Manuals Electric Jaw Crusher and Reciprocating Plate Feeders

2-443-20351 - 1

07/2

003

Electrical Dokumentation

Jaw Crusherand

Reciprocating Plate Feeder

Codelco El Teniente, ChilePipa Norte

2-443-20351P.O.4500297631

Year of manufacture 2002

ThyssenKrupp Frdertechnik GmbHP.O. Box 1463 D - 59306 Ennigerloh

Schleebergstrasse 12 D - 59320 EnnigerlohPhone: (02524) 30-0

Telefax: (02524) 2252Internet: www.thyssenkrupp.com

www.eprocessingplants.com

This operating manual in all its parts is protected by copyright. All rights reserved including those of translation into other languages. This manual as a whole or part of it is not allowed to be processed, reproduced or distributed in any form, electronic systems included, without the written permission of ThyssenKrupp Frdertechnik.

File 1 Pipa Norte 1. Lists and Drawing Motor and consumerlist Ident No. 4200 447 Ind. 3 Switch list 4200 446 Ind. 4 Function diagram 4200 559 Ind. 1 One line diagram 4200 454 Ind. 4 P & I diagram 4200 456 Ind. 2 Installation of instrumente 4200 457 Ind. 6 Grease lubrication system jaw crusher 4200 558 Ind. 1 Grease lubrication system plate feeder 4200 560 Installations instructions EASY 412-AC-R

File 2 2. Medium Voltage Smart Starter Medium voltage smart motor

controller Bulletin 1562 D Ident No. 4200 595 Ind. 2

Construction diagram and technical data SMC for crusher

Ident No. 7004 289-001-02 D Page 1 - 6

Circuit diagram SMC for crusher 7004 289-001-02E Page 1 - 5

Medium voltage dialog plus TM motor controller Bulletin 1562 D

Multifunctional motor management Bulletin 825 smart motor

3. Crusher motor and hydraulic motor Technical data sheet crusher motor Motor dimension crusher motor Test for asynchronous machines Safety instructions crusher motor Technical data for hydraulic motor Motor dimension print for hydraulic motor NEMA induction motor for hydraulic motor

File 3 4. Video control jaw crusher inlet Technical documents Operating instructions camera Operating instructions monitor 5. Ultrasonic measurement jaw crusher inlet Operating instructions Prosonic FDU 81 Technical information FMU 860 Software instructions FMU 860 6. Hydraulical adjustment of jaw distance Wiring diagram Ident No. 4200 712 Function discription 4200 590 7. Control- and measurement system DALOG Arragement drawing Terminal drawing Compoments dokumentation 8. Data sheets Limit switch bal valve oil tanks Limit switch plate feeder Speed control jaw crusher

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Index

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primary circuit

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control unit

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control unit

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cabinet

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terminal strip

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terminal strip

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Gerteliste

spare parts list

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Index

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primary circuit

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control unit

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control unit

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cabinet

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terminal strip

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terminal strip

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terminal strip

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spare parts list

Manual bsico

Mdulo de controlEASY 412-DC-R...EASY 412-AC-R...

04/98 AWB 2528-1316-EPrimera edicin 04/98

G Klckner-Moeller GmbH, Bonn

Autor: Dieter Bauerfeind

Editor: Jrg Eiserloh, Thomas Kracht

Traductor:Parlamon, Traductors i Intrprets, s.l.

u2e.fm Seite 1 Dienstag, September 8, 1998 4:38 PM

Cuidado!

Peligro. Alta tensin.

Antes de instalar:l Conecte los dispositivos con la

alimentacin elctrica desconectada.l Asegrese de que los dispositivos no

puedan conectarse de forma accidental.l Verifique el estado

fuente de alimental Conecte la puesta

instalacin contra l Cubra o proteja las

activas.l Siga las instruccio

dispositivo.l Slo el personal t

autorizado a manipsistema.

l Antes de instalar oasegrese de estaelectroesttica.

l Los cables de coneseales deben insinterferencias induinterfieran en las fu

l Instale los dispositcorrespondientes modo que se preveinvoluntaria de los

l Tome las medidasadecuadas, tanto software, para el inuna ruptura de lnecause estados inddispositivos conec

l Aplique un aislamifuente de 24 V de

l Utilice nicamente fuentes de alimentacin que cumplan con la norma IEC 364-4-41 o HD 384.04.41 (VDE 0100 Parte 40-1).

l Las desviaciones de los valores nominales del voltaje princip

IBM un marchio regInternational BusinesCorporation.

Tutti gli altri marchi omarchi registrati dai r

SICH_E.FM5 Seite 1 Mittwoch, September 9, 1998 9:23 AM del aislamiento desde la cin. a tierra y proteja la cortacircuitos. dems unidades

nes tcnicas (AWA) del

cnico cualificado est ular los dispositivos/el

lmites de tolerancespecificaciones, ymal funcionamientde operar peligros

l Todos los dispositemergencia que c60204 / IEC 204 (Vefectivos en todoslos dispositivos audesconexin de diseguridad no debe tocar el dispositivo, r libre de carga

xin y de transmisin de talarse de modo que las ctivas o capacitivas no nciones automticas.ivos automticos y los elementos operativos de nga la puesta en marcha

mismos. de seguridad en hardware como en terface I/O, de modo que a o cable en la fuente no efinidos en los tados.ento elctrico fiable a la baja tensin.

marcha accidental Los dispositivos m

cajas de control smanejarse despuinstalacin y con unidades fijas y pactivarse y mane

l Tome medidas pmarcha de modoque han sido intefallo de tensin. Ecualquier situacinecesidad, instalde emergencia.

istrato della s Machines

nomi di prodotto sono ispettivi costruttori.

Tutti i diritti, ancfhe laNessuna parte di queriprodotta in alcuna fmicrofilm o altro sistelutilizzo di sistemi disenza lautorizzazionMoeller di Bonn.al no deben exceder los ia descritos en las a que podran causar un

o y representan un modo o.ivos de parada de umplan la norma EN DE 0113) deben ser los modos operativos de tomticos. La chos dispositivos de causar la puesta en l o no controlada.ontados en cajas o en

lo deben activarse y s de su debida la caja cerrada. Las orttiles slo deben jarse con la caja cerrada.ara volver a poner en adecuado los programas rrumpidos por un bajn o vite en todo momento n de peligro y, en caso de e dispositivos de parada

traduzione sono riservati. sto manuale pu essere

orma (stampa, fotocopia, ma), elaborata o diffusa con elaborazione elettronica, e scritta della Klckner-

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ndice

1 Mdulo de control easy 3

Ms fcil con easy 4

Montaje del easy 6

1316e.bk : 1316e.IVZ Seite 1 Donnerstag, September 10, 1998 12:01 PM1

Conexin del easy 7

Funciones del easy 9

2 El cableado con easy 15

Manejo easy 15Establecer el idioma del men 16

Configurar hora 16

Seleccionar el modo de funcionamiento del easy 17

Elementos del esquema de contactos del easy 18

Ejemplo: Crear un esquema de contactos 20Rels de funcin 24

Ejemplo: Utilizar rels de funcin 30Circuitos principales 33

3 Interface easy 35

4 Caractersticas tcnicas 37

Caractersticas tcnicas 37

Gama easy 38

ndice alfabtico 39

21316e.bk : 1316e.IVZ Seite 2 Donnerstag, September 10, 1998 12:01 PM04/9

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1 Mdulo de control easy

Indicaciones tcnicas de seguridad

Voltaje elctrico peligroso!

Los trabajos de instalacin que se describen a

1316e.bk : 1316e01.fm Seite 3 Donnerstag, September 10, 1998 12:01 PM3

continuacin deben realizarse nicamente por personal tcnico cualificado.

No realice trabajos elctricos con la corriente conectada.

Siga las instrucciones siguientes :

Desconecte todos los aparatos

Asegrese de que no se pueden conectar de nuevo

Asegrese de que no tienen tensin

Recubra las partes cercanas que tengan corriente

Mdulo de control easy

4

Ms fcil con easy Conmutacin y control inteligente

easy es un mdulo de control de control para instalaciones pequeas de forma cmoda. easy es adecuado para la domtica y en la fabricacin de mquinas y aparatos. Easy se suministra con funciones de uso ergonmicas y eficientes.

Conecte el easy e introduzca su esquema de

1316e.bk : 1316e01.fm Seite 4 Donnerstag, September 10, 1998 12:01 PM04/9

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contactos simplemente pulsando las teclas. easy utiliza contactos a la apertura, contactos y rels.

Con easy implementar su esquema elctrico en tamao real. easy dispone de las funciones bsicas y especiales de controles por rels y por contactores, aparte de muchas ms posibilidades. Las modificaciones y ampliaciones pueden realizarse simplemente pulsando una tecla. El aparatoso recableado se hace prescindible.

Aplicacin universal

mbito domstico, sistemas de control de iluminacin, marquesinas y persianas.

Extractores, puertas giratorias, invernaderos, instalaciones de iluminacin exterior, accionamiento de ventanas, iluminacin de escaparates.

Mquinas e instalaciones, prensas, cintas transportadoras, transportadores vibrantes, clasificadoras, bombas.

Ms fcil con easy

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Vista general del easy

alimentacinentradas


salidas

Pantalla

Teclas de funcin

Interface para la conexin de la tarjeta de memoria PC

ESCOK

DELALT


6

Montaje del easy Montaje en carril DIN Colocar el easy en el borde superiordel carril y encajarlo.

El mecanismo de muelle permite que el easy encaje automticamente.

1.


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Montaje con tornillosEl montaje con tornillos puede realizarse utilizando los clips de fijacin que se suministran como accesorios.

2.

Conexin del easy

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Conexin del easy Conexiones de entrada y salida del easy de 24 V DC



8

Conexiones de entrada y salida del easy de 115/230 V AC

0.5 Nm3.5 mm

L

N

>

= 1150 / 60 (97...26 = 40 20

l1-I6 = 0,5 mA, 230 V= 0,25 mA, 115 V

I7, I8 = 6 mA, 230 V4 mA, 115 V

"1" 79 V

"0" 40 V

264 V

0 V DCN

8 A / B 16

L1, L2, L3 ( 115/2+ 24 V DC

1

e

e


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N L N l1 I2 I3 I4 I5 I6 I7 I8

1A

5/230 ACHz4 V AC)mA 115 VmA 230 V

30 AC )

25 000

R L

24 V DC115 V AC230 V AC

1000 W

10 58 W

1 2 1 2 1 2 1 2

0 000 000

Q1 Q2 Q3 Q4

8 A8 A8 A

2 A2 A2 A

Funciones del easy

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Funciones del easy Teclas de funcin

DEL: Eliminar del esquema de contactos

ALT: Funciones especiales en el esquema de contactos

Teclas de cursor : Mover cursor


Gestin de mens y entrada de valores

Seleccionar opciones de menEstablecer nmeros, contactos y valores

OK: Seguir, guardar

ESC: Ir atrs, cancelar

Llamar men especial

Pasar al siguiente nivel de menLlamar opcin de menGuardar entradas

Pasar al nivel de men anteriorDeshacer entradas efectuadas desde el ltimo OK

Saltar entre opciones de menModificar valor

Cambiar posicin

Funciones de la tecla P: entrada P1, entrada P2 entrada P3, entrada P4

y


10

Pantalla de estado

Entradas On / Off

Salidas On / Off

Da de la semanaHoraModo de funcionamientoRUN/STOP

Seleccin parpadea

men


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Pantalla del men

Pantalla del cursor

!"!#

Men principal con o sin proteccin por contrasea

actual en eleasy

""" !"!#

El cursor parpadea alternativamente

Cursor / Mover cursor con o tambin con en el esquema de contactos

Valor / Cambiar posicin con Cambiar valores con

En el manual, los valores parpadeantes se representan en color gris

$"% !$

$"% !$&

Funciones del easy

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Pantalla del esquema de contactos

Campos de Campo de bobina

Vas de corriente


Elementos del esquema de contactos

Conexiones

Va de corriente 1Va de corriente 2

Contacto: Tecla PContacto: EntradaContacto/bobina: SalidaContacto/bobina: MarcadorContacto/bobina: TemporizadorContacto/bobina: ContadorContacto: Reloj programableContacto: Comparador de valores analgicos

Campo de bobina

Va de corriente 3. . .Va de corriente 41

'(')'*+&&&&&&&&&&&&&&&&&&&&&&&

*,


12

Estructura del men

Men principal sin proteccin por contrasea

Men

STOP

STOP: Pantalla del esquema de contactosRUN: Pantalla del flujo de corriente

RUN Pantalla de parmetros

Esquema de contactos


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Registro de parmetros

Registro de parmetros

Pantalla de parmetros

Pantalla de configuracin

del reloj

Funciones del easy

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Men principal con proteccin por contrasea

Contrasea

Introducir contraseaentrar en el

easy

Men principal

cuatro entradas errneas

entrada correcta

Visualizzazione

Men


Men especial

di stato

Introducir contrasea

Establecer contrasea

Cambiar

impostazione password

Contrasea

Contrasea

Las funciones de men se describen en el manual AWB 2528-1304 E.

14


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2 El cableado con easy

Manejo easy Teclas para editar el esquema de contactos

Eliminar conexin, contacto, rel o conexin que no se utilicen


Abrir/Cerrar contactoresCablear contactos y relsInsertar conexiones Modificar valor

Mover cursor hacia arriba/abajo

Cambiar posicinMover cursor hacia la izquierda/derecha

Asignar teclas P: entrada P1, entrada P2 entrada P3, entrada P4

Deshacer entradas efectuadas desde el ltimo OKSalir de la pantalla actual

Modificar/insertar nuevo contacto relGuardar configuracin

El cableado con easy

16

Establecer el idioma del men

Conectar easy por primera vez

Establecer el idioma del men

E selezionare con i tasti cursore la lingua prescelta

GB Ingls

D Alemn

Configurar hora

!

-.""


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F Francs

E Espaol

I Italiano

E Confirmar configuracin con OK..

El easy pasa a la pantalla de estado .

La configuracin de la hora slo es posible en los modelos easy, versin ...-C.

Pasar a la pantalla de configuracin del reloj

!

""" !"!#

!

"""

!"!#

!"!#$"%

Seleccionar el modo de funcionamiento del easy

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Configurar da de la semana y hora

Seleccionar el mofuncionamiento deasy

!"!#$"%

$"% !$

seleccionar posicin modificar valor


Cambio de horario verano/invierno

do de el

El easy dispone de dos modos de funcionamiento : RUN o STOP.

RUN: El easy ejecuta el esquema de contactos.

STOP: Puede crearse un esquema de contactos

ILa opcin de men conmutable RUN/STOP siempre indica el posible cambio de modo de funcionamiento:

Modo de funcionamiento STOP: Indicacin: RUN

Modo de funcionamiento RUN: Indicacin: STOP

Guardar configuracinomantener valores anteriores

Salir del men

!"!#$"%

Indicacin: HOR.VERANOestablecido horario de invierno

Indicacin: HOR.INVIERNOestablecido horario de verano

cambiar configuracin

salir del men

""""


18

Elementos del esquema de contactos del easy

Contactos de conmutacin

Contacto de conmutacin Contacto cerrado

Contacto abierto

rea

Conexin de entrada easy ...

Tecla de cursor ...

Rel de salida easy ...


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Rels

Rel auxiliar (marcador) ...

Rel de funcin Contador ...

Rel de funcin Temporizador ...

Rel de funcin Reloj programable ...

Rel de funcin para el procesamiento de valores analgicos

...

Tipo de rel Smbolo easy

rea Funcin de bobina

Parmetro

Rel de salida ... X

Rel auxiliar (marcador) ... X

Rel de funcin Temporizador

... X X

Rel de funcin Contador

... X X

Rel de funcin Reloj programable

... X

Rel de funcin para el procesamiento de valores analgicos

... X

Elementos del esquema de contactos del easy

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Rels con activacin por estado

on

on


Rels de impulso

Rels enclavados

on

on

,


20

Ejemplo: Crear un esquema de contactos

Cablear contactos y rels

Cableado easy

Entrada I1 al cerrar el contacto S1Entrada I2 al cerrar el contacto S2Carga H1 a contacto de salida Q1

Cableado fijo


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Pasar a la pantalla del esquema de contactos

Introducir contacto I1

Esquema de contactos easy

""" !"!# " #"""

Punto de partida: Pantalla de estado

!

&

&

&

Pantalla del esquema de contactos


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Introducir contacto I2

&


Conectar los campos de contacto y de bobina

Seleccionar bobina de rel Q1

'&

'/'&

''''/

''''&

'''')''''&

'''')

''''')&


22

Seleccionar el modo de funcionamiento

"

"""

Esquema de contactos easy

''''')


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Comprobar el funcionamiento del esquema de contactos

!"!#

"" !"!#

easy trabaja en modo de funcionamiento RUN

""" !"!#

Pantalla de flujo de conexiones

""" !"!#

''''')


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Conectar los conmutadores S1 y S2

'''')

)

S1 on

S2 on


Volver a la pantalla de estado con ESC

En el siguiente ejemplo se ampla la funcin del esquema de contactos con un rel de funcin

)

La bobina de rel 01 opera

!

)

"" !"!#

Inicio desde la pantalla de estado

Seleccionar el modo de funcionamiento STOP:


24

Rels de funcin Representacin en el esquema de contactos

Rels de funcin

Rel de temporizacin, retardo a la conexin, por flanco o por nivel

Rel de temporizacin, retardo a desconexin, por flanco o por nivel


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Rels de temporizacin

Rel de temporizacin, con o sin retardo a conexin por flanco

Rel de temporizacin, pulso retentivoRel de temporizacin, parpadeante

Rel contador, reversible

Reloj programable, da de la semana/hora (slo en las versiones del easy con reloj en tiempo real

Rel para la comparacin de valores analgicos (slo en las versiones del easy de 24 V DC)

D R

on

on

TRG

RES

on

t t t

Rels de funcin

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Rel de temporizacin, con o sin retardo a desconexin por flanco

on

on

TRG


En el caso del rel de temporizacin con retardo por flanco, easy determina un tiempo de retardo entre cero y el tiempo nominal fijado.

Rel de temporizacin, pulso retentivo

RES

on

t t

on

on

TRG

RES

on

t t t


26

Rel de temporizacin, parpadeante

Frecuenciadi inter- mitencia

1

2 veces tiempo nominal=

on


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Pantalla de parmetros para rels temporizador

on

TRG

RES

on

tt t

Funcin deconmutacin

Margen de tiempo

Bobina de activacin

Bobina dereinicializacin

Tiempo real

Tempo nominal

N.


Rels de funcin

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Rel contador

on

on

CNT

DIR

on


Pantalla de parmetros para rels contadores

RES

on

86420

7531

C

Valor nominal

Direccin

Contaje

Bobina dereinicializacin

Valor real

N.



28

Reloj programable

Ejemplo de programacin: El reloj programable (1 conecta de lunes a viernes de 6.30 h a 9.00 h y de 17.00 h a 22.30 h.

0!'%123*

0!'%123*


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Pantalla de parmetros para el reloj programable

42-..567

42..5867

on

on

onA

B

LU MA MI JU VI S DO

!"#$ #%$&

Da(s) de lasemana de ... a

Hora

Hora de conexin

Hora dedesconexin

N.

Canal


Rels de funcin

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Comparador de valores analgicos

Opciones de comparacin

I7 I8, I7 I8

I7 valor nominal, I7 valor nominal

I8 valor nominal, I8 valor nominal

Los valores nominales y reales de 0.0 a 10.0


corresponden a los valores de tensin medidos.

Pantalla de parmetros para del comparador de valores analg

Comparar las entradas I7 y I8

Comparar la entrada con los valores nominales

Las oscilaciones de seales analgicas son mili-volticas. En lo relativo a los valores nominales de configuracin y reconfiguracin, procure mantener una diferencia de potencial mnima de 0,2 V para evitar vibraciones del rel de salida. No utilice rels con las funciones de bobina de contactor y de impulsin.

% %!$'()*%(+)

Valores reales

N.


Entrada I7

Comparacin

Entrada I8

% %!$'(),%

Entrada I7

Comparacin

Valor nominal

Valor real

N.



30

Ejemplo: Utilizar rels de funcin

Cableado fijo Cableado easy

easy conecta H1 con un retardo de 10 segundos Esquema de contactos easy


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E

Seleccionar rel de salida Marcador

Seleccionar contacto de marcador, conectar con salida

''''')'''''''''''''')

Punto de partida: Esquema de contactos del primer ejemplo

''''') ''''')

''''')

''''')&

Situar el cursor sobre Q

2 x

''''')&

''''')

''''')'''''')2 x 3 x2 x

Ejemplo: Utilizar rels de funcin

04/9

8 AW

B 25

28-1

316

E

Seleccionar rel de disparo para el tiempo

''''')'''''')

''''')'''''''

''''')'''''''

2 x


Introducir contacto para rel de temporizacin

Llamar pantalla de parmetros

&

''''')'''''''&

2 x

''''')'''''''

''''')'''''''

''''')'''''''

9:12"2)4 3567

2 x


32

Establecer 10 segundos

9:12"2)4 3567

9:12"2)4 3567

9:12 x


8 AW

B 25

28-1

316

E

Cableado de la salida

Para comprobar el esquema de contactos, pase al modo de funcionamiento RUN.

E Haga una prueba del esquema de contactos segn detallado en el primer ejemplo.

Adems, podr ver el parmetro del tiempo y modificar el valor nominal:

E Site el cursor sobre la T de T1 en el esquema del conjunto de circuitos y pulse OK.

2 x

2"2)4 3567

volver al esquema de contactos

''''')'''''''&

''''')'''''''/

''''')'''''''''''''')&

3 x 3 x

Circuitos principales

04/9

8 AW

B 25

28-1

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E

Circuitos principales Significado de los valores lgicos

0 contacto abierto, contacto a la apertura cerrado, bobina no excitada

1 contatto NA chiuso, contatto NC aperto, bobina eccitata

Negacin


Contacto permanente

Conmutador de impulso

Conexin serie

I1 Q1

10

01

--- Q1

1 1

I1 Estado Q1 Q1

0101

0011

0110

I1 I2 I3 Q1 Q2

0101

0011

0000

0000

1000

0101

0011

1111

0001

0000

;''''''')

''''''''')

'''''''


34

Conexin en paralelo I1 I2 I3 Q1 Q2

0101

0011

0000

0111

1111

0 0 1 1 1;('''''');4

('''''')4+


8 AW

B 25

28-1

316

E

Conexin de tres vas (XOR)

Autoenclavamiento

101

011

111

111

110

I1 I2 Q1

0101

0011

0110

I1 I2 ContattoQ1

BobinaQ1

0101

0011

0000

0001

101

011

111

011

;+

';(''');'+

('''')+

''''''';'''''''

alternativ

04/9

8 AW

B 25

28-1

316

E

3 Interface easy

A travs de la interface easy, los esquemas de contactos pueden transferirse a una tarjeta de memoria, o a un PC en que se haya instalado previamente el programa EASY-SOFT, mediante un


cable de transmisin de datos .

Tarjeta de memoriaOgni scheda di memoria - disponibile come accessorio easy M-8K - memorizza uno schema elettrico di easy.

La informacin guardada en la tarjeta de memoria se conserva an sin corriente, lo cual le permite utilizar la tarjeta para archivar, transportar y copiar esquemas de contactos.

En la tarjeta de memoria se guardan:

el esquema de contactos

todos los registros de parmetros del esquema de contactos

las configuraciones del sistema

Cargar o almacenar un esquema de contactos El intercambio de datos debe efectuarse en el modo de funcionamiento STOP.

EASY > TARJ.: Guardar el esquema de contactos easy en la tarjeta,

TARJ. > EASY: Cargar el esquema de contactos de la tarjeta en la memoria del easy,

SUPRIM. TARJ: Borrar el contenido de la tarjeta de memoria

2

1

=>#"#">="#

Interface easy

36

EASY-SOFT

EASY-SOFT es un programa de PC que le permite crear, comprobar y gestionar esquemas de contactos easy. Los esquemas de contactos pueden transferirse directamente desde el PC al easy y viceversa.

Para la transferencia de datos entre el PC y el easy


8 AW

B 25

28-1

316

E

debe utilizarse exclusivamente el cable de PC easy, el cual puede adquirirse como accesorio easy-PC-CAB.

Para comprobar un esquema de contactos creado en el PC con cableado real, el esquema debe transferirse al easy y seleccionar el modo de funcionamiento RUN del easy.

EASY-SOFT le ofrece una completa ayuda para aprender a trabajar con el programa.

Inicie EASY-SOFT, haga simplemente clic sobre Contenido y ver toda la informacin necesaria acerca de EASY-SOFT.

04/9

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B 25

28-1

316

E

4 Caractersticas tcnicas

Caractersticas tcnicas

Peso 200 g

Temperatura ambiente de 0 a 55 C

Grado de proteccin IP20

M4

10.75

35.75


Inmunidad a interferencias

Grado de lmite B, EN55011, EN55022

NormasAprobaciones

EN50178UL, CSA

45

4.547.556.5

58

90100

110

71.5

50 10.75

Caractersticas tcnicas

38

Gama easy EASY 412-DC-R24 V DC8 entradas digitales (2 de ellas pueden funcionar

como analgicas tambin)4 salidas de relPantalla LCDTeclas de funcin


8 AW

B 25

28-1

316

E

EASY 412-DC-RCigual que EASY 412-DC-R, con reloj programable

EASY 412-AC-R115/230 V AC8 entradas digitales 4 salidas de relPantalla LCDTeclas de funcin

EASY 412-AC-RCigual que EASY 412-AC-R, con reloj programable

Equipamiento adicional Software EASY-SOFTTarjeta de memoria EASY-M-8KCable de conexin EASY-PC-CABClips de fijacin ZB4-101-GF1

Documentacin Manual bsico AWB 2528-1316 EManual de instrucciones AWB 2528-1304 E

04/9

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ndice alfabtico

BBobina, funcionnes de 19

CCable de transmisin 35

Eeasy vista general 5Ejemplo de

circuitos principales 33contactos y rels 20

1316e.bk : 1316e.SIX Seite 39 Donnerstag, September 10, 1998 12:01 PM39

Circuito AND 33Circuito NOT 33Circuito OR 34Circuito principal

autoenclavamiento 34conexin de tres vas

(XOR) 34conexin en paralelo 34conexin serie 33conmutador de

impulsin 33contacto permanente 33negacin 33

Circuito XOR 34Comparador de valores

analgicos 29Conectar el easy AC 7, 8Conectar entradas 7, 8Conectar salidas 7, 8Configurar 19Configurar da de la

semana 17Contactor, funciones de 19Contactos de

conmutacin, tipos 18

DDimensiones easy 37

rel de funcin 30Encajar 19Esquema de contactos

cargar 36comprobar 22contacto, introducir 20ejemplos 20, 30, 33elementos 11funciones de las

teclas 15guardar 35, 36llamar pantalla 20llamar pantalla de

parmetros 31seleccionar bobina de

rel 21seleccionar marcador 30utilizar rels de

funcin 31Estructura del men 12

GGestin de mens 9

HHora, configurar 17Horario de invierno 17Horario de verano 17

IIdioma del men 16

40

ndice alfabtico

MMen especial 13Montaje 6

PPantalla de estado 10Pantalla de parmetros

comparador de valores analgicos 29

Rel de temporizacin 2426

Rels de funcincomparador de valores

analgicos 29rel de temporizacin 24reloj programable 28tipos de rels 24

Rels, tipos de rels 18

1316e.bk : 1316e.SIX Seite 40 Donnerstag, September 10, 1998 12:01 PM04/9

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rel contador 27rel de temporizacin 26reloj programable 27

Pantalla del cursor 10Potencial, diferencia 29

RReiniciar 19Rel contador 27Rel de impulsin 19

Reloj programable 28

SSeleccionar modo de

funcionamiento 17

TTablas lgicas 3334Tarjeta de memoria 35Teclas de funcin 9

L:\Dokumentationen-FrameMaker\A - Unterlieferanten fr Auftrge\2-443-20351-01 El Teniente\Elektrodokumentation\Brennen Pipa Norte\Datenblatt Kund_ Bulletin 1562D Sach_Nr_4200 595 Re_02.doc

-

-

Data sheet Sach Nr.: 4200 595 (4) rev. 02 19.12.02 Page 1 Page 1-3 Medium Voltage Smart Motor Controller Allen-Bradley Bulletin 1562D

Qty.: 1 Type: 1562D-TJEY Voltage: 4160V, 50/60Hz Power: 500HP Load profile: Variable torque Cooling method: Air Ambient temp.: 0-40C Enclosure: NEMA Type 12 Rel. humidity: max. 95%, non condensing Dimensions: (W)915 x (D)915 x (H)2315mm Weight: 636kg

Accessories included: Motor Protection Relais Bulletin 825 with RTD input Set of Lamps and push buttons Set of Lamps and push buttons

Bulletin 1562D

... / 2


Datenblatt Sach Nr.: 4200 595 (4) rev. 02 19.12.02 Blatt 2 Blatt 1-3

Specials of Bulletin 1560 / 1562 :

SMC Dialog Plus controller, fully programmable, communication adapters heat sink profile optimized for soft starter applications without fans or ventilation compact self powered gate drivers, no control transformer, no heat losses after soft

start redesigned compact structure: height 2315 mm, depth 915 mm, width: 660 - 2540 mm

depending on kV and nominal current

Bulletin 1562 = Bulletin 1560 + Input Starter: 3-pole gang-operated, non load break isolating switch with an

external operating handle, fully interlocked with isolation contactor and power cell doors

3 R-rated current limiting power fuses 3 bar type current transformers Fixed mounted ISOLATION vacuum contactor Control power transformer

Bulletin 1560 :

SMC Dialog Plus control module with 4 modes of starting Electronic overload protection Low voltage and power cell doors with a viewing window 2-line, 16 character backlit LCD display Metering without additional CPT or PT Built-in SCAN-port communications Programmable adjustments for setup Power SCRs with fibre optic isolated gate logic Fixed mounted vacuum BYPASS contactor Motor Protection Relais Bulletin 825

Technical Discription Medium Voltage Smart Motor Controller MV SMC Dialog Plus, Solid State Reduced Voltage Controller Unit with Bypass Contactor Codes and Standards: Each controller shall be designed, manufactured and tested to meet or exceed the requirements of the latest published standards of:

M 3~

... / 3


Datenblatt Sach Nr.: 4200 595 (4)ev. 02 19.12.02 Blatt 3 Blatt 1-3

Canadian Standards Association (CSA) Industrial Control Equipment C22.2 No. 14 American National Standards Institute (ANSI) Instrument Transformers C57.13 National Electrical Manufacturers Association (NEMA) Medium Voltage Controllers Rated

1501 to 7200 volts AC ICS 3-2 (formerly ICS 2-324) Underwriters Laboratories, Inc. (UL) High Voltage Industrial Control Equipment 347 Standard Features : Fixed mounted 400 amp "BYPASS" vacuum contactor SMC Dialog Plus control module with four modes of starting: Soft Start with

selectable Kickstart, Current Limit, Dual Ramps or Full Voltage. Programmable adjustments for setup. Power SCRs with fiber optic isolated gate logic. Viewing window in low voltage door to view the LCD display on the control module. Low voltage and power cell doors. Metering (does not require additional CPT or PTs) Electronic motor overload protection. Bulletin 825-NCM-20 converter module(mounted in cabinet) Built-in SCANport communications. 2-line, 16 character backlit LCD display. Additional Features for Bulletin 1562D (is quoted) :

Non Load Line Breaker with viewing window 3 phase line vacuum contactor interlocked with non load breaker 3 phase line power fuses

1 selector switch local remote 1 push button color green on local 1 push button color red off local 1 push button color green Resetl 1 potential-free contact on / off remote 1 potential-free contact UTS (soft start completed) 1 potential-free contact FAULT 1 potential-free contact Reset 1 lamp FAULT, in low-voltage unit, colour red 1 lamp UTS (soft start completed), in low-voltage unit, colour green Colour of switch cabinet, standard colour RAL 7005 Motor- and power supply cables connected from top Software for soft starter(DriveExplorer Lite) provided as CD-Rom including

connection cable 1203-SSS

Medium VMedium VMedium VMedium VMedium VoltageoltageoltageoltageoltageDialog PlusDialog PlusDialog PlusDialog PlusDialog PlusMotor ControllerMotor ControllerMotor ControllerMotor ControllerMotor ControllerBulletin 1503D, 1560DBulletin 1503D, 1560DBulletin 1503D, 1560DBulletin 1503D, 1560DBulletin 1503D, 1560D

and 1562Dand 1562Dand 1562Dand 1562Dand 1562D

User ManualUser ManualUser ManualUser ManualUser Manual

Important User Information Because of the variety of uses for the products described in this publication,those responsible for the application and use of this control equipment mustsatisfy themselves that all necessary steps have been taken to assure that eachapplication and use meets all performance and safety requirements, includingany applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in thisguide are intended solely for purposes of example. Since there are manyvariables and requirements associated with any particular installation,Rockwell Automation does not assume responsibility or liability (to includeintellectual property liability) for actual use based upon the examples shownin this publication.

Rockwell Automation publication SGI-1.1, Safely Guidelines for the Appli-cation, Installation, and Maintenance of Solid-State Control (available fromyour local Rockwell Automation office), describes some important differ-ences between solid-state equipment and electromechanical devices thatshould be taken into consideration when applying products such as thosedescribed in this publication.

Reproduction of the contents of this copyrighted publication, in whole or inpart, without written permission of Rockwell International Corporation, isprohibited.

Throughout this manual we use notes to make you aware of safetyconsiderations:

ATTENTION: Identifies information about practices orcircumstances that can lead to personal injury or death,property damage or economic loss.

Attention statements help you to: identify a hazard avoid the hazard recognize the consequences

Important: Identifies information that is critical for successful applicationand understanding of the product.

SMC Dialog Plus, SCANport, and Accu-Stop are trademarks of Rockwell Automation.DeviceNet is a trademark of the Open DeviceNet Vendors Association (O.D.V.A.).

Preface Service Procedure

Product Overview Chapter 1 Page

Manual Objectives ............................................................................ 1-1Documentation .................................................................................. 1-1Description ........................................................................................ 1-1

1503D Chassis Mount Retrofit Controller ............................... 1-11560D Retrofit Controller ........................................................ 1-11562D Combination Controller ............................................... 1-2

Starting Modes .................................................................................. 1-3Soft Start ..................................................................................... 1-3Selectable Kickstart .................................................................... 1-4Current Limit Start ...................................................................... 1-4Dual Ramp Start .......................................................................... 1-5Full Voltage Start ........................................................................ 1-5

Protection and Diagnostics ................................................................ 1-6Overload...................................................................................... 1-6Stall Protection and Jam Detection ............................................. 1-8Open Gate ................................................................................... 1-9Line Faults .................................................................................. 1-9Underload ................................................................................... 1-9Excessive Starts/Hour ............................................................... 1-10Overtemperature ....................................................................... 1-10

Metering .......................................................................................... 1-10Communication ............................................................................... 1-11Programming ................................................................................... 1-11Status Indication .............................................................................. 1-12Control Options ............................................................................... 1-12

Soft Stop Option ....................................................................... 1-12Pump Control Option ................................................................ 1-13 Application Considerations .................................................. 1-13Preset Slow Speed Option ........................................................ 1-15SMB Smart Motor Braking Option ...................................... 1-15Slow Speed with Braking Option ............................................. 1-16

Hardware Description ..................................................................... 1-17Power Module ........................................................................... 1-17Self-Powered Silicon-Controlled Rectifier Gate Driver Board ..... 1-17Interface Board ......................................................................... 1-18

System Diagram Figure 1.17 ........................................................ 1-19Functional Description .................................................................... 1-20

Bulletin 1562D Basic Control Standard Module ................ 1-20Bulletin 1562D Basic Control Soft Stop or Pump Control ... 1-20Bulletin 1562D SCANport Control Standard Module ........ 1-21Bulletin 1562D SCANport Control Soft Stop or Pump Control ... 1-21Bulletin 1560D Basic Control Standard Module ................ 1-22Bulletin 1560D Basic Control Soft Stop or Pump Control ... 1-22

Table of Contents

1560D-5.1 February 2000

1560D-5.1 February 2000

ii Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

Installation Chapter 2 Page

Receiving ........................................................................................... 2-1Safety and Codes ............................................................................... 2-1Unpacking and Inspection ................................................................. 2-1General Precautions........................................................................... 2-2Transportation and Handling ............................................................. 2-2Installation Site .................................................................................. 2-3Power Connections ............................................................................ 2-5Power Wiring .................................................................................... 2-8Interlocking ....................................................................................... 2-8Installation ......................................................................................... 2-9Surge Arrestor Protection Devices .................................................. 2-12Motor Overload Protection.............................................................. 2-13Human Interface Module................................................................. 2-14Communication Modules ................................................................ 2-18Converter Modules .......................................................................... 2-19Control Terminal Designations ....................................................... 2-21

Commissioning Procedure Chapter 3

Preliminary Set-Up ............................................................................ 3-1System Characteristics ...................................................................... 3-2Preliminary Check ............................................................................. 3-3Programming ..................................................................................... 3-3Hi-Pot and Megger Test .................................................................... 3-4Power Supply Tests ........................................................................... 3-6Control Function Tests ...................................................................... 3-9Resistance Checks ........................................................................... 3-10Start-Up ........................................................................................... 3-10

Programming Chapter 4

Overview ........................................................................................... 4-1Keypad Description ........................................................................... 4-1Programming Menu ........................................................................... 4-1Password ............................................................................................ 4-5Search ................................................................................................ 4-5Parameter Management ..................................................................... 4-6Parameter Modification ..................................................................... 4-8Soft Start ............................................................................................ 4-9Current Limit Start ............................................................................ 4-9Dual Ramp Start .............................................................................. 4-10Full Voltage Start ............................................................................ 4-10Basic Setup ...................................................................................... 4-11Advanced Setup ............................................................................... 4-12Example Settings ............................................................................. 4-13

1560D-5.1 February 2000

Table of Contents MV Dialog Plus Medium Voltage Controller User Manual iii

Calibration Chapter 5 Page

Overview ........................................................................................... 5-1Motor Data Entry .............................................................................. 5-1

Metering Chapter 6

Overview ........................................................................................... 6-1Viewing Metering Data ..................................................................... 6-1

Options Chapter 7

Overview ........................................................................................... 7-1Human Interface Module................................................................... 7-1Programming Parameters .................................................................. 7-3Control Wiring for SCANport Control ............................................. 7-4Soft Stop Option ................................................................................ 7-5Pump Control Option ........................................................................ 7-6SMB Smart Motor Braking Option ................................................... 7-7Preset Slow Speed Option ................................................................. 7-8Slow Speed with Braking Option ...................................................... 7-9

Serial Communications Chapter 8

Overview ........................................................................................... 8-1Logic Control Data ............................................................................ 8-1Control Wiring .................................................................................. 8-1Control Enable................................................................................... 8-2SMC Status Data ............................................................................... 8-3Reference/Feedback .......................................................................... 8-3Parameter Listing .............................................................................. 8-3Scale Factor Conversion .................................................................... 8-3Display Unit Equivalents .................................................................. 8-4Datalinks/SLC Block Transfers ........................................................ 8-4Interfacing ......................................................................................... 8-4Processing Time ................................................................................ 8-4Remote I/O Examples........................................................................ 8-5

Example #1 SLC 500 Controller without Block Transfer ....... 8-5Example #2 SLC 500 Controller with Block Transfer .......... 8-10Example #3 PLC 5/20, 5/40, 5/60 and 5/80 ........................... 8-20

DeviceNet Examples ....................................................................... 8-27Example #1 SLC 500 Controller with Explicit Messaging ... 8-271203-GK5 Communication Module Switch Settings ............... 8-28Explicit Messaging ................................................................... 8-33

1560D-5.1 February 2000

iv Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

Diagnostics Chapter 9 Page

Overview ........................................................................................... 9-1Fault Display ..................................................................................... 9-1Clear Fault ......................................................................................... 9-1Fault Buffer ....................................................................................... 9-2Fault Auxiliary Contact ..................................................................... 9-3Fault Definitions ................................................................................ 9-3

Troubleshooting Chapter 10

General Notes and Warnings ........................................................... 10-1Fault Identification .......................................................................... 10-2Control Module Removal ................................................................ 10-7Voltage Feedback Circuit Tests ...................................................... 10-8Circuit Board Replacement ............................................................. 10-8Power Circuit Troubleshooting ....................................................... 10-9

Thyristor Testing ...................................................................... 10-9SCR Replacement Procedure .................................................. 10-10

Snubber and Resistor Circuit Testing ........................................... 10-24Snubber Resistor Replacement ....................................................... 10-26

Maintenance Chapter 11

Safety and Preventative ................................................................... 11-1Periodic Inspection .......................................................................... 11-1

Appendix A Parameter Information .................................................................... A-1

Appendix B Spare Parts ............................................................................... B-1

Appendix C Accessories .............................................................................. C-1

1560D-5.1 February 2000

Table of Contents MV Dialog Plus Medium Voltage Controller User Manual v

Figures Page

Figure 1.1 Soft Start ...................................................................................................... 1-3Figure 1.2 Selectable Kickstart ......................................................................................1-4Figure 1.3 Current Limit Start .......................................................................................1-4Figure 1.4 Dual Ramp Start ........................................................................................... 1-5Figure 1.5 Full Voltage Start .........................................................................................1-5Figure 1.6 Overload Trip Curves ...................................................................................1-7Figure 1.7 Restart Trip Curves after Auto Reset ...........................................................1-7Figure 1.8 Stall Protection .............................................................................................1-8Figure 1.9 Jam Detection ...............................................................................................1-8Figure 1.10 SCANport Location ...................................................................................1-11Figure 1.11 Built-in Keypad and LCD ..........................................................................1-11Figure 1.12 Soft Stop Option .........................................................................................1-12Figure 1.13 Pump Control Option .................................................................................1-14Figure 1.14 Preset Slow Speed Option ..........................................................................1-15Figure 1.15 SMB Smart Motor Braking Option ............................................................1-15Figure 1.16 Slow Speed with Braking Option ...............................................................1-16Figure 1.17 System Diagram .........................................................................................1-19Figure 1.18a Bul. 1562D Basic Control Circuit Standard Module ................................. 1-23Figure 1.18b Bul. 1562D Basic Control Circuit Soft Stop or Pump Control .................. 1-24Figure 1.18c Bul. 1562D with SCANport Control Standard Module ............................ 1-25Figure 1.18d Bul. 1562D with SCANport Control Soft Stop or Pump Control ...........1-26Figure 1.19a Bul. 1560D Basic Control Circuit Standard Module ............................... 1-27Figure 1.19b Bul. 1560D Basic Control Circuit Soft Stop or Pump Control ...............1-28

Figure 2.1 Power Connections 1560D 400A, 2400V to 4160V .............................. 2-5Figure 2.2 Power Connections 1560D 400A, 6900 V ............................................. 2-6Figure 2.3 Power Connections 1560D 800A, 2400V to 6900V .............................. 2-7Figure 2.4 Typical One-Line Diagram Showing 2 Different Styles

of Power Factor Capacitor Connections ...............................................2-11Figure 2.5 SMC Dialog Plus Controller with Human Interface Module ....................2-15Figure 2.6 SMC Dialog Plus Controller with Communication Module ......................2-18Figure 2.7 Converter Module Connection Interface ....................................................2-19Figure 2.8 Current Transformer Connection to Converter Module .............................. 2-20Figure 2.9 SMC Dialog Plus Controller Control Terminals .......................................2-21

1560D-5.1 February 2000

vi Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

Figures (cont.) Page

Figure 3.1 Connection and Test Information for Interface Board .................................3-5Figure 3.2 Interface PCB ...............................................................................................3-6Figure 3.3 Test Power Application ................................................................................3-7Figure 3.4a Gate Pulse Detail ..........................................................................................3-8Figure 3.4b Gate Pulse Test Waveform ..........................................................................3-8

Figure 4.1 Menu Structure Hierarchy ............................................................................4-2Figure 4.2 Memory Block Diagram...............................................................................4-6

Figure 7.1 Soft Stop Option Sequence of Operation .....................................................7-5Figure 7.2 Pump Control Option Sequence of Operation .............................................7-6Figure 7.3 SMB Smart Motor Braking Sequence of Operation ....................................7-7Figure 7.4 Preset Slow Speed Option Sequence of Operation ......................................7-8Figure 7.5 Slow Speed with Braking Option Sequence of Operation .............................7-9

Figure 9.1 Fault Display ................................................................................................9-1

Figure 10.1 Low Voltage Panel & Power Cell Detail (1562D) .................................. 10-14Figure 10.2 1000/1300/1500/2400 Volt Heatsink Assembly, 180/360 A ................... 10-15Figure 10.3 Heatsink Clamp ........................................................................................10-15Figure 10.4 Removal of SCR1.....................................................................................10-16Figure 10.5 Removal of SCR2.....................................................................................10-16Figure 10.6 3300/4160 Volt Heatsink Assembly, 180/360 A ..................................... 10-17Figure 10.7 Heatsink Clamp ........................................................................................10-17Figure 10.8 Removal of SCR1.....................................................................................10-18Figure 10.9 Removal of SCR1 or SCR2 ...................................................................... 10-18Figure 10.10 6900V Module, 180/360 A ...................................................................... 10-19Figure 10.11 6900V Module with Gate Driver Boards Removed, 180/360 A ..............10-19Figure 10.12 6900V Module with Boards and Frame Removed, 180/360 A ................10-20Figure 10.13 6900V Heatsink Assembly, 180/360 A ....................................................10-21Figure 10.14 6900V SCR Replacement, 180/360 A .....................................................10-21Figure 10.15 Removing and Replacing SCRs ...............................................................10-22Figure 10.16 2300V Heatsink Module, 800A ...............................................................10-22Figure 10.17 3300 and 4160V Heatsink Module, 800A ............................................... 10-23Figure 10.18 6900V Heatsink Module, 800A ...............................................................10-23Figure 10.19 1500/2400V Module Wiring .................................................................... 10-27Figure 10.20 3300/4160V Module Wiring .................................................................... 10-28Figure 10.21 6900V Module Wiring .............................................................................10-29

1560D-5.1 February 2000

Table of Contents MV Dialog Plus Medium Voltage Controller User Manual vii

Tables Page

Table 4.A Parameter Linear List ...................................................................................4-4

Table 5.A Motor Codes .................................................................................................5-2

Table 8.A Logic Control Data .......................................................................................8-1Table 8.B SMC Status Data .......................................................................................... 8-3

Table 9.A Fault Code Cross-Reference ........................................................................9-2

Table 10.A Fault Display Explanation ..........................................................................10-3Table 10.B Motor Will Not Start No Output Voltage to Motor ................................10-5Table 10.C Motor Rotates (but does not accelerate to full speed) .............................. 10-5Table 10.D Motor Stops While Running ......................................................................10-5Table 10.E Miscellaneous Situations ...........................................................................10-6

Table A.1 Parameter List ............................................................................................. A-1Table A.2 Parameter Text/Display Unit Cross-Reference ........................................... A-5

Table B.1 Bulletin 1503D 1500V, 200/400A, 6-device ............................................ B-1Table B.2 Bulletin 1503D, 1560D/1562D 2300V, 200/400A, 6-device ................... B-2Table B.3 Bulletin 1503D, 1560D/1562D 2300V, 800A, 6-device .......................... B-3Table B.4 Bulletin 1503D, 1560D/1562D 3300V, 200/400A, 12-device ................. B-4Table B.5 Bulletin 1503D, 1560D/1562D 3300V, 800A, 12-device ........................ B-5Table B.6 Bulletin 1503D, 1560D/1562D 4160V, 200/400A, 12-device ................. B-6Table B.7 Bulletin 1503D, 1560D/1562D 4160V, 800A, 12-device ........................ B-7Table B.8 Bulletin 1503D, 1560D/1562D 6900V, 200/400A, 18-device ................. B-8Table B.9 Bulletin 1503D, 1560D/1562D 6900V, 800A, 18-device ........................ B-9Table B.10 Accessories Control Modules and Fans.................................................. B-10

Table C.1 Accessories .................................................................................................. C-1

1560D-5.1 February 2000

viii Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

1560D-5.1 February 2000

Service Procedure For your convenience, the Rockwell Automation Global Technical Services(GTS), provides an efficient and convenient method of servicing mediumvoltage products.

Contact your local area support office to make arrangements to have a quali-fied service representative come to your facility.

A complete listing of Area Support Offices may be obtained by calling yourlocal Rockwell Automation Distributor or Sales Office.

For MV Dialog Plus technical support on start-up or existing installations, contact your Rockwell Automationrepresentative. You can also call 1-519-623-1810 for assistance Monday through Friday from 7:30 a.m.to 5:15 p.m. (Eastern time zone).

Preface

1560D-5.1 February 2000

Preface

Product Overview

Manual Objectives This manual is intended for use by personnel familiar with Medium Voltage andsolid-state power equipment. The manual contains material which will allow theuser to operate, maintain and troubleshoot the MV Dialog PlusTM controller.

Documentation The following Rockwell Automation publications provide pertinentinformation for the MV Dialog Plus:

1500-5.5 Installation Manual Centerline Medium Voltage Controllers 1500-5.10 Routine General Maintenance Procedures 1502-5.0 Maintenance Instruction Manual Centerline Medium

Voltage Contactors (400 A size) 1502-5.1 Maintenance Instruction Manual Centerline Medium

Voltage Contactors (800 A size) 1560D-2.2 General Specifications

Description The MV Dialog Plus is a solid-state, three-phase, AC line controller. It isdesigned to provide microprocessor-controlled starting and stopping ofstandard three-phase, squirrel-cage induction motors, using the same controlmodule (in most cases) as the Allen-Bradley Bulletin 150 SMC Dialog Plus.

1503D Chassis Mount Retrofit Controller

A chassis-mount medium voltage solid-state controller designed to mount inan OEM or customer supplied structure, and designed to work in conjunctionwith an existing or OEM/customer supplied starter. It is comprised ofseveral modular components, including: Frame-mounted or loose power stacks including gate driver boards Loose interface and voltage divider/feedback boards Fiber optic cables for SCR firing Microprocessor based control module Vacuum bypass contactor

1560D Retrofit Controller

A medium voltage solid-state controller designed to work in conjunctionwith an existing customer-supplied starter. It includes: Tin-plated, copper, horizontal power bus (optional) A continuous, bare copper ground bus Power electronics A bypass vacuum contactor A low voltage control panel complete with microprocessor-based control module Top and bottom plates to accommodate entry cable connectors

Note: See Interlocking, page 2-8.

Chapter 1

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1-2 Product Overview

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Description (cont.) 1562D Combination Controller

A medium voltage solid-state controller that provides isolation andprotection on new installations. It includes: Tin-plated, copper, horizontal power bus (optional) A continuous, bare copper ground bus Power electronics A main non-load-break isolating switch and operating handle An isolation vacuum contactor A bypass vacuum contactor Three (3) current limiting power fuses for NEMA Class E2 operation Three (3) current transformers A control power transformer (optional) A low voltage control panel complete with microprocessor-based control

module Space for necessary auxiliary control and metering devices Top and bottom plates to accommodate entry cable connectors Motor overload protection

The MV Dialog Plus controller offers a full range of starting modes asstandard: Soft Start with Selectable Kickstart Current Limit Start with Selectable Kickstart Dual Ramp Start Full Voltage Start

Other features that offer further user benefit include: Expanded protective features Metering Communication capability

Innovative starting and stopping options provide enhanced performance: Soft Stop Pump Control ! Preset Slow Speed " SMB Smart Motor Braking " Slow Speed with Braking "

These modes, features and options are further described in this chapter.

NOTE: The Accu-Stop option is not available in the MV Dialog Plus.

! The MV Dialog Plus product uses a modified version of the Bulletin 150 Pump Control Module. Do not usea pump module for the low voltage product line in the medium voltage product. There is no difference forthe standard or soft stop modules.

" These options utilize gating patterns which result in motor and line currents that produce noise and vibrationin the motor and/or distribution transformer. The factory should be consulted before applying these options.

Product Overview 1-3

1560D-5.1 February 2000

Starting Modes Soft Start

This mode has the most general application. The motor is given an initialtorque setting, which is user-adjustable from 0 to 90% of locked-rotortorque. From the initial torque level, the output voltage to the motor issteplessly increased during the acceleration ramp time. The accelerationramp time is user-adjustable from 0 to 30 seconds. Once the MV DialogPlus controller senses that the motor has reached the up-to-speed conditionduring the voltage ramp operation, the output voltage automaticallyswitches to full voltage, and the bypass contactor is closed.

Figure 1.1Soft Start

Start Run

Percent Voltage

Initial Torque

100%

Time (seconds)


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Starting Modes (cont.) Selectable Kickstart !Selectable kickstart provides a power boost at start-up that is 550% offull-load current. The additional power helps motors generate highertorque to overcome the resistive mechanical forces of some applicationswhen they are started. The selectable kickstart is user-adjustable from 0.0to 2.0 seconds.

Figure 1.2Selectable Kickstart

Start Run

Kickstart

Initial Torque

100%

Percent Voltage

Time (seconds)

Current Limit Start#"This starting mode provides a fixed, reduced-voltage start that is used whenlimiting the maximum starting current is necessary. The Current Limit levelis user-adjustable from 50% to 600% of the motor's full-load ampere rating,and the current limit time is user-adjustable from 0 to 30 seconds. Once theMV Dialog Plus controller senses that the motor has reached the up-to-speed condition during the current limit starting mode, the output voltageautomatically switches to full voltage and the bypass contactor is closed.

Figure 1.3Current Limit Start

Start

600%

50%

Percent Full Load Current

Time (seconds)

! Kickstart is also available with Current Limit Start." The Current Limit Start mode design is based on a motor with a locked-rotor current rating that is 600% of

the full-load current rating.


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Starting Modes (cont.) Dual Ramp Start !

This starting mode is useful for applications that have varying loads (andtherefore varying starting torque requirements). Dual Ramp Start allowsthe user to select between two separate Soft Start profiles with separatelyadjustable ramp times and initial torque settings.

Figure 1.4Dual Ramp Start

Percent Voltage

Initial Torque #1

100%

Start #1 Run #1

Ramp #2

Ramp #1

Start #2

Time (seconds)

Run #2

Initial Torque #2

! Dual Ramp Start is available only with the standard controller.

Full Voltage Start

This starting mode is used for applications requiring across-the-line starting.The output voltage to the motor will reach full voltage within second.

Figure 1.5Full Voltage Start

100%

Percent Voltage

Time (seconds)


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Protection and Diagnostics The MV Dialog Plus controller is capable of providing the followingprotective and diagnostic features:

Overload

The MV Dialog Plus controller meets applicable requirements as a motoroverload protective device. Thermal memory provides added protectionand is maintained even when control power is removed. The built-inoverload algorithm controls the value stored in Parameter 11, MotorThermal Usage (see Chapter 4, Programming). An Overload Fault willoccur when this value reaches 100%. The programming parameters belowprovide application flexibility and easy setup. See Note 3.

Parameter RangeOverload Class Off, 10, 15, 20, 30Overload Reset Manual Auto

Motor FLC 1.0 - 999.9 AmpsService Factor 0.01 - 1.99

Important:During slow speed and/or braking operations, currentwaveforms exhibit non-sinusoidal characteristics. These non-sinusoidalcharacteristics inhibit the controller's current-measurement capability.To compensate for additional motor heating that may result, the controlleruses motor thermal modeling, which increments motor thermal usage.This compensation takes place when these options are in use: PresetSlow Speed, Smart Motor Braking, and Slow Speed with Braking.

Notes:1. The factory default setting for Overload Class, which is "OFF", disables

overload protection. An overload trip class and the motor's full-loadcurrent rating must be programmed to enable overload protection.

2. A Bulletin 825 converter module (Cat. No. 825MCM20) is required toprovide current feedback during bypass operation.

3. If the motor is started with the bypass contactor closed, the overloadfunction in the MV Dialog Plus is automatically disabled. In this case,a separate overload relay is required.

4. Automatic reset of an overload fault requires the start input to becycled in a two-wire control scheme. This applies to the followingfirmware releases: 1.07 (standard), 1A07L (Soft Stop), and 1B05L(Pump Control) or earlier.

5. If the MV Dialog Plus is used to control a multi-speed motor, or morethan one motor, the Overload Class parameter must be programmed to"OFF" and separate overload relays must be supplied for each speed/motor.


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Figure 1.6Overload Trip Curves

Approximate trip time for 3-phase balancedcondition from cold start.

Approximate trip time for 3-phase balancedcondition from cold start.

Class 10 Class 15 Class 20 Class 30

Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC

Appr

oxim

ate T

rip T

ime (

seco

nds)

Appr

oxim

ate T

rip T

ime (

seco

nds)

Appr

oxim

ate T

rip T

ime (

seco

nds)

Appr

oxim

ate T

rip T

ime (

seco

nds)

1.0

10.0

100.0

1000.0

10000.0

1 10 2 3 9 8 7 6 5 4 0.1

1.0

10.0

100.0

1000.0

1 10 2 3 9 8 7 6 5 4 1.0

10.0

100.0

1000.0

10000.0

1 10 2 3 9 8 7 6 5 4 1.0

10.0

100.0

1000.0

10000.0

1 10 2 3 9 8 7 6 5 4

Figure 1.7Restart Trip Curves after Auto Reset

Note:Figures 1.6 and 1.7 providethe overload trip curves forthe available trip classes.

hot

1000% 100% 0

1

10

100

1000

100000

Percent Full Load Current Setting

S

e

c

o

n

d

s

Class 10Class 15Class 20Class 30

Auto Reset Times:Class 10 = 90 sClass 15 = 135 sClass 20 = 180 sClass 30 = 270 s

Seco

nds

0.1

Per cent Full Load Current Setting


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Protection and Diagnostics Stall Protection and Jam Detection(cont.)

The MV Dialog Plus controller provides both stall protection and jamdetection for enhanced motor and system protection.

Stall protection is user-adjustable from 0.0 to 10.0 seconds (enabledonly after start time expires).

Jam detection allows the user to determine the jam level (up to 999% ofthe motor's full-load current rating) and the delay time (up to 10.0seconds) for application flexibility.

Figure 1.8Stall Protection

Figure 1.9Jam Detection !

100%

Running Jam

Percent Full

Load Current

Time (seconds)

User Programmed Trip Level

! Jam detection is disabled during slow speed and braking operation.


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Protection and Diagnostics Open Gate(cont.)

An open-gate fault indicates that improper SCR firing, typically caused byan open SCR gate or driver system, has been detected on one of the powerpoles. Before the controller shuts down, it will attempt to start the motor atotal of three times (or as programmed in Parameter 64).

Line Faults

The MV Dialog Plus controller continually monitors line conditions forabnormal factors. Pre-start protection includes: Power Loss (with phase indication) Line Fault (with phase indication)

Power loss Missing load connection Shorted SCR

Starting and Stopping protection includes: Line Fault (no phase indication)

Power loss Missing load connection Shorted SCR

Additional programmable parameters are provided for the followingprotective features: Undervoltage ! can be adjusted from 0 to 99% of the programmed line

voltage and has a programmable delay time of 0 to 99 seconds. Overvoltage ! can be adjusted from 0 to 199% of the programmed

line voltage and has a programmable delay time of 0 to 99 seconds. Phase reversal " protection can be toggled either ON or OFF. Voltage unbalance ! protection can be programmed for trip levels of 0

to 25% with a programmable delay time of 0 to 99 seconds.

Underload $

If a sudden drop in current is detected, motor operation can be halted byutilizing the underload protection of the MV Dialog Plus controller.

The MV Dialog Plus controller provides an adjustable underload tripsetting from 0 to 99% of the programmed motor full-load current rating.Trip delay time can be adjusted from 0 to 99 seconds. The Bulletin 825current converter module must be connected for this feature to be available.

! Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation." Phase reversal protection is functional only at pre-start.$ Underload protection is disabled during slow speed and braking operations.


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Protection and Diagnostics Excessive Starts/Hour(cont.)

The MV Dialog Plus module allows the user to program the desirednumber of starts per hour (up to 99). This helps eliminate motor stresscaused by repeated starting over a short time period.Note: The base rating of the MV Dialog Plus is two starts (thirty secondseach max.) per hour. Applications requiring more frequent starts, or longerduration starts, should be reviewed with the factory to avoid equipment damage.

OvertemperatureThe power module temperature is monitored during starting and stoppingmaneuvers by thermistors. The thermistor is connected to the gate driverboard where it is processed, and the status is transmitted by fibre-optic cablethrough the interface board to the control module. When an overtemperaturecondition exists, the control module trips and indicates a temperature fault.

An overtemperature condition could indicate high ambient temperature,overloading or excessive cycling. After the power module temperature isreduced to allowable levels, the fault can be cleared (see page 9-1 forinstructions).

Metering Power monitoring parameters include: Three-phase current Three-phase voltage Power in kW (see note 5 below) Power usage in kWh (see note 5 below) Power factor (see note 5 below) Motor thermal capacity usage Elapsed time

Notes:1. The current sensing capability of the MV Dialog Plus controller requires

a Bulletin 825 converter module to maintain the three-phase current,and mo

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