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MV SMC-Flex
Product Overview
February 2004
Why Use MV SMC-Flex Motor Controllers?
Major Reasons
• Help minimize
downtime / operating
costs
• Help provide cost
savings by minimizing
the effects of
– High inrush currents
– High starting torque
2
MV SMC-Flex Minimizes Downtime/Operating Cost
• Problem:
– Belts, gears and machinery can be damaged by across-the-line starting
Breakdown Torque
180% High torque can cause
Percentage physical damage to the
of Full Load mechanical system.
Torque
100%
• MV SMC-Flex Solution:
0
Percentage of Full Speed 100%
– Lengthens system life by reducing
mechanical stress during starting by using Soft Start
– Helps eliminate the need for maintenance people to repair the process
– No need to replace damaged parts
– Minimal production loss 3
MV SMC-Flex Minimizes Downtime/Operating Cost
• Problem:
– Materials can be
damaged by sudden
starts and stops
• MV SMC-Flex
Solution:
– Soft Start minimizes
damage by reducing
high starting torque
– Soft Stop reduces damage by minimizing load shifting or spillage
during stop
– Higher yield during production
4
MV SMC-Flex Provides Cost Savings by
Minimizing Inrush Currents
• Problem:
– Power company restrictions on incoming line current, or you pay
the penalty
– Weak power lines cannot handle 600%
high inrush currents, causing brown Percentage
outs or excessive line disturbances, of Current
Full Load
which in turn cause other processes
to shut down 100%
• MV SMC-Flex Solution: 0
Percentage of Full Speed
100%
– Current Limit starting minimizes the amount of inrush current,
meeting power company restrictions
– Process shut down and brown outs are minimized by reducing the
amount of current drawn during starting 5
MV SMC-Flex
Overview
• Three MV SMC-Flex Offerings:
– Bulletin 1562E, a complete motor control solution
– Bulletin 1560E, a retrofit solution, that builds on an
existing full voltage controller
– Bulletin 1503E, component kits for use by OEMs
• The MV SMC-Flex represents a continuing
legacy of product enhancement, since the initial
MV SMC shipments in 1993
• Part of the Centerline family of MV controllers
• CSA, UL and CE Approved
6
MV SMC-Flex
Overview
Retrofit – 1560E Combination – 1562E
Isolation
Switch &
SCR Power Stack Power Fuse
Assembly
Main Contactor
Bypass Bypass
Contactor Contactor
Current Current
Transformers Transformers
M M
7
MV SMC-Flex
Overview
• Efficient 1562E design
– enclosure choices
• NEMA 1, 1A, 12 & 3R
• IP 10, 21, 52, and 34
– power electronics and by-pass
contactor in top section
– isolation switch, power fuses and
main contactor in bottom section
– two large low voltage panels
• SMC-Flex controller (top)
• Main LV control (bottom)
Bulletin 1562E
8
MV SMC-Flex
Overview
• Uses SMC-Flex control module (the
same as low voltage products)
• New interface board with inherent
safety, using fiber optic isolation
• Human Interface Modules (HIMs) &
communication interfaces are also
used with the LV SMC-Flex and
PowerFlex drives (DPI-based)
• Power circuit enhancements
Bulletin 1562E
9
MV SMC-Flex
Power Ratings - HP
• 2,400 - 6,900 Volts
• 200 / 400 / 600 Amp
• 50 / 60 Hz
8000
7000
6000
5000 2400 V
HP 4000 3300 V
3000 4160 V
2000 6900 V
1000
0
200 Amp 400 Amp 600 Amp
10
MV SMC-Flex
Power Ratings
Maximum Output Ratings – HP (kW)
Voltage
200 Amp Unit 400 Amp Unit 600 Amp Unit
2,400 800 (600) 1,500 (1100) 2,750 (2050)
3,300 1,000 (750) 2,250 (1700) 4,000 (3000)
4,160 1,250 (950) 2,750 (2050) 4,500 (3350)
6,900 2,500 (1900) 4,500 (3350) 7,500 (5600)
11
MV SMC-Flex
Dimensions
Width Depth Height Weight
Bulletin Voltage Rating
in. mm in. mm in. mm lb. kg
2400 200 A 26 660 36 914 91 2311 800 363
3300 400 A 26 660 36 914 91 2311 800 363
4160 600 A 44 1117 36 914 91 2311 1,300 590
1560E
200 A 36 914 36 914 91 2311 1,220 554
6900 400 A 36 914 36 914 91 2311 1,220 554
600 A 44 1117 36 914 91 2311 1,300 590
2400 200 A 36 914 36 914 91 2311 1,400 636
3300 400 A 36 914 36 914 91 2311 1,400 636
4160 600 A 80 2032 36 914 91 2311 2,325 1056
1562E
200 A 62 1575 36 914 91 2311 2,325 1056
6900 400 A 62 1575 36 914 91 2311 2,325 1056
600 A 100 2540 36 914 91 2311 4,000 1812
12
MV SMC-Flex
Power Stacks
• Rockwell Automation design
– designed specifically for MV
soft starter duty
– efficient compact design
– 200 Amp - aluminum
– 400 / 600 Amp - copper
13
MV SMC-Flex
Control Module Overview
• Soft Start - with Selectable Kickstart
• Soft Stop
• Current Limit Start - with Selectable
Kickstart
• Linear Speed Acceleration - with
Selectable Kickstart
• Linear Speed Deceleration
• Dual Ramp - with Selectable
Kickstart
• Full Voltage
• Preset Slow Speed
• Pump Control (Optional) 14
MV SMC-Flex
Starting Mode - Soft Start
– Adjustable Ramp Time: 0 to 30 seconds
– Adjustable Initial Torque: 0 to 90% LRT
– Selectable Kickstart: 0.0 to 2.0 seconds
– Adjustable Kickstart Level: 0 to 90% LRT
15
MV SMC-Flex
Stopping Mode - Soft Stop
– Soft Stop extends stopping time to minimize
load shifting or spillage
– Adjustable Soft Stop time: 0 to 30 seconds
16
MV SMC-Flex
Starting Mode - Current Limit
– Current Adjustment: 50 to 600% FLA
– Current Limit Time: 0 to 30 seconds
– Selectable Kickstart: 0.0 to 2.0 seconds
– Adjustable Kickstart Level: 0 to 90% LRT
17
MV SMC-Flex
Starting/Stoping Mode - Linear Acceleration & Deceleration
• Linear Speed Control uses • Applications Include:
closed-loop feedback to – Overland conveyor
accelerate / decelerate the – Tunnel conveyor
motor at a constant rate – Feed conveyor for rock crusher
– 0 to 30 second start time • Requires the use of a
– 0 to 30 second stop time tachometer (customer supplied)
18
MV SMC-Flex
Starting Mode - Dual Ramp Start
– Provides two Start profiles with separate
ramp times and initial torque settings
– Adjustable ramp time: 0 to 30 seconds
– Adjustable initial torque: 5 to 90% LRT
– Selectable Kickstart: 0.0 to 2.0 seconds
– Adjustable Kickstart Level: 0 to 90% LRT 19
MV SMC-Flex
Starting Mode - Full Voltage
– High duty cycle
– Full inrush current and locked rotor torque are
achieved
– Applications requiring across-the-line starting
20
MV SMC-Flex
Starting Mode - Preset Slow Speed
• Preset Slow Speed furnishes two jog
speeds to facilitate process set-up and
alignment
– Forward Speeds: 7 or 15% of rated speed
– Reverse Speeds: 10 or 20% of rated speed 21
MV SMC-Flex
Pump Control (Optional)
• The SMC Flex controller’s unique, interactive Pump Control
reduces fluid surges in pumping systems
– Adjustable Pump Start time: 0 to 30 seconds
– Adjustable Pump Stop time: 0 to 30 seconds
– Selectable Kickstart: 0.0 to 2.0 seconds
– Adjustable Kickstart Level: 0 to 90% LRT
22
MV SMC-Flex
Pump Control
• Pump Control benefits for your applications
– Designed specifically for centrifugal pumps (not to
be used for positive displacement pumps)
– Reduces surges caused by uncontrolled
acceleration and deceleration of centrifugal pumps.
– Can eliminate the need for specialized flow control
valves
– Provides closed loop acceleration and deceleration
motor control-without the use of sensors or
feedback devices
– Performance not matched by any competitor
23
MV SMC-Flex
Starting Mode - Pump Control
Across the Line Start
Torque
Full
Load
Pump System
Speed Full Speed
MV SMC-Flex
Starting Mode - Pump Control
Across the Line Start
Torque
Soft Start
Full
Load
Pump System
Speed Full Speed
MV SMC-Flex
Starting Mode - Pump Control
DOL
Start
Torque
Full
Load
Pump Start
Pump System
Speed Full Speed
MV SMC-Flex
Starting Mode - Pump Control
100%
DOL Soft
Start
Pump
Control
Flow
Time
MV SMC-Flex
Stopping Mode - Pump Control
100%
Pump
Control
DOL
Flow Soft
Stop
Time
MV SMC-Flex
Protection & Diagnostics
• Electronic Motor Overload Protection
• Stall Detection
• Jam Detection
• Ground Fault Protection
• Thermistor Input (PTC)
• Diagnostics and Warnings
• Monitoring
• Configurable Auxiliary Contacts
29
MV SMC-Flex
Stall Detection
FLA
600%
Ramp Stall TIME
• Utilizes a programmable time delay
– Adjustable up to 10 seconds
• Enabled with a setting above zero
30
MV SMC-Flex
Jam Protection
FLA
100%
Running Jam TIME
• Enabled by programming the Jam Trip Level
– Jam trip level adjustable up to 999% FLA
• Utilizes a programmable delay time
– Delay time adjustable up to 99 seconds
• Operational only during the at speed condition
31
MV SMC-Flex
Ground Fault Protection
• Class I protection
– No high current inhibit function
• 100:1 zero sequence CT required (825-CBCT or
equivalent)
• Equipment Protection Only
– Not intended as a Ground Fault Circuit-Interrupter for
personnel protection
• Adjustments
– Inhibit time adjustable: 0 - 250 seconds
– Trip delay adjustable: 2 - 25 seconds
– Trip level adjustable: 1.0 - 5.0 amperes
– Warning level adjustable: 1.0 - 5.0 amperes
32
MV SMC-Flex
Thermistor Input (PTC)
• The SMC-Flex controller offers enhanced motor
protection with additional circuitry to monitor motor
stator-embedded positive temperature coefficient
(PTC) thermistors
• PTC Characteristic
Resistance Ohms (W)
per IEC 34-11-2
33
MV SMC-Flex
Fault Diagnostics
– Overtemperature – Line Fault
– Stall Detection – Power Loss
– Open SCR Gate – Voltage Unbalance
– Shorted SCR Gate – Phase Reversal
– Overload – Undervoltage
– Underload – Overvoltage
– Excessive Starts per – Jam Detection
Hour – Communication Fault
– Thermistor (PTC) – Ground Fault
– Current Unbalance
34
MV SMC-Flex
Fault Alarms
• Alarm Settings Can Be Programmed for:
– Thermal Overload
– Ground Fault
– Jam
– Underload
– Thermistor (PTC)
– Over Voltage
– Under Voltage
• Alarm Settings Can Be Used to Provide Advance
Notification of Impending Trips
Allows for corrective action to avoid downtime!!
35
MV SMC-Flex
Monitoring
• Eliminate the mystery of your motor’s operation by
applying the SMC-Flex controller with its built-in
metering capabilities
– Three-phase currents
– Three-phase voltages
– Three-phase power (MW, MWh)
– Power factor of the running motor
– Motor thermal capacity usage
– Elapsed time of motor operation
– Motor speed (with optional use of tachometer)
36
MV SMC-Flex
Configurable Auxiliary Contacts
• One Normally Open Auxiliary Contact
– Programmed for Up-To-Speed for MV applications
• One Fault Auxiliary Contact
– Programmable for Normally Open or Normally Closed
• One Alarm Auxiliary Contact
– Programmable for Normally Open or Normally Closed
• One Normal Auxiliary Contact
– Programmable for Normally Open or Normally Closed
37
MV SMC-Flex
Human Interface Modules (HIMs)
• Built-in
– Easy parameter access
speeds commissioning and
maintenance
• External (Optional)
– Handheld
– On Panel
-A2 -A3 -A4
38
MV SMC-Flex
HIM Communications
• Built-in LCD display is easy to use
– data presented clearly Fault Pop Up
– pop-up menus and messages
F->
F Stopped
Stopped Ready A
Auto
0.00 Hz.
for better alerts / access - Fault - F05
Overvoltage
Main Menu:
• Change Languages Quickly Time Since Fault
Diagnostics
1:10:07
Parameter
– 2 keystrokes for any language Device Select
• Languages
– English, French, Spanish, Italian,
German, Portuguese, Chinese
39
MV SMC-Flex
Optional Communication Modules
• The SMC Flex uses the same
Communication Modules and Human
Interface Modules (HIMs) as the PowerFlex
drives family (DPI communication)
• DPI communication modules
– DeviceNet™
– ControlNet
– EtherNet/IP
– Remote I/O
– RS 485-DF1
– ProfiBUS-DP
ControlNet
40
MV SMC-Flex
Typical Communication Architecture
Typical DeviceNet Unit Architecture
SMC-Flex
825P
DSA
41
MV SMC-Flex
Communications, Programming & Monitoring
• Using the MV SMC-Flex communication capabilities
provides enhanced control & monitoring
– Parameter settings
– Fault Diagnostics
– Metering
– Start-stop control via network (DeviceNet,
ControlNet, Ethernet)
• Use DriveTools software to program
and monitor the MV SMC-Flex
• IntelliCENTER compatibility
– System status & detailed
unit information
42
MV SMC-Flex
Standard Units for Quick Shipment
• Bulletin 1560E and 1562E units are
available for the following reduced factory
lead-times:
– 200 to 400 Amps, 2400 to 4160 V
• 15 to 20 business days
• Includes standard options
– Motor protection relays (825P, E3/E3+)
– Pump control module
– IntelliVAC™ solid-state contactor control
– Communication
43
MV SMC-Flex
Summary
• Minimizes stress on mechanical drive and
power systems
• Safe & Reliable design
• Flexible control and communication
• Enhanced performance, to meet the challenge
of a wide variety of applications
44
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