Rockwell Automation Allen-Bradley Dialog Plus 1503D User manual

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

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

Product Overview
Manual Objectives This manual is intended for use by personnel familiar with Medium Voltage and
solid-state power equipment. The manual contains material which will allow the
user to operate, maintain and troubleshoot the MV Dialog PlusTM family of
controllers. The family consists of the following Bulletin numbers: 1503D,
1560D and 1562D.
Documentation The following Rockwell Automation publications provide pertinent
information for the MV Dialog Plus:
• MVB-5.0 General Handling Procedures for MV Controllers
• 1500-UM055B-EN-P Medium Voltage Controller – Two-High cabinet
• 1502-5.0 Maintenance Instruction Manual – Centerline
Medium Voltage Contactors (400 A size)
• 1502-UM051B-EN-P Maintenance Instruction Manual – Centerline
Medium Voltage Contactors (800 A size)
• 1560D-SR022B-EN-P Medium Voltage Dialog Controllers – General
Specifications
Description The MV Dialog Plus is a solid-state, three-phase, AC line controller. It is
designed to provide microprocessor-controlled starting and stopping of
standard three-phase, squirrel-cage induction motors, using the same control
module (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 in
an OEM or customer supplied structure, and designed to work in conjunction
with an existing or OEM/customer supplied starter. It is comprised of
several 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 conjunction
with 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 power cables.
Note: See Interlocking, page 2-8.
Chapter 1
1560D-UM051D-EN-P–February2005

1-2 Product Overview
1560D-UM051D-EN-P–February2005
Description (cont.) 1562D – Combination Controller
A medium voltage solid-state controller that provides isolation and
protection for 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 power cables
• Motor overload protection
Dialog Plus™ Control Module
The MV Dialog Plus controller offers a full range of starting modes as standard:
• 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 X
• Preset Slow Speed Y
• SMB™ Smart Motor Braking Y
• Slow Speed with Braking Y
These modes, features and options are further described in this chapter.
NOTE: The Accu-Stop™ option is not available in the MV Dialog Plus.
XThe MV Dialog Plus product uses a modified version of the Bulletin 150 Pump Control Module. Do not use
a pump module for the low voltage product line in the medium voltage product. There is no difference for
the standard or soft stop modules.
YThese options utilize gating patterns which result in motor and line currents that produce noise and vibration
in the motor and/or distribution transformer. The factory should be consulted before applying these options.

Product Overview 1-3
1560D-UM051D-EN-P–February2005
Starting Modes Soft Start
This mode has the most general application. The motor is given an initial
torque setting, which is user-adjustable from 0 to 90% of locked-rotor
torque. From the initial torque level, the output voltage to the motor is
steplessly increased during the acceleration ramp time. The acceleration
ramp time is user-adjustable from 0 to 30 seconds. Once the MV Dialog
Plus™ controller senses that the motor has reached the up-to-speed condition
during the voltage ramp operation, the output voltage automatically
switches to full voltage, and the bypass contactor is closed.
Percent
Voltage
Initial
Torque
100%
Time (seconds)
Start Run
Percent
Voltage
Initial
Torque
100%
Time (seconds)
Start Run
Figure 1.1– Soft Start
Selectable Kickstart X
Selectable kickstart provides a power boost at start-up that is 550% of
full-load current. The additional power helps motors generate higher
torque to overcome the resistive mechanical forces of some applications
when they are started. The selectable kickstart is user-adjustable from 0.0
to 2.0 seconds.
Start Run
Kickstart
Initial
Torque
100%
Percent
Voltage
Time (seconds)
Start Run
Kickstart
Initial
Torque
100%
Percent
Voltage
Time (seconds)
Figure 1.2 – Selectable Kickstart

1-4 Product Overview
1560D-UM051D-EN-P–February2005
Starting Modes (cont.) Current Limit Start Y
This starting mode provides a fixed, reduced-voltage start that is used when
limiting the maximum starting current is necessary. The Current Limit level
is 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 the
MV Dialog Plus™ controller senses that the motor has reached the up-to-
speed condition during the current limit starting mode, the output voltage
automatically switches to full voltage and the bypass contactor is closed.
600%
50%
Percent
FullLoad
Current
Time (seconds)
Start
600%
50%
Percent
FullLoad
Current
Time (seconds)
Start
Figure 1.3 – Current Limit Start
XKickstart is also available with Current Limit Start.
YThe 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.

Product Overview 1-5
1560D-UM051D-EN-P–February2005
Dual Ramp Start X
This starting mode is useful for applications that have varying loads (and
therefore varying starting torque requirements). Dual Ramp Start allows
the user to select between two separate Soft Start profiles with separately
adjustable ramp times and initial torque settings.
Percent
Voltage
Initial Torque #1
100% Ramp #2
Ramp #1
Time (seconds)
Initial Torque #2
Start #1 Run #1 Run #2Start #2
Percent
Voltage
Initial Torque #1
100% Ramp #2
Ramp #1
Time (seconds)
Initial Torque #2
Start #1 Run #1 Run #2Start #2
Figure 1.4 – Dual Ramp Start
XDual 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 ¼ second.
100%
Percent
Voltage
Time (seconds)
100%
Percent
Voltage
Time (seconds)
Figure 1.5 – Full Voltage Start

1-6 Product Overview
1560D-UM051D-EN-P–February2005
Protection and Diagnostics The MV Dialog Plus™ controller is capable of providing the following
protective and diagnostic features:
Overload
The MV Dialog Plus controller meets applicable requirements as a motor
overload protective device. Thermal memory provides added protection
and is maintained even when control power is removed. The built-in
overload algorithm controls the value stored in Parameter 11, Motor
Thermal Usage (see Chapter 4, Programming). An Overload Fault will
occur when this value reaches 100%. The programming parameters below
provide application flexibility and easy setup. See Note 3.
Parameter Range
Overload Class Off, 10, 15, 20, 30
Overload Reset Manual – Auto
Motor FLC 1.0 – 999.9 amps
Service Factor 0.01 – 1.99
Important: During slow speed and/or braking operations, current
waveforms exhibit non-sinusoidal characteristics. These non-sinusoidal
characteristics inhibit the controller's current-measurement capability.
To compensate for additional motor heating that may result, the controller
uses motor thermal modeling, which increments motor thermal usage.
This compensation takes place when these options are in use: Preset
Slow 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-load
current rating must be programmed to enable overload protection.
2. A Bulletin 825 converter module (Cat. No. 825MCM20) is required to
provide current feedback during bypass operation.
3. If the motor is started with the bypass contactor closed, the overload
function 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 be
cycled in a two-wire control scheme. This applies to the following
firmware 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 more
than one motor, the Overload Class parameter must be programmed to
"OFF" and separate overload relays must be supplied for each speed/
motor.

Product Overview 1-7
1560D-UM051D-EN-P–February2005
Approximate trip timefor 3-phase balanced
condition from cold start. Approximate trip timefor 3-phase balanced condition from hot start.
Class 10 Class 15 Class 20 Class 30
Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC
ApproximateTripTime(seconds)
ApproximateTripTime(seconds)
ApproximateTripTime(seconds)
ApproximateTripTime(seconds)
1.0
10.0
100.0
1000.0
10000.0
1 102 3 987654
0.1
1.0
10.0
100.0
1000.0
1 102 3 987654 1.0
10.0
100.0
1000.0
10000.0
1 102 3 987654
1.0
10.0
100.0
1000.0
10000.0
1 102 3 987654
Approximate trip timefor 3-phase balanced
condition from cold start. Approximate trip timefor 3-phase balanced condition from hot start.
Class 10 Class 15 Class 20 Class 30
Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC
ApproximateTripTime(seconds)
ApproximateTripTime(seconds)
ApproximateTripTime(seconds)
ApproximateTripTime(seconds)
1.0
10.0
100.0
1000.0
10000.0
1 102 3 987654
0.1
1.0
10.0
100.0
1000.0
1 102 3 987654 1.0
10.0
100.0
1000.0
10000.0
1 102 3 987654
1.0
10.0
100.0
1000.0
10000.0
1 102 3 987654
Figure 1.6 – Overload Trip Curves
100000
1000
100
10
1
0100% 1000%
Percent Full Load Current Setting
Auto Reset Times:
Class 10 = 90 s
Class 15 = 135 s
Class 20 = 180 s
Class 30 = 270 s
Class 10
Class 15
Class 20
Class 30
Seconda
100000
1000
100
10
1
0100% 1000%
Percent Full Load Current Setting
Auto Reset Times:
Class 10 = 90 s
Class 15 = 135 s
Class 20 = 180 s
Class 30 = 270 s
Class 10
Class 15
Class 20
Class 30
Class 10
Class 15
Class 20
Class 30
Seconda
Figure 1.7 – Restart Trip Curves after Auto Reset
Note: Figures 1.6 and 1.7
provide the overload trip curves
for the available trip classes.

1-8 Product Overview
1560D-UM051D-EN-P–February2005
Protection and Diagnostics Stall Protection and Jam Detection
(cont.) The MV Dialog Plus™ controller provides both stall protection and jam
detection for enhanced motor and system protection.
• Stall protection is user-adjustable from 0.0 to 10.0 seconds (enabled
only after start time expires).
• Jam detection allows the user to determine the jam level (up to 999% of
the motor's full-load current rating) and the delay time (up to 10.0
seconds) for application flexibility.
600%
Percent
Full Load
Current
Programmed Start Time Stall
Time (seconds)
600%
Percent
Full Load
Current
Programmed Start Time Stall
Time (seconds)
Figure 1.8 – Stall Protection
600%
Percent
Full Load
Current
Running Jam
Time (seconds)
600%
Percent
Full Load
Current
Running Jam
Time (seconds)
Figure 1.9 – Jam Detection X
XJam detection is disabled during slow speed and braking operation.

Product Overview 1-9
1560D-UM051D-EN-P–February2005
Open Gate
An open-gate fault indicates that improper SCR firing, typically caused by
an open SCR gate or driver system, has been detected on one of the power
poles. Before the controller shuts down, it will attempt to start the motor a
total of three times (or as programmed in Parameter 64).
Line Faults
The MV Dialog Plus™ controller continually monitors line conditions for
abnormal 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 following
protective features:
• Undervoltage Xcan be adjusted from 0 to 99% of the programmed line
voltage and has a programmable delay time of 0 to 99 seconds.
Note: For medium voltage applications, undervoltage protection
should be set from 80 to 99%.
• Overvoltage Xcan be adjusted from 0 to 199% of the programmed
line voltage and has a programmable delay time of 0 to 99 seconds.
Note: For medium voltage applications, overvoltage protection should
be set from 100 to 115%.
• Phase reversal Yprotection can be toggled either ON or OFF.
• Voltage unbalance Xprotection can be programmed for trip levels of 0
to 25% with a programmable delay time of 0 to 99 seconds.
XUndervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.
YPhase reversal protection is functional only at pre-start.

1-10 Product Overview
1560D-UM051D-EN-P–February2005
Protection and Diagnostics Underload Z
(cont.) If a sudden drop in current is detected, motor operation can be halted by
utilizing the underload protection of the MV Dialog Plus controller.
The MV Dialog Plus controller provides an adjustable underload trip
setting 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 825
current converter module must be connected for this feature to be available.
ZUnderload protection is disabled during slow speed and braking operations.
Excessive Starts/Hour
The MV Dialog Plus™ module allows the user to program the desired
number of starts per hour (up to 99). This helps eliminate motor stress
caused by repeated starting over a short time period.
Note: The base rating of the MV Dialog Plus is two starts (thirty seconds
each max.) per hour. Applications requiring more frequent starts, or longer
duration starts, should be reviewed with the factory to avoid equipment damage.
Overtemperature
The power module temperature is monitored during starting and stopping
maneuvers by thermistors. The thermistor is connected to the gate driver
board where it is processed, and the status is transmitted by fibre-optic
cable through the interface board to the control module. When an
overtemperature condition exists (>85°C), 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 is
reduced to allowable levels, the fault can be cleared (see page 9-1 for
instructions).
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) during starting and stopping
(fixed at 0.85 during bypass)
• Motor thermal capacity usage
• Elapsed time