODULE STATUS STATUS CONTACTOR...
Page 46 Chapter 1 Product Overview Figure 25 - Typical Bulletin 1562F IntelliVAC Control Circuit • With Communication and Optional Local/Off/Remote 115V M-IV 0.6V TO SMCLEXIB MAIN CONTACTOR (M) -TB6 ESTOP ØA ØB ØC B-IV BYPASS CONTACTOR (B) M-IV B-IV START STOP CONTROL RELAY (CR) M-IV MODULE...
Page 47 Product Overview Chapter 1 Figure 26 - Typical Bulletin 1560F IntelliVAC Control Circuit 115V 0.6V TO SMCLEXIB -TB6 B-IV ØA ØB ØC BYPASS CONTACTOR (B) START/STOP SIGNAL FROM EXISTING STARTER B-IV CONTROL RELAY (CR) MODULE STATUS SMC 50IB_TB6 CL_FLT FAULT RELAY CL_FLT ESTOP CL_FLT...
Page 48 Chapter 1 Product Overview Figure 27 - Typical Bulletin 1560F IntelliVAC Control Circuit • With Communication and Optional Local/Off/Remote 115V 0.6V TO SMCLEXIB -TB6 B-IV ØA ØB ØC BYPASS CONTACTOR (B) START/STOP SIGNAL B-IV FROM EXISTING STARTER CONTROL RELAY (CR) MODULE STATUS SMC 50IB_TB6...
Page 49: Installation
Chapter Installation ATTENTION: Perform the installation duties correctly. Errors may cause commissioning delays, equipment damage, or personal injury. IMPORTANT For the 1503E, refer to applicable documentation from OEM installation, grounding, interlocking and wiring. This manual should be utilized in conjunction with the OEM supplied documentation, and is suitable for commissioning, programming, calibration, metering, serial communications, diagnostics, troubleshooting, and maintenance of a standard solid-state controller.
Page 50: Unpacking And Inspection
Chapter 2 Installation Unpacking and Inspection After unpacking the material, check the item(s) received against the bill of lading to ensure that the nameplate description of each item agrees with the material ordered. Inspect the equipment for physical damage, as stated in the Rockwell Automation Conditions of Sale.
Page 51: Installation Site
Installation Chapter 2 ATTENTION: Care must be exercised when using either a forklift, or the pipe rolling technique, for positioning purposes to ensure that the equipment is not scratched, dented or damaged in any manner. Always exercise care to stabilize the controller during handling to guard against tipping and injury to personnel.
Page 52: Mounting
Chapter 2 Installation Mounting The 1503E, 1560F and 1562F 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 1560F/1562F. Please refer to OEM documentation for the 1503E. Refer to the drawings supplied with your order for mounting locations.
Page 53: Recommended Torque Values
2.5…4.0 N•m (2.0…3.3 lb•in) CLGD Power Assembly Terminals 5.6 N•m (50 lb•in) SMC-50 Control Module Terminals 0.6 N•m (5 lb•in) TIP For 3/8 in. hardware in the “T”-slots of aluminum heatsinks, the recommended torque is 22 N•m (16 lb•ft). Do not overtorque these connections as the slots will be damaged and the connection will be compromised.
Page 54: Bulletin 1560F
Chapter 2 Installation Bulletin 1560F Refer to Figure 31 Figure 33 to make power connection for a 1560F unit (depending on the rating of the unit). • Make line connections to the line connection terminals • Make load connections to the current transformer terminals TIP The CT assembly can be oriented to allow either top or bottom load cable exit.
Page 55 Installation Chapter 2 Bulletin 1562F Figure 28 - Cabinet Layout • 1562F – 180/360A, 2400V to 4160V (with LV panels not shown) (Non arc-resistant cabinet shown) Power Stack Assembly Terminal Block Assembly Bypass Vacuum Contactor Voltage Sensing Module Non Load Break Isolation Switch Load Cable Connection Point...
Page 56 Chapter 2 Installation Figure 29 - Incoming Line Cable Connections (Rear View with Cover Removed) (Non Arc-resistant Cabinet) Power Cable Lugs Ground Bus Lug Figure 30 - Bottom Cable Exit Configuration (LV Panel Open to the left) (Non Arc-resistant Cabinet) Cable Duct Barrier Motor Cable Terminals Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 57 Installation Chapter 2 Bulletin 1560F Figure 31 - Power Connections • 1560F – 180/360A, 2400…4160V (Not available in an Arc- resistant design) Phase 2 Power Stack Assembly Phase 1 Power Stack Assembly Phase 3 Power Stack Assembly Voltage Sensing Module Load Connections (top exit shown) Phase 1 (front)
Page 58 Chapter 2 Installation Figure 32 - Power Connections • 1560F – 180/360A, 5500…6900V (Not available in an Arc- resistant design) Phase 1 Line Connections Phase 1 Power Stack Assembly Voltage Sensing Module Phase 2 Line Connections Phase 2 Power Stack Assembly Load Connections (top exit shown) Phase 1 (front)
Page 59 Installation Chapter 2 Figure 33 - Power Connections • 1560F – 600A, 2400…6900V (Not available in an Arc-resistant design) Phase 1 Line Connections Phase 1 Voltage Sensing Module Power Stack Assembly Phase 2 Line Connections Phase 2 Power Stack Assembly Load Connections (top exit shown) Phase 1 (front)
Page 60: Bulletin 1503E
Hinged doors and panels, which provide access to medium voltage components, must be mechanically interlocked to ensure circuit isolation. If a combination SMC-50 (1562F) is purchased from Rockwell Automation, all medium voltage compartments will be mechanically interlocked such that they cannot be opened unless the isolating switch for the unit is open.
Page 61: Installation
Installation Chapter 2 TIP Rockwell Automation can assist with the selection of an appropriate interlocking method, which may include mechanical modifications to the cabinet(s) or key-type lock systems. TIP An auxiliary cabinet may be attached to the main structure. It will be ram- interlocked with the main power cell door, which will not allow it to be opened until the main power cell door is opened.
Page 62: Fiber-Optic Cables
The capacitors must be located on the line side of the controller. This is required to prevent damage to the SCRs in the SMC-50 controller. A separate switching contactor is recommended to apply the capacitors only after the bypass contactor has closed, and to remove them when the bypass contactor opens.
Page 63: Surge Arrestor Protection Devices
Installation Chapter 2 Figure 34 - Typical One-Line Diagram (Showing 2 Different Styles of Power Factor Capacitor Connections) Power Bus Isolation Switch Isolation Switch Fuse Fuse Contactor Isolation Contactor di/dt Inductor di/dt Inductor Capacitor PFCC PFCC Contactor (Power Factor Correction Capacitor) Bypass Contactor Motor...
Page 64: Motor Overload Protection
Motor Overload Protection Thermal motor overload protection is provided as standard (though it must be programmed) with the SMC-50 control module. If the overload trip class is less than the acceleration time of the motor, nuisance tripping may occur. ATTENTION: Overload protection should be properly coordinated with the motor to avoid damage to equipment.
Page 65: Emc Compliance
– When using an external HIM (or DPI interface), a core should be added to the HIM cable near the SMC-50 control module. The recommended core is Fair-Rite no. 0431167281 or equivalent.
Page 66: Control Power
SMC-50 control modules come standard with two 24V DC digital on/off inputs and two relay outputs for auxiliary control functions. The standard digital I/O wiring terminal block is on the upper right portion of the SMC-50 module. The terminal block is removable.
Page 67: Rockwell Automation Publication 1560F-Um001A-En-P - June
Installation Chapter 2 Figure 35 - Standard Control Terminal Block Identification Aux 1 Aux 2 Control Power 24V DC Inputs Relay Outputs and Ground (1) See the controller nameplate to verify the control power ratings (120/240V AC or 24V DC). ATTENTION: IN1 DC (terminal 11) and IN2 DC (terminal 10) are 24V DC inputs on controllers rated 120/240V AC and on controllers rated 24V DC.
Page 68 Chapter 2 Installation Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 69: Commissioning Procedure
Chapter Commissioning Procedure Preliminary Setup 1. Ensure the work area is clean and tidy. Pathways to main disconnect and emergency stop push button must be clear and unobstructed. 2. The following test equipment is to be prepared for use: • Test power supply, supplied with each controller •...
Page 70: Important Commissioning Checks
• Verify that motor mechanical installation is complete. • Verify that Incoming Power wiring to SMC-50 is complete and all connections are tight. • Verify that Motor cabling to SMC-50 is complete and that all connections are tight. • Verify that Control wiring to SMC-50 is complete.
Page 71: Preliminary Check
Commissioning Procedure Chapter 3 • Verify that circuit board plug connectors are installed and fully inserted in their sockets. • Verify that the cooling fan (if supplied) is secured and the rotor is not obstructed. • Complete device resistance checks per user manual (refer to Resistance Checks on page 80 of Chapter •...
Page 72: Programming
IMPORTANT When SMC-50 module is energized for the very first time, HIM may take couple of minutes to recognize Medium voltage controller. Once the ID file is recognized, HIM will display ‘MV Soft Start’...
Page 73: Motor Tuning
Motor tuning includes the identification of the motor parameters and the detection of the motor connection type (Line or Delta). The SMC-50 control module uses the motor tuning data in its control algorithm. During the tuning process, the motor does not turn and makes some audible noise, including pulsing and buzzing.
Page 74 Table 6 lists Parameter 194 Force Tuning along with the key motor parameters checked by the SMC-50 control module during a motor tuning cycle. Table 6 - Key Motor Parameters Checked During a Motor Tuning Cycle Parameter Minimum/Maximum...
Page 75 Commissioning Procedure Chapter 3 Figure 36 - Typical SMC-50 Power System Wiring Diagram (5500/6900V shown) TO SMC-50 MODULE TO C.T.s POWER CT INPUTS GATE TRANSMITTERS POWER PHASE A PHASE B PHASE C TEMP. 115/230V AC 115/230V AC 50/60Hz Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 76 Figure 37 - Connection and Test Information for Interface Board SW2: When ON LED (Red): ON when (right) provides test test pulses on pulses to gate driver circuits. SMC-50 Control Module NOTE: Must be OFF (left) for normal TB6: Option operation. Stop Current Input and...
Page 77: Power Supply Tests
4. Check voltage on each gate driver board by connecting a DC voltmeter at TP4(+) and TP3(-). (See Figure 38.) The voltage should be 18…22V DC. 5. Locate the SMC-50 Interface board in the control section (see Figure 37). This circuit board has the control module mounted on it. Locate the switch labeled SW2 at the upper left corner of the board.
Page 78 Chapter 3 Commissioning Procedure Figure 38 - Test Power Application on Gate Driver Board Gate signal fiber- Temperature signal fiber- optic receiver optic transmitter Yellow LED Plug-in test Current loop CT Thermistor power supply +5V test point connector TP3 TP4 Snubber terminal Gate signal...
Page 79 Commissioning Procedure Chapter 3 Figure 39 - Gate Pulse Detail – Typical SCR (ABB) Microseconds Figure 40 - Gate Pulse Test Waveform - 2.0 - 1.5 - 1.0 - 0.5 Milliseconds 10. If no pulse is observed, and the yellow LED is lit, check for a shorted gate on the SCR by removing the green plug and connecting an ohmmeter to the gate leads.
Page 80: Control Function Tests
Chapter 3 Commissioning Procedure 12. Open the switch SW2 on the interface board (see Figure 37) before returning the unit to service. Ensure the red LED is off. ATTENTION: If the SW2 switch is not in the open position when the SMC is energized, the motor will start in an uncontrolled manner and may cause severe damage.
Page 81: Voltage Sensing Module
The voltage sensing board has six independent channels, with different sized resistors base on voltage range, which convert voltages up to 10,800V (7.2 kV @ 1.5 pu) down to low voltage levels which can be used by the SMC-50 control logic.
Page 82: Start-Up
Chapter 3 Commissioning Procedure Start-Up 1. Remove any temporary jumpers or grounding devices used during commissioning. 2. Check that all tools are removed from the equipment. Any tools or hardware used or dropped during installation and commissioning must be retrieved and accounted for. 3.
Page 83: Programming
TIP The 20-HIM-A3 cannot configure the option modules or use the general startup configuration wizard. Therefore, the 20-HIM-A3 is not recommended for use with the SMC-50 controller and is not mentioned in this document. The 20-HIM-A6 is typically inserted into the HIM bezel port located on the upper right of the control module.
Page 84 Chapter 4 Programming Figure 41 - HIM Mounting Locations Front View HIM Bezel Port Top View DPI Port 2 (Port 2 and 3 if you use a splitter) The following information describes some of the basic screens and keypad functions of the 20-HIM-A6 or 20-HIM-C6S. Additional details about all HIM functions can be found in the user manual, publication 20HIM-UM001.
Page 85: Password Modification Using The Him
• Performs intended actions Password Modification Using the HIM The SMC-50 control module provides password protection by numeric code (0…65,535) to prevent unwanted modification of parameters. You can view or monitor data and parameter values without entering the password, but modification requires password entry.
Page 86: Parameter Access Level Modification Using The Him
SMC-50 control module’s memory. Parameter Access Level Modification Using the HIM The SMC-50 control module provides three different parameter access levels: Monitor, Basic, and Advanced. These access levels let you limit user access and/or speed viewing or changing of certain parameters.
Page 87: Parameter Management
5. Press Enter (#5) to view that access level. Parameter Management Before you begin programming, it is important to understand how the memory is structured within the SMC-50 and used on power-up and during normal operation. Figure 43 - Memory Block Diagram...
Page 88: Ram (Random Access Memory)
Programming RAM (Random Access Memory) RAM is the work area of the module after it is powered up. The SMC-50 control module uses an Auto Store feature when programming parameters. When parameters are modified in the program mode, the new values are stored immediately in RAM and then in EEPROM (Electrically Erasable Programmable Read-only Memory), once the enter key has been pressed.
Page 89: Eeprom
Using the START UP Configuration Tool (20-HIM-A6 or 20-HIM-C6S) The general START UP configuration tool lets you rapidly configure an controller. Enabled by the SMC-50 control module and the 20-HIM-A6 or 20- HIM-C6S, a series of questions required to configure starting (for example, Soft, Linear, Pump, etc.) and stopping (for example, Coast, Pump, etc.) modes are...
Page 90 4. Press the Yes soft key to begin the process or Abort soft key to return to the START UP folders screen. Allen-Bradley SMC-50 Run General Start-Up? Abort The HIM displays a series of questions about the Motor, Start, and Stop processes.
Page 91 Programming Chapter 4 TIP If you enter an incorrect value: Press the ESC soft key to return to the previous screen, then enter the desired value. Use the left arrow soft key to delete a single digit at a time from the data field to enter the correct digit. If a group of selections is displayed, the left arrow soft key moves to the lowest numbered selection.
Page 92 Chapter 4 Programming Figure 44 - Flow Chart—General Startup Parameters Line Voltage Starting Mode Input 1 or Input 2 Dual Ramp Current Limit Soft Start Linear Speed Torque Pump Full Voltage Starting Mode Ramp Time Ramp Time Ramp Time Ramp Time Ramp Time 2 (repeat of Starting Mode...
Page 93: Parameter Search And Configuration
1. Ensure that the initial controller Power Up screen appears on the HIM. Allen-Bradley AUTO Stopped 0 Amps SMC-50 Standard Rev 1. 001 Ser. A PAR# TEXT 2. Using the PAR# soft key, type the desired parameter number to display, press the ENTER soft key, then press the EDIT soft key.
Page 94: Parameter Search And Configuration By File-Group
109 of this chapter. Parameter Search and Configuration by File-Group (SMC-50 Control Module Category Search) 1. From the HIM Power-Up screen, press the FOLDERS single-function key. 2. Press the LEFT or RIGHT arrow key until the screen displays DEV PARAM.
Page 95 Programming Chapter 4 Allen-Bradley AUTO Stopped 0 Amps Port 00 Param File-Group PROPERTIES FILE Monitoring FILE Set Up FILE Motor Protection FILE Communications FILE Utility 5. With Basic highlighted, press ENTER (number 5 on the keypad). 6. Scroll to the desired parameter (for example, Line Voltage) to modify it, then press ENTER (number 5 on the keypad).
Page 96: Parameter Configuration - Using The Setup File Group
ATTENTION: For Overload Protection, it is critical that you enter the data into the SMC-50 control module as it appears on the motor nameplate. Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 97: Soft Start And Stop
Programming Chapter 4 Figure 45 shows the initial FILE Setup screens using the HIM. Figure 45 - Initial FILE Setup Screens Allen-Bradley AUTO Stopped 0 Amps Port 00 Param File-Group PROPERTIES FILE Monitoring FILE Set Up FILE Motor Protection FILE...
Page 98 NOTE: This function enables forcing an output, ON or OFF. ATTENTION: For Overload Protection, it is critical that you enter the data into the SMC-50 control module as it appears on the motor nameplate. Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 99: Current Limit Start With Simple Stop Mode
Programming Chapter 4 Current Limit Start with Simple Stop Mode Use the parameters in Table 13 to program a Current Limit Start with simple Stop Mode operation. You can access the Basic parameter set with the HIM. Table 13 - Current Limit Start with Simple Stop Mode Parameters Parameter Description Options...
Page 100: Linear Acceleration (Linear Speed) Start With Stop
Chapter 4 Programming ATTENTION: For Overload Protection, it is critical that you enter the data into the SMC-50 control module as it appears on the motor nameplate. Linear Acceleration (Linear Speed) Start with Stop Use the parameters in Table 14 to program a Linear Acceleration Start and Simple Stop Mode operation.
Page 101: Torque Start With Stop
NOTE: This function enables forcing an output, ON or OFF. ATTENTION: For Overload Protection, it is critical that you enter the data into the SMC-50 control module as it appears on the motor nameplate. Torque Start with Stop Use the parameters in...
Page 102: Pump Start With Stop
Table (5) Torque Ramp Starting mode requires you to perform a Motor Tuning Cycle. The SMC-50 control module does this automatically the first time the motor is run. You can also force this manually by setting the Force Tuning, Parameter 194, to TRUE (=1), which is accessed from the File Setup, Group Adv. Tuning or by pressing and holding the SMC-50 control module’s Reset button for 10 seconds with the motor stopped.
Page 103 Table (5) For best results with a Pump Start, it is recommended that the tuning cycle be run. The SMC-50 control module automatically performs the tuning cycle the first time the motor is run. You can also force this manually by setting the Force Tuning parameter to TRUE (=1), which is accessed from the File Setup, Group Adv. Tuning or by pressing and holding the SMC-50 control module’s Reset button for 10 seconds with the motor stopped.
Page 104: Full Voltage Start With Stop
Programming Full Voltage Start with Stop The SMC-50 control module may be programmed to provide a full voltage start (output voltage to the motor reaches full voltage within five line power cycles). To provide a Full Voltage Start to the motor, the only start parameter that requires adjustment is the Starting Mode.
Page 105: Dual Ramp Start With Stop
NOTE: This function enables forcing an output, ON or OFF. ATTENTION: For Overload Protection, it is critical that you enter the data into the SMC-50 control module as it appears on the motor nameplate. Dual Ramp Start with Stop Thecontroller lets you select between two start profiles.
Page 106: Motor Protection
(2) Available for Soft Start, Current Limit, and Torque Start modes. Set to zero to disable Kickstart. (3) Torque Ramp and Linear Speed Starting modes require you to perform a Motor Tuning Cycle. The SMC-50 control module does this automatically the first time the motor is run. You can also force this manually by setting the Force Tuning, Parameter 194, to TRUE (=1), which is accessed from the File Setup, Group Adv.
Page 107 Programming Chapter 4 To modify any Fault or Alarm bit for enable/disable functionality, perform the following steps. 1. From the Motor Protection Group, select the desired group. Allen-Bradley AUTO Stopped 0 Amps Port 00 Param File-Group PROPERTIES FILE Motor Protection...
Page 108 Chapter 4 Programming 3. Select the desired 16 bit field, then press EDIT. Allen-Bradley AUTO Stopped 0 Amps Po rt 00 Dev Pa ra m PROPERTIES Motor Fault Enable 0000 0000 0000 0000 Bit 01 - Underload UPPER PAR #...
Page 109: Parameter File-Group Structure
Programming Chapter 4 Parameter File-Group The five parameter File-Groups are structured as shown below. The access levels for each parameter are abbreviated as follows: Structure • M—Monitoring, • B—Basic, • A—Advanced, and • MBA—Monitoring, Basic, and Advanced. Table 19 - Monitoring Group Monitoring File Group Parameters Metering Metering Basic...
Page 110 Chapter 4 Programming Table 20 - Setup File Group Setup File Group Parameters Dual Ramp Basic (BA) Starting (BA) Stopping (BA) Advanced I/O (BA) Advanced Tuning (BA) Motor Config Input 2 Starting Mode Stop Mode Starting Mode 2 Pump Pedestal (A) Input 1 Force Tuning (A) Phase Shift 0% (A)
Page 111 Programming Chapter 4 Table 21 - Motor Protection Group (Continued) Motor Protection File Group Parameters Reactive - Power Apparent Power Voltage Unbal Current Imbal Leading PF (BA) Lagging PF (BA) Voltage THD (BA) Current THD (BA) (BA) (BA) (BA) (BA) Motor Fault Enable Motor Fault Enable Motor Fault Enable...
Page 112: Option Module Configuration
One Digitial I/O card (150-SM4) is always required for MV applications, and it is always inserted in Slot 7. TIP Before proceeding with these steps: Take note of the SMC-50 control module port number (07, 08, or 09) that the option module is connected to.
Page 113 00 SMC-50 02 20-HIM-x6 03 1203-USB 09 SMC-50 Option 3. Use the up or down arrow until the noted port number of the option module is displayed. The HIM displays the HOST PARM file screen and indicates the option module port control module number below the AB logo.
Page 114: 150-Sm4 Digital I/O Option Module
In addition to the two on-board 24V DC input and two auxiliary relay outputs of the SMC-50 control module, the 150-SM4 Digital I/O Option Module has four 120...240V AC inputs and three auxiliary relay outputs. You can use these inputs and outputs for control functions.
Page 115 TIP Before proceeding with the following steps, perform steps through Basic Configuration using the HIM. 1. Use the up or down arrow to select the one of the Aux Outputs, then press ENTER (number 5 on the keypad). Allen-Bradley AUTO Stopped 0 Amps Port 09 Param File-Group...
Page 116 Factory Default (1) "X" indicates the port number (07, 08, or 09) the 150-SM4 is connected to the SMC-50 control module. This port number is displayed on the HIM screen below the Allen-Bradley brand logo. (2) An auxiliary output configured for Aux Control using the AuxX Config parameter is under control of its associated bit form the AuxControl, Parameter 180.
Page 117: 150-Sm2 Ptc, Ground Fault, And External Current
SMC-50 control module, the following installation requirements must be followed: • Only one 150-SM2 can be installed in one SMC-50 control module. • The 150-SM2 must reside in port 7 or 8 only. DO NOT use port 9 with the 150-SM2.
Page 118 If the parameter is not bit configured (for example, Turns Ratio): a. Press the EDIT. b. Change the value within the displayed limits, then press ENTER to load the parameter contents into memory. Allen-Bradley AUTO Stopped 0 Amps P o rt 07...
Page 119 Ready Factory Default (1) "X" indicates the port number (07, 08, or 09) the 150-SM6 is connected to the SMC-50 control module. This port number is displayed on the HIM screen below the AB brand logo. (2) Configure Turns Ratio to the value of the Ground Fault sensor CT Turns Ratio (for example, 825-CBCT=100:1 Set X.5 to 100.
Page 120 Chapter 4 Programming Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 121: Metering
Chapter Metering Overview While the SMC-50 operates a motor, it is also monitoring several different parameters to provide a full-function metering package. Viewing Metering Data To access the metering information using the 20-HIM-A6, use the keypad to follow the procedure below.
Page 122: Resetting Metering Parameters
PM Starts, Parameter 127. Metering Parameters Current The SMC-50 control module calculates true RMS current based on Current Transformer (CT) feedback for all three phases. It also calculates an average value of the three phase currents. During Braking operation, the calculated current is estimated based on time and current settings.
Page 123: Voltage
Volts Phase B-N Volts Phase C-N Torque The SMC-50 control module calculates true electromechanical torque based on the existing motor voltage and current feedback data. TIP • During Braking operations, Torque reads 0. • For the Torque parameter to display correctly, the motor value for Rated Torque, Parameter 47, and Rated Speed, Parameter 48, must be correctly configured.
Page 124: Power
Chapter 5 Metering Power Real, Reactive, and Apparent power calculations (along with demand and maximum demand) are made on each line power phase along with a total for all three phases. The Energy parameters can be cleared using the Meter Reset parameter. See Resetting Metering Parameters on page 122 for further details.
Page 125: Power Factor
Power Factor Elapsed Time The SMC-50 control module keeps a log of the total accumulated hours the controlled motor has been running via the Elapsed Time metering parameter. The Elapsed Time meter value is updated every 10 minutes and stored at power down (accurate to 1/6 of an hour).
Page 126: Running Time
0…100 Actual Start Time The SMC-50 control module logs the start time of the last five motor starts and stores that information in Parameters 24 through 28. The start time data is stored in a first-in, first-out method so the record of the last five starts is always maintained.
Page 127: Peak Start Current
Chapter 5 Peak Start Current The SMC-50 control module logs the peak average RMS current during each start and stores that information in Parameters 29 through 33. The Peak Start Current data is stored in a first-in, first-out method so the record of the last five starts is always maintained.
Page 128: Line Frequency
THD I Line Frequency The SMC-50 control module measures and displays the system 3-phase AC Line Frequency. Upon power up, the Line Frequency parameter displays zero until a valid AC Line Frequency is measured. When three-phase power is removed from the controller, the parameter maintains the value of the previous frequency reading.
Page 129: Voltage Unbalance
Chapter 5 Voltage Unbalance The SMC-50 control module provides a calculated Voltage Unbalance value. The Voltage Unbalance calculation is equal to the largest deviation of the three RMS phase voltage signals from the average RMS phase voltage divided by the average.
Page 130 Chapter 5 Metering Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 131: Optional Him Operation
Chapter Optional HIM Operation Overview The SMC-50 control module offers a variety of unique control options that provide enhanced motor starting and stopping capabilities. HIM Control Buttons The control buttons available with the Bulletin 20-HIM-A6 LCD modules are compatible with the control options on the controller.
Page 132: Him Control Screen
IMPORTANT To navigate from the Control Screen to another HIM menu screen, you must press the ESC soft key. This deactivates the Control Screen and displays the previous screen. Figure 46 - HIM Control Screen Control Screen Key Function Control Screen Navigation Number Keys Allen-Bradley AUTO Stopped 0 Amps REMOVE PROPERTIES...
Page 133: Copycat Function Of The 20-Him-A6
Allows HIM removal without causing a fault if the HIM is not the last controlling device. The REMOVE HIM label is not available when the HIM has a manual control of the host SMC-50 controller. In this case, a fault occurs if the HIM is removed.
Page 134 Chapter 6 Optional HIM Operation Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 135: Communications
DPI as an internal method of communication bus; therefore, all standard DPI communication interfaces that are used by other devices (for example, PowerFlex® Drives) can be used in the SMC-50 control module. SCANport™ devices are not supported by the SMC-50 control module.
Page 136: Him Keypad And Displays
20-HIM-A6 LCD display. Parameters are organized in a multi-level menu structure and are divided into programming groups. Connecting the HIM to the Control Module Figure 47 shows how to connect a HIM and DPI device to the SMC-50 control module. Table 46 provides a description of each port.
Page 137: Control Enable
Stop through the controller’s DPI ports 1, 2, 3, or 4. To enable motor control from either of the four ports using a connected 20- HIM-A6, the following steps must be performed from the SMC-50 control module standard power-up screen.
Page 138 Chapter 7 Communications Allen-Bradley AUTO Stopped 0 Amps Allen-Bradley Port 00 Param File-Group PROPERTIES FILE Monitoring AUTO FILE Set Up Stopped FILE Motor Protection 0 Amps FILE Communications Port 00 Param File-Group FILE Utility PROPERTIES FILE Communications GROUP Comm Masks...
Page 139: Loss Of Communication With Dpi Device
Reference (1) The feedback word is always Ave Current. (2) The reference word is not used with the SMC-50 control module, however the space must be reserved. TIP The total data size produced or consumed may vary, depending on the communication card being used.
Page 140: Control Module-Bit Identification
To configure DataLinks, see Configuring DataLink™ on page 142. SMC-50 Control Module— Product Functional (Logic) Status, Parameter 43, is used to provide SMC-50 control module functional (logic) status to communication devices. Table 50 Bit Identification details Parameter 43, which is a read-only parameter.
Page 141: Reference/Feedback
Write Example Motor FLC, Parameter 78—The example value, which is to be written to the SMC-50 control module, is 75 A. Because this value has one decimal place, the value should be multiplied by 10. The correctly written value is 750.
Page 142: Display Text Unit Equivalents
Criteria for Using DataLink • Each set of DataLink parameters in an SMC-50 can be used by only one adapter. If more than one adapter is connected, multiple adapters must not try to use the same DataLink.
Page 143: Updating Firmware
(1) The data transferred via the DataLink function is the setting (content(s)) of the parameter number as entered by you here. Updating Firmware You can obtain the latest version of firmware and instructions for the SMC-50 control module can be obtained from http://ab.rockwellautomation.com/...
Page 144 Chapter 7 Communications Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 145: Diagnostics
This chapter describes the fault diagnostics of the controller and the conditions that cause various faults to occur. Protection Programming Many of the protective features available with the SMC-50 control module can be enabled and adjusted through the programming parameters provided. For further details on programming, see Motor Protection on page 106.
Page 146: Fault Display (20-Him-A6)
Chapter 8 Diagnostics Fault Display (20-HIM-A6) When you use the SMC-50 control module with a 20-HIM-A6, the HIM displays the fault information. Figure 48 - Fault Display Allen-Bradley AUTO Faulted 0 Amps F A U L T E D PROPERTIES...
Page 147: Fault And Alarm Buffer - Parameter List
Diagnostics Chapter 8 Fault and Alarm Buffer - The SMC-50 stores the five most recent Fault and Alarm codes (Fault Parameter List 138 to 142, Alarm Parameter List 143 to 147) in parameter memory from Parameter List newest to oldest.
Page 148: Accessing The Fault And Alarm Buffers
151. Accessing the Fault and Alarm Buffers In addition to the SMC-50 control module storing the most recent Alarm and Fault codes as parameters, the date and time the Fault or Alarm occurred is stored in the Fault Buffer (last five faults) and Alarm Buffer (last 100 alarms). To access Fault buffers and Alarm Buffers using the 20-HIM-A6, you must access the Diagnostic folder.
Page 149 9026 Exp Removed 0 None TIP The Fault/Alarm buffers are available using Connected Components Workbench software via the Explore and Device properties drop-down menu. Ensure 0-SMC-50 controller is selected from the list of Devices. Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 150: Fault Codes
Chapter 8 Diagnostics Fault Codes Table 56 provides a complete cross-reference of the available fault codes and corresponding fault descriptions. Table 56 - Fault/Alarm Code Cross-Reference Fault/Alarm Fault/Alarm Name Name Line Loss — — Under Power Real — M — — —...
Page 151 F/A Indicates that an abnormal condition that causes faulty firing (for example, open SCR Gate) has been sensed during the starting sequence. SCR Overtemp F The SMC-50 control module protects the SCRs from damage caused t. NOTE: by overtemperature operation using an internally configured I This fault is always enabled.
Page 152 F Removing an expansion module (device) (for example, a 150-SM4) Exp Removed from a SMC-50 control module will result in a x026 fault, where "x" is the SMC-50 control module port number (7, 8, or 9) the expansion module was installed. DPI devices (for example, 20-HIM-A6 or 20- COMM-X) will only generate this fault if its associated bit in Logix Mask parameter is set.
Page 153 (incompatible) power pole is installed. This Fault is always enabled. NVS Error F Indicates an error in the SMC-50 control module ‘s nonvolatile memory storage. Clearing the Fault requires a change to the parameter or loading defaults (preferred). It is not cleared by cycling power. This Fault is always enabled.
Page 154 This fault is always enabled. Test Fault F Occurs when the Push-to-Reset, Hold-to-Test push button on the SMC-50 control module is pushed for  3 seconds but < 10 seconds. Under PF Lag F/A Occurs when the lagging Power Factor goes below the user- defined fault/alarm level.
Page 155: Auxiliary Relay Output Fault Or Alarm Indication
78…9 Future Use. System Faults 100… A general Fault/Alarm typically associated with the SMC-50 control module hardware (for example, system Watchdog Time failure). (1) Overload is inherently a time-based fault. Auxiliary Relay Output You can program Auxiliary Relay Output contacts for Fault or Alarm, N.O., or N.C.
Page 156 Chapter 8 Diagnostics Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 157: Troubleshooting
Chapter Troubleshooting Introduction For safety of maintenance personnel and others who might be exposed to electrical hazards associated with maintenance activities, follow the local safety related work practices (for example, NFPA 70E, Part II in the United States). Maintenance personnel must be trained in the safety practices, procedures, and requirements that pertain to their respective job assignments.
Page 158 Chapter 9 Troubleshooting Figure 49 - Troubleshooting Flowchart Fault Displayed? Define Nature of Trouble Motor starts but Motor will not start. Motor stops while Miscellaneous There is no output does not accelerate running. situations to full speed. voltage to the motor. Table 58 Table 59 Table 60...
Page 159 • Loose connection at Control Terminals 1 (+L1) • Check the control power and verify it is within the specification; and 2 (-L2) check the line connections and grounding to the SMC-50 V24 Loss In All Modes • Excessive load on internal 24V supply controller control terminals.
Page 160 Chapter 9 Troubleshooting Table 58 - Fault Display Explanation (Continued) Display Fault Code Fault Enabled Possible Causes Possible Solutions • Check the control power and verify it is within the specification; • Loose connection at Control Terminals 1 (+L1) check the connections and grounding to the controller control V Control Loss In All Modes and 2 (-L2)
Page 161 • To reset the Test fault, press the Push to Reset/Hold to Test push • The SMC-50 control module’s Push to Reset/ button for less than two seconds. Hold to Test push button was pressed for more...
Page 162 Underload, Overload, Jam, Stall, etc.) does not provide. To understand what is an abnormal running operation, you need to determine a "normal" or "typical" value, usually established during system startup. (2) "X" indicates a port number in which the expansion module resides in the SMC-50 control module . (3) If controller based motor overload is disabled, external motor overload protection should be used.
Page 163 Troubleshooting Chapter 9 Table 61 - Motor Stops While Running Display Possible Cause Possible Solutions Fault displayed • See fault description • See addressing fault conditions • Failed HIM • Replace HIM • Control voltage is absent • Check control wiring and correct if necessary HIM display is blank •...
Page 164: Control Module Removal
6.xxx (or later). Real Time Clock (RTC) The SMC-50 Control Module comes standard with a RTC used to time and date stamp Faults and Alarms. When the control power is not applied to the SMC-50, Battery Replacement the operation of the RTC is maintained by an off-the-shelf Lithium™...
Page 165 Troubleshooting Chapter 9 Bottom Side of SMC-50 Remove and replace battery with postive (+) symbol facing upward. 3. Remove the existing battery, disposing of it according to local environmental codes. 4. With the positive symbol of the new battery facing upward, properly seat the battery into place.
Page 166: Voltage Feedback Circuit Tests
SMC-50 module. In this case, the three line voltages (Line A, Line B, Line C) measured with respect to ground should be approximately 1 volt rms.
Page 167: Voltage Sensing Board Replacement
Troubleshooting Chapter 9 Voltage Sensing Board 1. Ensure there is no power to the equipment. Replacement SHOCK HAZARD: To prevent electrical shock, ensure the main power has been disconnected before working on the sensing board. Verify that all circuits are voltage free using a hot stick or appropriate high voltage- measuring device.
Page 168: Current Loop Power Supply
Chapter 9 Troubleshooting Current Loop Power Supply The current loop gate driver (CLGD) boards receive power from two sources: 1. The snubber circuit (while the SCR power modules are active). 2. The current loop power supply, which maintains a pre-charge level of power during periods when the SCR power modules are inactive (this allows SCR gating while the snubber circuit is being charged).
Page 169: Circuit Board Replacement
Troubleshooting Chapter 9 Circuit Board Replacement The replacement of printed circuit boards is straightforward, however, there are a number of precautions which must be considered when handling the boards. ATTENTION: Some circuit boards may contain CMOS components which can be destroyed by static charges generated by friction of materials made with synthetic fibres.
Page 170: Power Circuit Troubleshooting
Chapter 9 Troubleshooting Power Circuit Thyristor (SCR) Testing Troubleshooting If a power semiconductor is suspected of malfunctioning, it may be checked as follows: 1. Remove all power from the equipment. SHOCK HAZARD: To avoid shock hazard, ensure the main power has been disconnected before working on the controller, motor or control devices.
Page 171: Scr Replacement Procedure
Troubleshooting Chapter 9 SCR Replacement Procedure TIP This procedure applies to 180 A and 360 A units < 5000V only. IMPORTANT Refer to OEM documentation for SCR stack location in 1503E. A. Remove SCR Stack from Unit For all types of SMCs, the stack requiring new SCRs must first be removed from the unit as follows: 1.
Page 172 Chapter 9 Troubleshooting B. Replace SCRs TIP For 600A units, it is mandatory that the entire stack be replaced. The high clamping force requires the factory to tighten the clamp hardware. See Appendix H, Spare Parts for part numbers. Proceed to step C. TIP Refer to Figure 52 Figure...
Page 173 Troubleshooting Chapter 9 8. Tighten the center nut until the indicator washer becomes loose with some friction. The clamp is now at the proper force and must not be clamped any tighter. If the indicator washer becomes too loose (no friction), back the center nut off slowly until the washer is loose with some friction.
Page 174 Chapter 9 Troubleshooting Figure 52 - Upper Low Voltage Panel and Power Cell Detail (1562F) • 2400…4160V, 180/360A Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 175 Troubleshooting Chapter 9 Figure 53 - Power Module Assembly (one phase) • 1000/1300/1500/2400V, 180/360A Heatsink 1 SCR 1 Heatsink 2 SCR 2 Heatsink 3 Figure 54 - Heatsink Clamp (Do not loosen) Center Nut Locking Nut (Do not adjust) Indicating Washer To remove clamp pressure, loosen lower center nut so that the gap between the clamp surface and the heatsink is...
Page 176 Chapter 9 Troubleshooting Figure 55 - Removal of SCR (1000…240V, 180/360A) To Remove SCR: • Remove shorting bar hardware • Pry opposing heatsinks apart • Extract SCR To Insert New SCR: • Apply thin film of electrical joint compound to surfaces of SCR •...
Page 177 Troubleshooting Chapter 9 Figure 56 - Power Module Assembly (one phase) • 3300/4160V, 180/360A Heatsink 1 SCR 1 Heatsink 2 SCR 2 Heatsink 3 SCR 3 Heatsink 4 SCR 4 Heatsink 5 Note: SCR 1 and SCR 3 are a matched set. SCR 2 and SCR 4 are a matched set.
Page 178 Chapter 9 Troubleshooting Figure 58 - Removal of SCR 2 and SCR 4 (3300…4160V, 180/360A) To Remove SCR 4: • Remove shorting bar hardware • Pry Heatsinks 4 and 5 apart • Extract SCR To Insert New SCR: • Apply thin film of electrical joint compound to surfaces of SCR •...
Page 179 Troubleshooting Chapter 9 Figure 59 - Power Module Assembly (one phase) • 5500/6900V, 180/360A Line connection Gate Driver Boards Load connection Load connection Figure 60 - Power Module Assembly (one phase) with Gate Driver Boards Removed • 5500/6900V, 180/360A Line connection Board Mounting Frame Load connection Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 180 Chapter 9 Troubleshooting Figure 61 - Power Module Assembly (one phase) with Boards and Frame Removed • 5500/6900V, 180/360A Module retaining hardware locations (4) Figure 62 - 6900V Heatsink Assembly, 180/360A Positioned on bench for SCR replacement SCR 4 SCR 3 SCR 5 SCR 2 SCR 1...
Page 181 Troubleshooting Chapter 9 Figure 63 - 6900V SCR Replacement, 180/360A Do not loosen Center Nut To remove clamp pressure: Loosen lower center nut so that the gap between the clamp surface and the Locking Nut (Do not adjust) heatsink is approximately 6 mm (0.25 in.). A 21-mm open end wrench is required.
Page 182 Chapter 9 Troubleshooting Figure 65 - Power Module Assembly (1-Phase) • 2300V, 600A Heatsink Assembly Line connection Load connection Gate Driver Boards Gate Driver, Snubber Circuit and Sharing Resistor Frame Assembly Figure 66 - Power Module Assembly (one phase) • 3300/4160V, 600A Heatsink Assembly Line connection Load connection...
Page 183 Troubleshooting Chapter 9 Figure 67 - Power Module Assembly (1-Phase) • 5500/6900V, 600A Heatsink Assembly Line connection Load connection Gate Driver Boards Gate Driver, Snubber Circuit and Sharing Resistor Frame Assembly Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 184: Snubber And Resistor Circuit Testing
Chapter 9 Troubleshooting Snubber and Resistor If the resistance checks from the thyristor testing section were abnormal and the thyristors checked out OK, there may be a problem in the snubber or resistor Circuit Testing circuits. 1. Remove all power from the equipment. SHOCK HAZARD: To avoid shock hazard, ensure main power has been disconnected before working on the controller, motor or control devices.
Page 185 Troubleshooting Chapter 9 Figure 68 - Voltage Sensing Board To Interface Board Ground Connections V O L T A G E F E E D B A C K M A D E U S A A T E D V O L T A G E S E I A L P A T T 1 4...
Page 186: Snubber Resistor Replacement
Chapter 9 Troubleshooting Measure across R25, R27, R29, R31, R33, and R35 located at the bottom of each leg of the module. The resistance should be 11.3 kΩ. (The two ground connections must be connected to ground, or to each other if the module has been removed.) If the values for each leg vary by more than 1%, the voltage sensing module may need to be replaced.
Page 187 Troubleshooting Chapter 9 Figure 69 - Typical 1500/2400V Module Wiring (180/360 A) Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 188 Chapter 9 Troubleshooting Figure 70 - Typical 1500/2400V Module Wiring (600 A) Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 189 Troubleshooting Chapter 9 Figure 71 - Typical 3300/4160V Module Wiring (180/360/600 A) Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 190 Chapter 9 Troubleshooting Figure 72 - Typical 6900V Module Wiring (180/360/600 A) GATE DRIVER BOARDS THERMISTOR LINE THERMISTOR LOAD LEGEND: RR SHARING RESISTOR RS SNUBBER RESISTOR CS SNUBBER CAPACITOR HS HEATSINKS GATE LEAD (WHITE) CATHODE LEAD (RED) Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 191: Maintenance
Protection PM Hours Fault (Code 50) and Alarm You can configure the SMC-50 control module to provide a Fault and/or Alarm to indicate that PM should be performed after a programmed number of hours have elapsed, Fault Code 50. Do this by setting a value in the Time to PM, Parameter 21, to indicate the amount of running time before PM needs to be done.
Page 192: Pm Starts Protection-Fault And Alarm
PM Starts Protection—Fault and Alarm PM Starts Fault (Code 51) and Alarm You can configure the SMC-50 control module to provide a Fault and/or Alarm to indicate that PM should be performed after a pre-defined number of starts have occurred, Fault Code 51. Do this by using the PM Starts, Parameter 127, Starts to PM, Parameter 22, and Meter Reset, Parameter 16.
Page 193: Periodic Inspection
Dirty, wet or contaminated parts must be replaced unless they can be cleaned effectively by vacuuming or wiping. 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 194: Terminals
Chapter 10 Maintenance Terminals Loose connections can cause overheating that can lead to equipment malfunction or failure. Check the tightness of all terminals and bus bar connections and securely tighten any loose connections. Replace any parts or wiring damaged by overheating.
Page 195: Overload Maintenance After A Fault Condition
Maintenance Chapter 10 Overload Maintenance After a Fault Condition See NEMA Standards Publication No. ICS 2 Appendix A entitled “Maintenance of Motor controllers after a fault condition”. Final Check Out After maintenance or repair of industrial controls, always test the control system for proper functioning under controlled conditions that avoid hazards in the event of a control malfunction.
Page 196: Barriers
Chapter 10 Maintenance Barriers Verify that all barriers are in place and securely fastened. Environmental Hazardous Materials Considerations Environmental protection is a top priority for Rockwell Automation. The facility that manufactured this medium voltage product operates an environmental management system that is certified to the requirements of ISO 14001. As part of this system, this product was reviewed in detail throughout the development process to ensure that environmentally inert materials were used wherever feasible.
Page 197: Printed Circuit Boards
Maintenance Chapter 10 Printed Circuit Boards Printed circuit boards may contain lead in components and materials. Shipping and handling of these boards are typically not restricted by environmental regulations, however, lead is considered a hazardous substance. Circuit boards must be disposed of according to local regulations and must not be disposed of with general landfill refuse.
Page 198 Chapter 10 Maintenance Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 199: Parameter List
Volts Phase PP Ave Volt 0/15000 Displays the calculated average voltage of the applied three phase to phase line voltages being measured by the SMC-50. Volts A-B Volts 0/15000 Displays the Phase A to Phase B voltage applied to the SMC at the supply terminals.
Page 200 Appendix A Parameter Information Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Running Time Hours 0/50000 Displays the time the motor has been running since the last start command. This value will go to zero when a motor is restarted after a stop command or fault.
Page 201 Parameter Information Appendix A Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Peak Current 5 Amps 0/15000 Displays the measured peak current of the 5th previous start. Motor Speed 0/100 Displays the estimated motor speed during starting and stopping.
Page 202 Appendix A Parameter Information Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Product Status 0/65535 bit 0 = The product Logic Status is made available to all DPI devices and Enabled/Ready is also available as a bit enumerated parameter "Product Status".
Page 203 Parameter Information Appendix A Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Starting Mode -Full Voltage Used to program the SMC controller for the type of starting mode that best fits the application. -Current Limit Full Voltage: Apply full voltage to the motor at start.
Page 204 (High). Starting Mode 2 Full Voltage Allows the user to program an alternate starting mode for the SMC-50 that suits the application. Current Limit Full Voltage: Apply full voltage to the motor at start. [Soft Start] Current Limit: Apply limited current for a programmed period Linear Speed of time.
Page 205 Min/Max Default Enum Text Description Stop Mode [Coast] Allows the user to program the SMC-50 for the type of stopping that best suits the application. Soft Stop [Coast]: Coast-to-Rest. Linear Speed Soft stop: Slowly reduces current by reducing voltage applied Pump Stop to the motor over a programmed period of time.
Page 206 Appendix A Parameter Information Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Locked Rtr F Lvl %FLC 400/1000 The peak phase current to the load that, if exceeded for the time period defined in Locked Rtr Delay, will signal a fault. The Locked Rotor bit in the Motor Fault En parameter must be set to signal a fault.
Page 207 Parameter Information Appendix A Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Undervolt F Lvl 0/100 If the average three phase line voltage drops below this level for the time period set in the Undervolt F Dly parameter, an Undervolt fault will be signaled.
Page 208 Appendix A Parameter Information Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Cur Imbal F Dly Secs 0.1/99 The time period that the current imbalance exceeds the Cur Imbal F Lvl to signal a fault. The Cur Imbal bit in the Motor Fault En parameter must be set to signal a fault.
Page 209 45/66 The highest line voltage frequency that can be applied to the SMC-50 before causing a Freq High F Lvl fault. The Freq High bit in the Starter Fault En parameter must be set to signal a fault. Freq Low F Lvl...
Page 210 Logic Mask 0/65535 The bits in this parameter allow the user to enable (bit=1) or disable (bit=0) which DPI ports the SMC-50 will accept Start and Maneuver commands from. Coast Stop commands are always accepted from any port. bit 1 = port 1 (On board HIM) [Default=0]...
Page 211 Description Logic Mask Act 0/65535 Displays which DPI port the SMC-50 will accept a start command from. It may be different from the Logic Mask set by the local user if someone changes it over the network. bit 1 = port 1 (on board HIM)
Page 212 Appendix A Parameter Information Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Data In B2 0/159999 This is the a channel IN Datalink index, holding the parameter number of the parameter that will be written to during Datalink communications.
Page 213 UTS: Aux 1 closes when motor reaches up to speed and opens Ext Brake when motor is not at speed. DeviceLogix Fault: Aux1 closes when the SMC-50 enters a fault state and Aux Conrol opens when the fault is cleared. Network 1...
Page 214 UTS: Aux2 closes when motor reaches up to speed and opens Ext Brake when motor is not at speed. DeviceLogix Fault: Aux2 closes when the SMC-50 enters a fault state and Aux Conrol opens when the fault is cleared. Network 1...
Page 215 0/37 Provides the ability to adjust the level at which the SMC-50 expects to see current or the level of current which the SMC-50 determines the SCR has turned off. A common reason for increasing this value would be to compensate for the inability of the control to sense a voltage notch due to significant LINE voltage noise or LINE distortion.
Page 216 Description UTS Level 0/100 The SMC-50 has the ability to determine if the motor is up-to- speed (UTS). If the SMC-50 encounters a problem detecting motor UTS, this parameter can be modified by the user to compensate. If the SMC-50 is detecting the UTS condition to soon (e.g., abrupt speed change), this number should be...
Page 217 Parameter Information Appendix A Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Transient Zero 0/10 5.00 Provides the ability to adjust the gain factor used in speed measurement algorithms. These parameters are not typically modified and it is recommended that RA Technical Support be contacted for assistance before attempting to do so.
Page 218 (future) Line Frequency 0/100 Displays the line frequency of the three phase voltage applied to the SMC-50 at terminals L1, L2, and L3. Freq High F Dly Secs 0.1/99 Allows the user to configure the time period that the supplied line voltage frequency must exceed Freq High F Lvl parameter value before causing a Freq High fault.
Page 219 Option Module parameters. Motor Fault En Bit Value 0/1 [Overload] Allows the user to enable Motor related faults that can be detected by the SMC-50. Underload 0 = Fault Disabled MWatts Over 1 = Fault Enabled Mwatts Under...
Page 220 Enum Text Description Motor Alarm En Bit Value 0/1 Overload Allows the user to enable Motor related alarms that can be detected by the SMC-50. Underload 0 = Fault Disabled MWatts Over 1 = Fault Enabled Mwatts Under [All Disabled as Default]...
Page 221 Parameter Information Appendix A Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description +MVAR Un F Lvl MVAR 0/1000 0.000 Allows the user to enter a value for the Consumed Reactive Power Under Fault Level (+MVAR Un F Lvl). If the current actual +MVAR value is less than the +MVAR Un F Level for a time period greater than that defined by +MVAR Un F Dly, a +MVAR Un Fault will be signaled.
Page 222 Appendix A Parameter Information Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description MVA Un A Lvl 0/1000 0.00 Allows the user to enter a value for the MVA Under Alarm Level (MVA Un A Lvl). If the current actual value of the Apparent Power (MVA) is less than the MVA Un A Lvl for a time period greater than that defined by MVA Un A Dly, a MVA Un Alarm will be signaled.
Page 223 Motor Restart En Manual P111: (Refer to 264) The SMC-50 can be configured to automatically reset the overload fault when it has cooled to the set Overload Reset Level, Parameter 80. The Motor Restart Enabled (Motor Restart En), Parameter 264, must be enabled (Overload = Set) to allow the Overload Reset Level parameter to function.
Page 224 Appendix A Parameter Information Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Motor Restart En Bit Value 0/1 Overload Enables the user to adjust the Motor Restart Enable conditions. Setting (=1) a bit causes the motor to attempt a restart after Underload the selected event is detected.
Page 225 Parameter Information Appendix A Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Reactive Power A MVAR -1000/1000 0.000 Displays the reactive power of the Phase A branch. Reactive Power B MVAR -1000/1000 0.000 Displays the reactive power of the Phase B branch.
Page 226 Appendix A Parameter Information Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description -MVAR Ov F Dly Secs 0.1/99 Enables the user to enter a time value for the Generated Reactive Power Over Fault Delay (-MVAR Ov F Dly). If the current actual value for the Generated Reactive Power is more than the -MVAR Ov F Lvl for a time period greater than that defined by - MVAR Ov F Dly, a -MVAR Ov fault will be signaled.
Page 227 Enum Text Description Input Status 0/65535 Displays the status of all the digital inputs for the SMC-50 Input 1 Bit 0 - Displays status of control module input #1; Input 2 Bit 1 - Displays status of Control Module Input #2.
Page 228 0 - Opens any Output Configured for "Network 4"; Rebalance Level 0/100 The percentage of motor current imbalance above which the SMC-50 will rebalance the motor current Va Peak Volts 0/15000 The peak value of the Phase A line to neutral voltage during the motor start, run, and stop cycle.
Page 229 Parameter Information Appendix A Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description SSCurrent Phas C Amps 0/15000 Snapshot of the Phase C current when a fault occurs. The value is overwritten if a subsequent fault occurs. SSPower Factor -1/1 Snapshot of the Motor Power Factor when a fault occurs.
Page 230 Engine. DLX DL Input 1 0/159999 General purpose datalink used to select another parameter within the SMC-50 as an input to the DeviceLogix Engine. DLX DL Input 2 0/159999 General purpose datalink used to select another parameter within the SMC-50 as an input to the DeviceLogix Engine.
Page 231 Parameter Information Appendix A Table 66 - SMC -50 Parameter List (Continued) Number Name Unit Min/Max Default Enum Text Description Ref Source Allows selection of Source for Resistive Heater Output Voltage [Output V Ref] -Output Voltage Reference Parameter (Set in Par349) P7 In1 -Analog Input #1 from 150-SM3 option module in Expansion Port 7...
Page 232 [Disable] Disable/Enable CT Function. (GF) Enable SM2.13 CT Scaling A 0.01 Displayed result of the SMC-50 tuning feature determination of the scaling between external CT and the internal current (GF) measuring circuitry. SM2.14 CT Scaling B 0.01 Displayed result of the SMC-50 tuning feature determination of...
Page 233 Enum Text Description Read/ Write SM2.16 Phase Shift A -12.5/12.5 Displayed result of the SMC-50 tuning feature determination of the phase shift between external CT and the internal current (GF) measuring circuitry. SM2.17 Phase Shift B -12.5/12.5 Displayed result of the SMC-50 tuning feature determination of...
Page 234 Appendix A Parameter Information Table 68 - 150-SM4 Parameters Number Name Unit Min/Max Default Enum Text Description Read/ Write SM4.01 Module Status 0/256 Ready Displays information about the operational status of the 150- SM4 Digital I/O Option Module. (DIO) Input 1 Ready: Bit 0 = Ready;...
Page 235 Parameter Information Appendix A Table 68 - 150-SM4 Parameters (Continued) Number Name Unit Min/Max Default Enum Text Description Read/ Write SM4.03 Input 2 0/13 [Disable] Allows the user to select the operation of Input Terminal A2, Option Input 2 on the 150-SM4 Digital I/O Option Module. (DIO) Start Disable: Disable the input - ignores any assertion to Input 1,...
Page 236 Appendix A Parameter Information Table 68 - 150-SM4 Parameters (Continued) Number Name Unit Min/Max Default Enum Text Description Read/ Write SM4.05 Input 4 0/13 [Disable] Allows the user to select the operation of Input Terminal A4, Option Input 4 on the 150-SM4 Digital I/O Option Module. (DIO) Start Disable: Disable the input - ignores any assertion to Input 1,...
Page 237 UTS: Aux 1 closes when motor reaches up to speed and opens Ext Bypass when motor is not at speed. Ext Brake Fault: Aux1 closes when the SMC-50 enters a fault state and DeviceLogix opens when the fault is cleared. Aux Conrol...
Page 238 UTS: Aux 2 closes when motor reaches up to speed and opens Ext Bypass when motor is not at speed. Ext Brake Fault: Aux2 closes when the SMC-50 enters a fault state and DeviceLogix opens when the fault is cleared. Aux Conrol...
Page 239 UTS: Aux3 closes when motor reaches up to speed and opens Ext Bypass when motor is not at speed. Ext Brake Fault: Aux3 closes when the SMC-50 enters a fault state and DeviceLogix opens when the fault is cleared. Aux Conrol...
Page 240 Appendix A Parameter Information Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 241: Starting Duty
Appendix Controller Duty Cycle Ratings 1560F/1562F Medium The following tables outline the starting duty cycles for the Bulletin 1560F and Bulletin 1562F controllers. Voltage SMC Motor Controller Starting Duty Table 69 - Controller Starting Duty Ratings Rated Voltage (V) Rated Current (A) 1500…2400 Duty Cycle 1 Duty Cycle 1...
Page 242 Appendix B Controller Duty Cycle Ratings Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 243: Functional Description
This holds the bypass contactor closed for several seconds as set in Par 192 of SMC-50 module to protect the power electronics from any voltage transients due to opening the motor circuits. If terminal A2 is programmed to be Stop Option, the SMC-50 module will initiate the option stop.
Page 244: Bulletin 1562F • Programming Interface Control
Appendix C 1560F and 1562F Relay Control If the loss of current loop transformer assembly is detected by SMC-50 control module, then the terminal A2 will be maintained at high, and terminal A3 will be adopted to initiate the stop. In this situation, when the stop button is pressed, the...
Page 245: Bulletin 1560F • Standard Control
(or breaker) in the event of a fault condition sensed by the SMC-50 module. If possible, it is better to have the SMC-50 module control the main contactor directly. In this case, the control circuit would look like, and function like, the descriptions above for the Bulletin 1562F.
Page 246 Appendix C 1560F and 1562F Relay Control Figure 73 - Typical 400 Amp Bulletin 1562F Relay Control Circuit 115V 0.6V TO SMCLEXIB -TB6 ØA ØB ØC MAIN CONTACTOR (M) RECTIFIER REC/MOV#1 BYPASS CONTACTOR (B) RECTIFIER REC/MOV#2 STOP CONTROL RELAY (CR) SMC 50IB_TB6 CL_FLT FAULT RELAY...
Page 247 1560F and 1562F Relay Control Appendix C Figure 74 - 400 Amp Bulletin 1562F Relay Control Circuit • With DeviceNet (or DPI) Communication and Optional Local/Off/Remote 115V 0.6V TO SMCLEXIB -TB6 ØA ØB ØC MAIN CONTACTOR (M) RECTIFIER REC/MOV#1 BYPASS CONTACTOR (B) RECTIFIER REC/MOV#2 STOP...
Page 248 Appendix C 1560F and 1562F Relay Control Figure 75 - 400 Amp Bulletin 1560F Relay Control Circuit • Without Stop Control 115V 0.6V TO SMCLEXIB -TB6 ØA ØB ØC BYPASS CONTACTOR (B) RECTIFIER REC/MOV#2 START/STOP SIGNAL FROM EXISTING STARTER CONTROL RELAY (CR) SMC 50IB_TB6 CL_FLT FAULT RELAY...
Page 249 1560F and 1562F Relay Control Appendix C Figure 76 - 400 Amp Bulletin 1560F Relay Control Circuit • With DeviceNet (or DPI) Communication and Optional Local/Off/Remote 115V 0.6V TO SMCLEXIB -TB6 ØA ØB ØC BYPASS CONTACTOR (B) RECTIFIER REC/MOV#2 START/STOP SIGNAL FROM EXISTING STARTER CONTROL RELAY (CR) SMC 50IB_TB6...
Page 250 Appendix C 1560F and 1562F Relay Control Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 251: Overview
Appendix ArcShield Unit Information Overview ArcShield™ units have a robust arc resistant enclosure design that has been tested per IEEE C37.20.7 (2001). Each ArcShield structure was tested to withstand the effects of an arc flash at 40 kA or 50 kA for 0.5 s.
Page 252: Exhaust Systems: Chimney Or Plenum Option
Appendix D ArcShield Unit Information Exhaust Systems: Chimney Plenum Information or Plenum Option A plenum can be provided for each unit, and is to be field-mounted on the top of the unit structure (some incoming units may not have a plenum if top cable entry is required).
Page 253: Plenum Exhaust Considerations
ArcShield Unit Information Appendix D Figure 78 - Cross-section of plenum extension, dimensions in mm [inches] 584 [23] 633 [25] Plenum Exhaust The following options for locating the plenum exhaust are presented: Considerations 1. Plenum ducted to an area of the control room where arc gases are permitted to escape, with plenum extensions (see Figure Figure 80...
Page 254 Appendix D ArcShield Unit Information Figure 79 - Plenum Exit Left with Extension(s) to Internal Controlled Access Area (Top View) Personnel Access Barriers Figure 80 - Plenum Exit Left with Extensions to Internal Controlled Access Area (Front View) Personnel Access Barriers Minimum H = 3.5 m [138 inches] Minimum L = 1.2 m [47 inches]...
Page 255: Additional Notes
ArcShield Unit Information Appendix D Figure 81 - Chimney Exhaust Space Requirements Minimum H1: 1.7m (67”) Minimum H: 1m (37”) Additional Notes The walls of the plenum exit area must be capable of withstanding the pressure generated. Any painted surfaces which face direct contact with the arc products may ignite. Flame suppression is recommended.
Page 256: Chimney Information
Appendix D ArcShield Unit Information Chimney Information Where adequate clean height (space) is available, chimney can be provided for each unit in place of the plenum system. It is to be field mounted on top of the unit structure. The purpose of the chimney is to direct the hazardous flames and gases away from the top of the resistant enclosure for the chimney is secured to the top of each unit structure.
Page 257: Recommended Torque Values
Appendix ArcShield Plenum Installation Instructions The following instructions are provided to ensure the proper installation and function of plenum components supplied with ArcShield enclosures. Refer to Appendix D for additional information related to ArcShield plenums before attempting to follow these instructions. TIP See publication MV-QS050 for level floor surface requirements.
Page 258 Appendix E ArcShield Plenum Installation Instructions Figure 82 - Plenum Exhaust Label DANGER DANGER ARC FLASH HAZARD HAZARD D’ARC ÉLECTRIQUE PRESSURE RELIEF EXIT SORTIE DE L’ÉVENT RÉGION ÊTRE: AREAS TO BE: - INACCESSIBLE AUX PERSONNEL - INACCESSIBLE TO PERSONNEL PENDANT QUE L’ÉQUIPEMENT WHILE EQUIPMENT ENERGIZED.
Page 259: General Plenum Layout For Arcshield Line-Up
ArcShield Plenum Installation Instructions Appendix E 18 in. long Extension 26 in. long Extension 36 in. long Extension Connected to the last Plenum on the Connected to the last Plenum on the Connected to the last Plenum on the exhaust end of the “line-up” exhaust end of the “line-up”...
Page 260: Step 1 - Mounting A Single Plenum
Appendix E ArcShield Plenum Installation Instructions STEP 1 – Mounting a Single Before mounting a single Plenum over an MV enclosure, the front duct section must first be removed. This is shown in Figure Plenum Figure 85 - Removing Front Duct Section Front Duct Section Components Cabinet Preparation...
Page 261: Plenum Placement On Structure
ArcShield Plenum Installation Instructions Appendix E Plenum Placement on Structure Once the Plenum has been lifted in place directly over the relief vent (shown in Figure 88), all 1/4-20 fasteners, removed in Cabinet Preparation above, are replaced to attach the Plenum to the top of the enclosure. Use hand tools only. Figure 88 - Plenum Placement Use recommended torque value for 1/4-20 fasteners...
Page 262: Rockwell Automation Publication 1560F-Um001A-En-P - June
Appendix E ArcShield Plenum Installation Instructions Figure 89 - Aligning “Side-by-Side” Plenums IMPORTANT Any unused holes must be filled with thread forming screws. i.e.: “Lifting Lug holes”. All Gaps must be sealed and filled with silicone. STEP 3 – Sequence of Final All Plenums in a Line-up must be mounted to the top of each enclosure and to the Plenum directly beside it before the front duct sections are re-attached (see Assembly...
Page 263: Step 4 – Closing The Front Of The Plenum Sections
ArcShield Plenum Installation Instructions Appendix E STEP 4 – Closing the Front After the first stage of the Plenum assemblies have been mounted, the Plenums can then be “closed-up” by replacing the front duct sections as shown in Figure 91 of the Plenum Sections Figure Figure 91 - Top Plate...
Page 264: Step 6 – Mounting Extension/Elbow To Plenum "Line-Up
Appendix E ArcShield Plenum Installation Instructions Figure 94 - 90° Elbow Section Assembly, Step 5A (Front View) Figure 95 - 90° Elbow Section Assembly, Step 5B (Front View) Screen Cover Plate 36" Extensions 2-piece 90 deg. Elbow Section Figure 96 - 90° Elbow Section Assembly, Step 5C (Front View) Screen Cover Plate The Extension components are attached to the Elbow Section using 5/16-inch Hardware.
Page 265: Step 7 – Additional Mounting Support
ArcShield Plenum Installation Instructions Appendix E Figure 97 - Optional Extension/Elbow with Vertical Extension (Right side exit) Last Plenum in Line-up remains open for installation of Extension Assembly After the Extension/Elbow assembly is attached through the fastener holes on the inside flange of the Plenum, the front duct section can be replaced and fastened through the holes on the outside flanges.
Page 266 Appendix E ArcShield Plenum Installation Instructions Figure 98 - Completed Assembly for optional vertical exit Plenum (Right hand exit) TIP During an arc fault, the plenum will be subjected to a brief high pressure shock wave. The Extension/Elbow assembly may experience dynamic loading. It is important to account for dynamic loading when selecting supporting means and materials.
Page 267: Recommended Torque Values
Appendix ArcShield Chimney Installation Instructions The following instructions are provided to ensure the proper installation and function of chimney supplied with ArcShield enclosures. Refer to Appendix D for additional information related to ArcShield chimney before attempting to follow these instructions. Recommended Torque •...
Page 268: General Plenum Layout For Arcshield Line-Up
Appendix F ArcShield Chimney Installation Instructions General Plenum Layout for An example of a general chimney assembly configuration is shown in Figure 100. Chimneys of varying widths are mounted directly over the MV enclosures of the ArcShield Line-up corresponding width. Figure 100 - ArcShield Line-ups Cabinet Preparation In preparation for mounting a chimney, remove 1/4-20 fasteners from the Relief...
Page 269: Chimney Placement On Structure
ArcShield Chimney Installation Instructions Appendix F The chimneys are designed to fit over the fastener heads at the (4) corners of the Relief vent. The corner fasteners are required to secure the Relief vent during installation. Chimney Placement on Structure Once the Chimney has been lifted in place directly over the relief vent (shown in Figure 102), all 1/4-20 fasteners, removed in...
Page 270 Appendix F ArcShield Chimney Installation Instructions Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 271: Introduction
Appendix Using DeviceLogix Introduction DeviceLogix is a standard feature in the SMC-50 control module (firmware 4.002 and higher). DeviceLogix can be used to control and monitor the controller. Program DeviceLogix for the controller through a DeviceLogix Editor component ( icon), available in Connected Components Workbench software version 6 and later.
Page 272: Macro Blocks
Appendix G Using DeviceLogix • Select/Limit • Timer/Counter • Compare • Compute/Math • Move/Logical • Macro Block The DeviceLogix Editor provides a graphical interface for configuring Function Blocks to provide local control within the drive. DeviceLogix Editor navigation and programming basics are not covered in this manual. Refer to the DeviceLogix user manual, publication RA-UM003 for additional information.
Page 273: Bit Inputs
Using DeviceLogix Appendix G Bit Inputs Available bit inputs to the DeviceLogix program include: Bit Inputs Name Description Input 1, Input 2 State of the 2 inputs on the control module. Status indicating that the expansion card installed into P7 Ready, P8 Ready, P9 the corresponding expansion port is functioning and (17) Hardware Boolean Inputs Ready...
Page 274: Analog Inputs
Appendix G Using DeviceLogix Table 73 - Bit Output Mapping Bit Outputs Name Description Aux 1, Aux2 Auxiliary Relays available on the control board. (11) Hardware Boolean Outputs Auxiliary Relays #1 - #3 available on the Digital I/O PX Aux1 – PX Aux3 (150-SM4) Expansion Card Coast Start...
Page 275: Analog Outputs
The DeviceLogix implementation supports 32-bit integers only. DeviceLogix Scratchpad Registers The SMC-50 control module provides 2 input (parameter #335, #336) and 2 output (parameter #343, #344) scratchpad registers. The input parameters can be written by any configuration or network device and used as an input to DeviceLogix.
Page 276 Appendix G Using DeviceLogix Table 77 - Four-position Selector Switch I/O Inputs Outputs Input 1 Input 2 Output Selection Selector Switch Output Volt PP Ave Volt Phase A-B Volt Phase B-C Volt Phase C-A Parameter Configuration Because the individual phase voltage parameters are not directly available in DeviceLogix (only the average voltage –...
Page 277: Example 2: Wet Well Operation
Port #8 Aux #2 Critical Level Pilot light Indicates that the Critical Level Sensor is active. Outputs No External Wiring Start Start signal to the SMC-50 control module. No External Wiring Stop Stop signal to the SMC-50 control module. Example logic requirements: •...
Page 278 Appendix G Using DeviceLogix • Activate the Critical High Level Pilot when the Critical High Level sensor is active. • Reset alarms / faults with a Reset push button input Parameter Configuration The parameters that are listen in Table 80 are configured for this example.
Page 279 Using DeviceLogix Appendix G Figure 106 - Function Block Programming Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 280 Appendix G Using DeviceLogix Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 281: Power Stacks
Appendix Spare Parts Power Stacks Table 81 - Replacement SCRs SMC Rated Description Part Number Voltage 180 Amp 360 Amp (max.) 1500 Individual – no matching required (6 per controller) 80156-815-61-R 80156-894-71-R 2500 Individual – no matching required (6 per controller) 80156-893-71-R 80156-894-71-R 4800...
Page 282 Appendix H Spare Parts Table 84 - Common Parts Quantity Description Part Number 1 per SCR pair Sharing resistor 32.5 kΩ, 225W, two 2.5 kΩ taps 80025-753-01-R 1 per SCR Current loop self-powered gate driver board (CLGD) 80190-519-01-R 1 per controller Voltage Sensing Board (VSB) 1500V 80187-708-51-R...
Page 283 80144-491-02 Notes: 1. Reference only. 2. 1503 – For OEM products, refer to OEM-supplied documentation for specific spare parts list. 1560/1562F are Allen-Bradley manufactured starters. 3. For spare parts for starter and contactor components, refer to Additional Resources on page...
Page 284 Appendix H Spare Parts Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 285: Accessories
Appendix Accessories Accessories Table 87 - Accessories Description Description/Used With Catalog Number Remote Door Mounted 20-HIM-C6S IP66 (Type 4/12) Programmer Only Communication Modules Remote I/O 20-COMM-R RS 485 (DF-1) 20-COMM-S DeviceNet® 20-COMM-D ControlNet 20-COMM-C EtherNet/IP™ 20-COMM-E PROFIBUS 20-COMM-P INTERBUS 2 20-COMM-I LonWorks 20-COMM-L...
Page 286 Appendix I Accessories Notes: Rockwell Automation Publication 1560F-UM001A-EN-P - June 2019...
Page 287: Index
66 alarm code control terminals cross reference 150 linear list 151 150-SM4 37 alarm indication 155 SMC-50 37 control wiring 66 ArcShield current imbalance 28 chimney 256 chimney installation 267 current limit start chimney installation instructions 267...
Page 288 35 detail 175 DeviceLogix 35 function block element 271 basic configuration 112 parameters 271 connect to SMC-50 136 using 271 control buttons 131 diagnostics 145 control screen 132 DPI 35 function keys 84 keypad 136...
Page 289 HIM 136 150-SM4 234 control terminals 37 monitoring file group 109 DeviceLogix 271 motor protection group 110 heatsinks 38 SMC-50 199 interface board 39 THD 33 motor tuning 73 password 85 overview 14 PFCC 62 parameters 199...
Page 290 Index snubber resistor replacement 186 underload protection 27 soft keys 85 undervoltage protection 27 soft start utility group parameter 112 parameters 97 soft stop 21 parameters 97 timing diagram 21 voltage feedback circuit test 166 spare parts voltage sensing board replacement 167 power stacks 281 stall protection 28 voltage sensing module 81...
Page 292 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, ArcShield, CENTERLINE, Connected Components Workbench , PowerFlex, Rockwell Automation, Rockwell Software, SCANport, and SMC-50 are trademarks of Rockwell Automation, Inc. ControlNet, DeviceNet, and Ethernet/IP are trademarks of ODVA, Inc.

Allen-Bradley SMC-50 User Manual

Preface

Chapter 1 Overview

Product Overview

Chapter 2 Receiving

Installation

Chapter 3 Preliminary Setup

Commissioning Procedure

Chapter 4 Overview

Programming

Chapter 5 Overview

Metering

Chapter 6 Overview

Optional HIM Operation

Chapter 7 Overview

Communications

Diagnostics

Chapter 8 Overview

Troubleshooting

Chapter 10 Preventive Maintenance Protection

Maintenance

Parameter List

Appendix A Starting Duty

Appendix C

Functional Description

Appendix D Arcshield Design

Overview

Appendix E

Appendix F General Plenum Layout for Arcshield Line-Up

Chapter 9 Introduction

Appendix G

Accessories

Appendix H

Appendix I

Index

Quick Links

Troubleshooting

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Summary of Contents for Allen-Bradley SMC-50