Rockwell Automation Allen-Bradley Dialog Plus 1503D Bedienungsanleitung

Medium Voltage

Dialog Plus™

Motor Controller

Bulletins 1503D, 1560D

and 1562D

User Manual

Solid state equipment has operational characteristics differing from those of electro-

mechanical equipment. Safety Guidelines for theApplication, Installation and

Maintenance of Solid State Controls (Publication SGI-1.1 available from your local

RockwellAutomation sales office or online at http://www.ab.com/manuals/gi) describes

some important differences between solid state equipment and hard-wired electromechanical

devices. Because of this difference, and also because of the wide variety of uses for solid

state equipment, all persons responsible for applying this equipment must satisfy

themselves that each intended application of this equipment is acceptable.

In no event will RockwellAutomation, Inc. be responsible or liable for indirect or

consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes.

Because of the many variables and requirements associated with any particular

installation, RockwellAutomation, Inc. cannot assume responsibility or liability for actual

use based on the examples and diagrams.

No patent liability is assumed by RockwellAutomation, Inc. with respect to use of

information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written

permission of RockwellAutomation, Inc. is prohibited.

Throughout this manual we use notes to make you aware of safety considerations.

Important User Information

Identifies information about practices or circumstances that can

cause an explosion in a hazardous environment, which may lead to

personal injury or death, property damage, or economic loss.

Identifies information that is critical for successful application and

understanding of the product.

Identifies information about practices or circumstances that can

lead to personal injury or death, property damage, or economic

loss. Attentions help you:

• identify a hazard

• avoid a hazard

• recognize the consequence

Labels may be located on or inside the equipment to alert people

that dangerous voltage may be present.

Labels may be located on or inside the equipment to alert people

that surfaces may be dangerous temperatures.

ATTENTIONATTENTION

IMPORTANTIMPORTANT

WARNINGWARNING

SHOCK HAZARDSHOCK HAZARD

BURN HAZARDBURN HAZARD

Page

Preface Service Procedure ........................................................................... P-1

Product Overview Chapter 1

Manual Objectives ............................................................................ 1-1

Documentation .................................................................................. 1-1

Description ........................................................................................ 1-1

1503D – Chassis Mount Retrofit Controller............................... 1-1

1560D – Retrofit Controller........................................................ 1-1

1562D – Combination Controller ............................................... 1-2

Dialog Plus™ Control Module ....................................................1-2

Starting Modes .................................................................................. 1-3

Soft Start ..................................................................................... 1-3

Selectable Kickstart .................................................................... 1-3

Current Limit Start...................................................................... 1-4

Dual Ramp Start.......................................................................... 1-5

Full Voltage Start........................................................................ 1-5

Protection and Diagnostics................................................................ 1-6

Overload...................................................................................... 1-6

Stall Protection and Jam Detection............................................. 1-8

Open Gate ................................................................................... 1-9

Line Faults .................................................................................. 1-9

Underload ................................................................................. 1-10

Excessive Starts/Hour ............................................................... 1-10

Overtemperature ....................................................................... 1-10

Metering .......................................................................................... 1-10

Communication ............................................................................... 1-11

Programming ................................................................................... 1-12

Status Indication .............................................................................. 1-12

Control Options ............................................................................... 1-12

Soft Stop Option ....................................................................... 1-12

Pump Control Option................................................................ 1-13

Application Considerations ..................................................1-13

Preset Slow Speed Option ........................................................ 1-15

SMB™ Smart Motor Braking Option ...................................... 1-15

Slow Speed with Braking Option ............................................. 1-16

Hardware Description ..................................................................... 1-17

Power Module........................................................................... 1-17

Self-Powered Silicon-Controlled Rectifier Gate Driver Board..... 1-17

Interface Board ......................................................................... 1-18

Typical MV Dialog Plus Power System Diagram........................... 1-19

Functional Description .................................................................... 1-20

Bulletin 1562D • Basic Control – Standard Module ................ 1-20

Bulletin 1562D • Basic Control – Soft Stop or Pump Control ... 1-20

Bulletin 1562D • SCANport Control – Standard Module ........ 1-21

Bulletin 1562D • SCANport Control – Soft Stop or Pump Control... 1-21

Bulletin 1560D • Basic Control – Standard Module ................ 1-22

Bulletin 1560D • Basic Control – Soft Stop or Pump Control ... 1-22

Table of Contents

1560D-UM051D-EN-P–February2005

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

Installation Chapter 2 Page

Receiving........................................................................................... 2-1

Safety and Codes ............................................................................... 2-1

Unpacking and Inspection ................................................................. 2-1

General Precautions........................................................................... 2-2

Transportation and Handling............................................................. 2-2

Installation Site.................................................................................. 2-3

Mounting......................................................................................2-3

Grounding Practices.....................................................................2-4

Recommended Torque Values ...........................................................2-4

Power Connections............................................................................ 2-5

Power Wiring .................................................................................... 2-8

Interlocking ....................................................................................... 2-8

Installation ......................................................................................... 2-9

Physical Location........................................................................ 2-9

Fan ...............................................................................................2-9

Ground Bus Bar ...........................................................................2-9

Power and Control Wiring...........................................................2-9

Control Cables .............................................................................2-9

Fiber-Optic Cables.......................................................................2-9

Power Factor Correction Capacitors..........................................2-10

Surge Arrestor Protection Devices .................................................. 2-12

Motor Overload Protection.............................................................. 2-13

Emergency Bypass.................................................................... 2-13

Two-speed Motors .................................................................... 2-13

Multi-motor Protection ..............................................................2-13

Human Interface Module................................................................. 2-14

Connecting the Human Interface Module to the Controller ......2-15

Control Enable ...........................................................................2-16

Communication Modules ................................................................ 2-18

Wiring...............................................................................................2-19

Accessory Requirements........................................................... 2-19

Converter Modules .......................................................................... 2-20

Control Terminal Designations ....................................................... 2-22

Commissioning Procedure Chapter 3

Preliminary Set-Up............................................................................ 3-1

System Characteristics ...................................................................... 3-2

Preliminary Check ............................................................................. 3-3

Programming ..................................................................................... 3-3

MV Dialog Plus™ Module..........................................................3-3

Hi-Pot and Megger Test .................................................................... 3-4

Power Supply Tests ........................................................................... 3-6

Control Function Tests ...................................................................... 3-9

Resistance Checks ........................................................................... 3-10

Start-Up ........................................................................................... 3-10

1560D-UM051D-EN-P–February2005

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

Programming Chapter 4 Page

Overview ........................................................................................... 4-1

Keypad Description........................................................................... 4-1

Programming Menu........................................................................... 4-1

Password............................................................................................ 4-5

Search ................................................................................................ 4-5

Parameter Management .................................................................... 4-6

Random Access Memory (RAM) ............................................... 4-6

Read-only Memory (ROM) ........................................................ 4-6

Electrically Erasable Programmable Read-only Memory

(EEPROM).............................................................................. 4-6

Using Parameter Management.................................................... 4-7

Parameter Modification..................................................................... 4-8

Soft Start............................................................................................ 4-9

Current Limit Start ............................................................................ 4-9

Dual Ramp Start .............................................................................. 4-10

Full Voltage Start ............................................................................ 4-10

Basic Setup ...................................................................................... 4-11

Advanced Setup............................................................................... 4-12

Example Settings............................................................................. 4-13

Calibration Chapter 5

Overview ........................................................................................... 5-1

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

Metering Chapter 6

Overview ........................................................................................... 6-1

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

Options Chapter 7

Overview ........................................................................................... 7-1

Human Interface Module................................................................... 7-1

Programming Parameters .................................................................. 7-3

Control Wiring for SCANport Control ............................................. 7-4

Soft Stop Option................................................................................ 7-5

Pump Control Option ........................................................................ 7-6

SMB Smart Motor Braking Option ................................................... 7-7

Preset Slow Speed Option ................................................................. 7-8

Slow Speed with Braking Option...................................................... 7-9

1560D-UM051D-EN-P–February2005

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

Serial Communications Chapter 8 Page

Overview ........................................................................................... 8-1

Logic Control Data............................................................................ 8-1

Control Wiring .................................................................................. 8-1

Control Enable................................................................................... 8-2

SMC Status Data ............................................................................... 8-3

Reference/Feedback .......................................................................... 8-3

Parameter Listing .............................................................................. 8-3

Scale Factor Conversion.................................................................... 8-3

Display Unit Equivalents .................................................................. 8-4

Datalinks/SLC Block Transfers ........................................................ 8-4

Interfacing ......................................................................................... 8-4

Processing Time ................................................................................ 8-4

Remote I/O Examples........................................................................ 8-5

Example #1 – SLC 500 Controller without Block Transfer ....... 8-5

Example #2 – SLC 500 Controller with Block Transfer .......... 8-10

Example #3 – PLC 5/20, 5/40, 5/60 and 5/80........................... 8-20

DeviceNet Examples ....................................................................... 8-27

Example #1 – SLC 500 Controller with Explicit Messaging ... 8-27

1203-GK5 Communication Module Switch Settings ............... 8-28

Explicit Messaging ................................................................... 8-33

Example Ladder Logic Program ................................................8-37

Diagnostics Chapter 9

Overview ........................................................................................... 9-1

Fault Display ..................................................................................... 9-1

Clear Fault ......................................................................................... 9-1

Fault Buffer ....................................................................................... 9-2

Fault Codes ..................................................................................9-2

Fault Auxiliary Contact ..................................................................... 9-3

Fault Definitions................................................................................ 9-3

Troubleshooting Chapter 10

General Notes and Warnings........................................................... 10-1

Fault Identification .......................................................................... 10-2

Fault Display Explanation .........................................................10-3

Control Module Removal................................................................ 10-7

Voltage Feedback Circuit Tests ...................................................... 10-8

IGDPS Boards ................................................................................. 10-9

IGDPS Board LEDs ...................................................................... 10-10

Circuit Board Replacement ........................................................... 10-11

Power Circuit Troubleshooting ..................................................... 10-12

Thyristor Testing .................................................................... 10-12

SCR Replacement Procedure.................................................. 10-13

Snubber and Resistor Circuit Testing ........................................... 10-27

Snubber Resistor Replacement.......................................................10-29

Wiring Diagrams ............................................................................10-30

1560D-UM051D-EN-P–February2005

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

Maintenance Chapter 11 Page

Safety and Preventative ................................................................... 11-1

Periodic Inspection .......................................................................... 11-1

Contamination............................................................................11-1

Vacuum Bottles .........................................................................11-2

Terminals ...................................................................................11-2

Coils ...........................................................................................11-2

Solid-State Devices....................................................................11-3

Static-Sensitive Items ................................................................11-3

Overload Maintenance After a Fault Condition ........................11-3

Final Check Out .........................................................................11-3

"Keep Good Maintenance Records"..........................................11-4

Power Components ....................................................................11-4

Control Components – Electronic .............................................11-4

Fans ............................................................................................11-4

Interlocks ...................................................................................11-4

Barriers ......................................................................................11-4

Appendix A Parameter Information

Parameter List ...................................................................................A-1

Parameter Text/Display Unit Cross-Reference .................................A-5

Appendix B Spare Parts

Bulletin 1503D • 1000-1500 V, 180/360A, 6-device........................ B-1

Bulletin 1503D, 1560D, 1562D • 2300V, 180/360A, 6-device ........ B-2

Bulletin 1503D, 1560D, 1562D • 2300V, 600A, 6-device ............... B-3

Bulletin 1503D, 1560D, 1562D • 3300V, 180/360A, 12-device ...... B-4

Bulletin 1503D, 1560D, 1562D • 3300V, 600A, 12-device ............. B-5

Bulletin 1503D, 1560D, 1562D • 4160V, 180/360A, 12-device ...... B-6

Bulletin 1503D, 1560D, 1562D • 4160V, 600A, 12-device ............. B-7

Bulletin 1503D, 1560D, 1562D • 5500/6900V, 180/360A, 18-device .. B-8

Bulletin 1503D, 1560D, 1562D • 5500/6900V, 600A, 18-device....... B-9

Accessories...................................................................................... B-10

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

1560D-UM051D-EN-P–February2005

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

1560D-UM051D-EN-P–February2005

Service Procedure For your convenience, the Rockwell Automation Global Manufacturing

Solutions (GMS), provides an efficient and convenient method of servicing

medium voltage products.

Contact your local area support office to make arrangements to have a

qualified service representative come to your facility.

A complete listing of Area Support Offices may be obtained by calling your

local Rockwell Automation Distributor or Sales Office.

For MV Dialog Plus technical support on start-up or existing installations,

contact your Rockwell Automation representative. You can also call

1-519-740-4790 for assistance Monday through Friday from 9:00 a.m.

to 5:00 p.m. (Eastern time zone).

Preface

1560D-UM051D-EN-P–February2005

Preface

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