M.V. DEVELOPMENT by ewghwehws

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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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