Rockwell Automation 150 MNL User Manual

SMC Controllers

Bulletin 150



Application and Product Guide

Please Read!

This manual is intended to guid qualified personnel in th installation and operation of this product.

Because of the variety of uses for this equipment and because of the differences between this solid-state equipment and electromechanical equipment, the user of and those responsible for applying this equipment must satisfy themselves as to the acceptability of each application and use of the equipment. In no event will Allen-Bradley Company, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The illustrations shown in this manual are intended solely to illustrate the text of this manual. Because of the many variables and requirements associated with any particular installation, the AllenBradley Company, Inc. cannot assume responsibility or liability for actual use based on t he illu str ative uses and applications.

No patent liability is assumed by Allen-Bradley Company, Inc., with respect to use of information, circuits, or equipment described in this text.

Reproduction of the content of this manual, in whole or in part, without written permission of the Allen-Bradley Company, Inc. is prohibited.

For Smart M otor Controller technical support, contact your AllenBradley representative.

In the United States and Canada you may also call 1-800-765-SMCS (765-7627) for assistance during the hours of 8:00 AM to 12:00 noon and 1:00 PM to 4:30 PM (Central Time Zone) from Monday through Friday.

Important User Information

The information in this manual is organized in numbered chapters. Read each chapter in sequence and perform procedures when you are instructed t o do so. Do not proceed to t he next c ha pter u n til you have complete d al l pr ocedures.

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

ATTENTION: Identifies information about practices or circumstances t hat c an le ad to personal injury or

Attentions help you:

• identify a hazard

• avoid the hazard

• recogniz e t he conse quences Important: Identifies information that is especially important for

STC, SMC-2, SMC PLUS, SMC Dialog Plus, SMB, and Accu-Stop are trademarks of the Allen-Bradley Company, Inc. DeviceNet is a trademark of the

death, property damage, or economic loss.

successful application and understanding of this product.

Open DeviceNet

Vendor Association, Inc.

Chapter 1 STC Starting Torque Controller

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

Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Across-the-Line Response . . . . . . . . . . . . . . . . . . . . . 1-2

STC Controller Response . . . . . . . . . . . . . . . . . . . . . . 1-2

Across-the-Line Response Versus STC

Controller Response . . . . . . . . . . . . . . . . . . . . . . . 1-2

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Suitable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Chapter 2 SMC-2 Smart Motor Controller

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Fault Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Series Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Description of Interface Options . . . . . . . . . . . . . . . . . 2-8

Soft Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Wiring Diagram with Interface Option . . . . . . . . . . . . . 2-9

Overload Relay Option . . . . . . . . . . . . . . . . . . . . . . . .2-10

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Chapter 3 SMC Dialog Plus Smart Motor Controller

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Starting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Soft Start with Selectable Kickstart . . . . . . . . . . . . . . . 3-2

Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

toc–ii

Table of Contents

Chapter 3 (cont.)

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Keypad Programming . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Electronic Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Built-in Communication Port . . . . . . . . . . . . . . . . . . . . 3-5

Stall Protection and Jam Detection . . . . . . . . . . . . . . . 3-6

Phase Rebalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Energy Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Modular Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Control Terminal Description . . . . . . . . . . . . . . . . . . . . 3-9

Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Soft Start without Options . . . . . . . . . . . . . . . . . . . . . .3-10

Current Limit Start without Options . . . . . . . . . . . . . . .3-11

Dual Ramp Start without Options . . . . . . . . . . . . . . . .3-12

Full Voltage Start without Options . . . . . . . . . . . . . . . .3-14

Typical Wiring Diagrams (without options) . . . . . . . . . . .3-15

Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Soft Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Programming - Soft Start with Soft Stop Option . . . . .3-21

Pump Control Option . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Programming - Pump Control Starting and Stopping . .3-25

Preset Slow Speed Option . . . . . . . . . . . . . . . . . . . . .3-27

Programming - Soft Start with Preset Slow

Speed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

SMB Smart Motor Braking Option . . . . . . . . . . . . . . . .3-32

Programming - Soft Start with SMB Smart Motor

Braking Option . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Accu-Stop/Slow Speed with Braking Option . . . . . . . .3-36

Accu-Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

Programming - Soft Start with Accu-Stop Option. . . . .3-38

Accu-Stop/Slow Speed with Braking Option . . . . . . . .3-41

Slow Speed with Braking Capability . . . . . . . . . . . . . .3-42

Programming - Soft Start with Slow Speed

with Braking Capability . . . . . . . . . . . . . . . . . . . . .3-43

Chapter 4 Application Profiles for the SMC Dialog Plus Controller

Table of Contents

Chapter 5 SMC Dialog Plus Controller Special Application Considerations

SMC Dialog Plus Controllers in Drive Applications . . . . . . 5-1

Use of Protective Modules . . . . . . . . . . . . . . . . . . . . . . . 5-1

Current Limit Fuses (Overcurrent Protection of SCRs) . . . 5-3

Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . 5-4

Phase Rebalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Stall Protection and Jam Detection . . . . . . . . . . . . . . . . . 5-5

Built-in SCANport Communications . . . . . . . . . . . . . . . . 5-5

Power Factor Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Multi-motor Applications . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Special Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Wye-Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Part Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Wound Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Synchronous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Altitude De-rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Isolation Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

SMC Dialog Plus Controller with Bypass Contactor (BC) .5-11 SMC Dialog Plus Controller with Reversing Contactor . . .5-11 SMC Dialog Plus Controller as a Bypass to an AC Drive .5-12 SMC Dialog Plus Controller with a Bulletin 1410

Motor Winding Heater . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Motor Torque Capabilities with SMC Dialog Plus

Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

SMB Smart Motor Braking . . . . . . . . . . . . . . . . . . . . .5-14

Preset Slow Speed . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

Accu-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

Energy Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

Energy Saver Operation . . . . . . . . . . . . . . . . . . . . . . .5-15

Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Application Requirements . . . . . . . . . . . . . . . . . . . . . .5-17

Preliminary Estimates . . . . . . . . . . . . . . . . . . . . . . . . .5-17

toc–iii

Chapter 6 SMC Product Line Applications Matrix

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Mining and Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Food Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Pulp and Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Petrochemical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Transportation and Machine Tool . . . . . . . . . . . . . . . . . . 6-6

OEM Specialty Machine . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Lumber and Wood Products . . . . . . . . . . . . . . . . . . . . . . 6-8

Water/Wastewater Treatment and Municipalities . . . . . . 6-9

toc–iv

Table of Contents

Chapter 7 Design Philosophy

Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Line Voltage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Current and Thermal Ratings . . . . . . . . . . . . . . . . . . . . . 7-1

Mechanical Shock and Vibration . . . . . . . . . . . . . . . . . . . 7-1

Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Chapter 8 Reduced Voltage Starting

Introduction to Reduced Voltage Starting . . . . . . . . . . . . 8-1

Reduced Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Solid-state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Chapter 9 Solid-state Starters Using SCRs

Solid-state Starters Using SCRs . . . . . . . . . . . . . . . . . . . 9-1

Chapter 10 Reference

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

Motor Output Speed/Torque/Horsepower . . . . . . . . . . . .10-1

Torque and Horsepower . . . . . . . . . . . . . . . . . . . . . . . . .10-1

Locked-Rotor Torque (LRT) . . . . . . . . . . . . . . . . . . . . .10-3

Pull-Up Torque (PUT) . . . . . . . . . . . . . . . . . . . . . . . . . .10-3

Breakdown Torque (BT) . . . . . . . . . . . . . . . . . . . . . . .10-3

Full-load Torque (FLT) . . . . . . . . . . . . . . . . . . . . . . . . .10-4

Full-load Current . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4

Locked-rotor Current . . . . . . . . . . . . . . . . . . . . . . . . .10-4

kVA per Horsepower is Calculated as Follows: . . . . . .10-5

Motor Output for NEMA Design Designations

Polyphase 1–500 HP . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7

Calculating Torque (Acceleration Torque Required for

Rotating Motion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11

Calculating Horsepower . . . . . . . . . . . . . . . . . . . . . . . . .10-12

Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12

Torque Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13

AC Motor Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14

Torque Characteristics on Common Applications . . . . . .10-15

Electrical Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-17

Ohm’s Law: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-17

Power in DC Circuits: . . . . . . . . . . . . . . . . . . . . . . . . .10-17

Calculating Motor Amperes . . . . . . . . . . . . . . . . . . . . . .10-18

Other Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-19

Calculating Accelerating Force for Linear Motion: . . . .10-19

Table of Contents

Chapter 10 (cont.)

Engineering Constants . . . . . . . . . . . . . . . . . . . . . . . . . .10-19

Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-19

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-19

Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10- 20

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20

Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20

Mathematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20

Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-21

Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-21

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-21

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-21

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-21

Power/Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-21

Work/Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22

Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22

Rotation/Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22

Mathematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22

Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22

Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-23

toc–v

SMC Controllers

The Allen-Bradley SMC Controller lines offer a broad range of products for starting or stopping AC induction motors from 1/3 HP to 6,000 HP. Th e innovative features, compact d esign, and available enclosed controllers meet world-wide industry requirements for controlling motors. Whether you need to control a single motor or an integrated automation system, our range of controllers meet your required needs with the Starting Torque Controller (STC) and Smart Motor Controller family (SMC-2, SMC PLUS, and SMC Dialog Plus).

Features

Soft Start Kickstart Current Limit Start Dual Ramp Start Full Voltage Start Energy Saver Soft Stop Pump Control Preset Slow Speed SMB Smart Motor Braking Accu-Stop

Slow Speed with Braking Single-phase Operation Normal/Up-to-speed Aux Fault Contact Modular Design Overload Protection Metering Communication Backlit LCD Display Programming Keypad Phase Reversal Phase Rebalance Jam Detection Underload Detection



STC Controller SMC–2 Controller

100–240V

1-phase

1–22A

  



200–600V

3-phase

1–22A

200–600V

1–97A



  

SMC Dialog Plus

Controller

200–600V

1–1000A



  



①



           



= Available

① Included with the Accu-Stop option

STC Starting Torque Controller

Chapter 1

Description

The STC Starting Torque Controller is designed for low horsepower single-phase and three-phase squirrel cage induction motors. It is intended to relieve the starting torque surge encountered in typical across-the-line starting. This will provide smoother starts and decrease downtime due to shock and vibration related problems.

The STC is a global product available in three current rated sizes: 11, 16, an d 22 Amp, with voltage rang e s f rom 100–60 0V , 50/60 Hz., UL Listed, CSA Approved, and CE labeled. Its compact design makes new installations as well as retrofitting easy. Setting the initial torque and ramp time of the controller is accomplished with digital rotary switches.

Figure 1.1 STC Controller (11, 16, and 22 Amps)

1-2

STC Starting Torque Controller

Modes of Operation

Across-the-Line Response

Excessive motor starting torque can damage the motor and driv equipment. Figure 1.2 illustrates the torque developed in a typical across-the-line start.

Figure 1.2 Torque Developed in a Typical Across-the-Line Start

75 50

Tor qu e

-25

-50 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Time (sec.)

STC Controller Response

The STC controller r educes the ma gnitu de of st ar ting torque surges as illustrated in Figure 1.3. This limits the starting shock to the motor and drive train.

Figure 1.3 STC Controller Respons

Tor qu

-25

-50 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Time (sec.)

Across-the-Line Response Versus STC Controller Response

Figure 1.4 compares a typical across-the-line start response and the STC control ler respo nse.

Figure 1.4 Across-the-Line Response Versus STC Controller Response

100

75 50

Torque

-25

-50 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Time (sec.)

STC Starting Torque Controller

1-3

Features

Adjustments

The STC controller is a compact device with feed through wiring for ease of installation. To set up the controller, ad just the digital rotary switches. The initial torque value is set between 10 and 80% of locked rotor torque. The voltage ramp time is adjustable from 0.1 to

4.5 seconds. This flexible combination enables the STC controller to be installed in a wide variety of applications.

Figure 1.5 STC Controller Adjustments

Digital Rotary switches for easy adjustments

Table 1.A Initial Torque Level (Nominal)

Position

% of Locked

Rotor Torque

Table 1.B

Position

Time

(Seconds)

0123456789

10 15 20 25 30 40 50 60 70 80

Voltage Ramp Time (Nominal)

0123456789

0.1 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

(With Initial Torque Set At 0)

1-4

STC Starting Torque Controller

Wiring Diagrams

Figure 1.6 Typical Wiring Diagrams for STC Controller in Three-phase

Applications

L1/1

Power Input

3-Phase

Protection

Branch

➀

Start

Stop

➀

Existing Motor

Starter

➀

O.L.

Starting Torque

➀

T1/2

L2/3

T2/4

L3/5

T3/6

Controller

Existing Control Circuit

Customer supplied

➀

Figure 1.7 Typical Wiring Diagrams for STC Controller in Single-phase

Applications

Starting Torqu

Control ler

L1/1

T1/2

L2/3

T2/4

➀

L3/5

T3/6

O.L.

➀

1Ø

Motor

➀

Motor

➀

Start

➀

O.L.

➀

Stop

Customer supplied

➀

STC Starting Torque Controller

Stop

➀

Forward

➀

Reverse

➀

3-Phase

Power Input

Branch

Protection

➀

Overload Rela

(O.L.)

➀

Starting Torque

Contro ller

➀

Figure 1.8 Typical Wiring Diagrams for STC Controller – Reversing

L1/1

T1/2

Motor

Customer supplied

O.L.

L2/3

T2/4

L3/5

T3/6

Existing Control Circuit

1-5

1-6

STC Starting Torque Controller

Suitable Replacement

Applications

The STC controller is a suitable replacement for:

• W ye-delta Starters

• Resistor Ballast Starters

• Line Reactors

• Clutches

• Flywheels

• Fluid Coup lings

• Other Mechanical and Electrical Soft Start Devices

In this section a few of the many STC controller applications are described.

Illustrations are included to he l p identify the particular application. Motor ratings are specified but this may vary in other typical applications.

Typical applications include:

• Bridge Cranes

• Trolleys

• Monorails

• Shrink Wrap Machines

• Overhead Doors

• Conveyor

• Material Handling Equipment

• Compressors

• Fans and Pumps

• Lifts

• Elevators

• Grinders

•Mixers

STC Starting Torque Controller

1-7

Applications (cont.)

Figure 1.9 Chair Elevator

Problem: A single-pha se chain driven chair elev ator was started

across-the-line. The starting torque caused the chair to lurch during the start and occasionally caused chain alignment problems.

Solution: An STC controller was installed to provide controlled

acceleration.This minimized the mechanical shock encountered during across-the-line starting and reduced alignment problems. It also allowed for regularly scheduled preventive maintenance inspections, rather than emergency maintenance repair.

1-8

STC Starting Torque Controller

Applications (cont.)

Figure 1.10 Paint Shaker

Problem: The commercial paint shaker was operated with a single

phase motor and used across-the-line starting. This method of starting caused the facility’s line voltage to dip. The building’s fluorescent lighting, with electronic ballasts, was extremely sensitive to line voltage dips and would momentarily shut off when the paint shaker was started.

Solution: A single-phase STC controller was used to provide a soft

start to t he paint shaker. The ramp time was set to three seconds, thereby eliminating the line voltage dip.

Figure 1.11 Chain Conveyor with Torque Control

Bundle Bundle

Motor

STC Starting Torque Controller

Chain

1-9

480 Volts

7.5 HP

Problem: A chain conveyor is used for transporting bundles of

paper . Due to the high sta rting torque the co nveyor motor applies to the chain during startup, the chain was breaking on an average of once per day. Maintenance of the con veyor caused interruptions in the production schedule.

Solution: The STC controller was installed to reduce the starting

torque on the motor and mechanical system. This resulted in less downtime and higher productivity. The STC controller was easy to retrofit due to its compact size and feed through wiring.

1-10

STC Starting Torque Controller

Applications (cont.)

Figure 1.12 Crane with Torque Control

480 Volts 2 HP

Traverse Motor (STC Controlled)

Tra ck

Load

Problem: An overhead crane required frequent jogging due to

adjustments in the traverse (horizontal) position. An across-the-line starter was used and this caused overshoot or undershoot when trying to position over a load.

Solution: The STC controller was installed in the application. By

reducing the starting torque of the motor, this allowed th crane to be positioned effectively. This meant fewer starts were required to position the crane over the load. This solution reduced the maintenance required as well as improved the productivity of the crane. The STC controller was a cost effective solution.

STC Starting Torque Controller

Figure 1.13 Aircraft Hangar Door

1-11

480 Vol 2 Hp

Chain

Motor

Problem: A chain driven aircraft hangar door was started across-

the-line. The starting torque caused chain alignment problems. This required frequent inspection and maintenance.

Solution: An STC controller was installed to provide controlled

acceleration. This minimized the mechanical shock encountered during across-the-line starting and reduced maintenance inspection. The digital adjustments of the STC controller were easily set and did not drift with ag or vibration.

Chapter 2

SMC-2 Smart Motor Controller

Description

The SMC-2 Smart Motor controller is a compact, multi-functional solid state controller used in starting standard three-phase squirrel cage induction motors and controlling resistive loads.

The SMC-2 p ro duc t line includes c urr e nt range s from 5–9 7 Amps, 200 to 600V, 50/60 Hz., UL Listed, CSA Approved, and CE labeled. This covers applications up to 75 horsepower.

Figure 2.1 SMC-2 Controller (5–97 Amps)

Modes of Operation The following modes of operation are standard within a single

controller:

• Soft Start

• Current Limit Start

• Full Voltage Start The built-in energy saver feature allows the controller to conserv

energy on applications where the motor is lightly loaded or unloaded for long periods of time.

2-2

Start Run

Percent Voltage

Initial

Torque

100%

Time (seconds)

SMC-2 Smart Motor Controller

Modes of Operation (cont.)

Soft Start

This is th e m o st co mmon me t hod of s tar t ing . The initi al torque value is set between 0 – 70% of locked rotor torq ue. The motor voltage is steplessly increased dur ing the acceleration ramp period, which is adjustable from 2–30 seconds.

Figure 2.2 Soft Start

Current Limit Start

This starting mode is used when it is necessary to limit the maximum starting c urrent. This can be adjuste d from 25 t o 550% of full load amperes. The current limit starting time is customer set. If the motor is not up to speed after the selected time, the motor will transition to full voltage

Figure 2.3 Current Limit Start

550

Percent

Full Loa

Amp

Start

Time (seconds)

SMC-2 Smart Motor Controller

100%

Percent Voltage

Time (seconds)

2-3

Full Voltage Start

This mode is used in applications requiring across-the-line starting. The ramp time is l ess than 1/10 second.

Figure 2.4 Full Voltage Start

Features

Fault Trips

There is a single red LED on the front of the SMC-2 controller for diagnostic in di c ati o n. Wh en three -phase power is a ppl ied to the controller, the LED will be on.

The SMC-2 controller monitors the following fault conditions:

• Shorted SCR (pre-start only)

• Phase Loss (line side and pre-start only

• Stalled Motor (when stall switch is on) If a shorted SCR or phase loss exists, the SMC-2 controller will not

start and the LED will flash. If a stalled motor condition exists, th controller s h uts down and flashe s the LED. In the event three-phase input power is lost, the LED turns off.

2-4

SMC-2 Smart Motor Controller

Adjustments

Figure 2.5 SMC-2 Soft Start

Mode Selec

Time Select

Starting Time

Initial Torque Leve

NOTE:

The switches shown above are for a 10 second Soft Start with a 3 0

Starting Time

Soft Stopping Time (Active only with interface option)

initial torque and 25 seconds soft stop.

Full Voltage Start

Current Limit

Energy Saver Select (ON OFF)/

50/60 H (ON/OFF)

Auxiliary Contact (Up-to-Speed./Instant.) (Active only with interface option)

ON Positio

Stall Select (ON/OFF)

Soft Stop Selec (Active only with interface option) Must be OFF when Soft Stop not use

Soft Stop Select (Active only with interface option) Must be OFF when Soft Stop not use

Table 2.A Rotary Position Initial Torque Level

Position

% of Locked Rotor Torque

0123456789

0125102030405070

Table 2.B Soft Start Time

Switch

Number

15 Off On Off On Off On Off

14 Off Off On On Off Off On

13 Off Off Off Off On On On

2 5 10 15 20 25 30

Time (seconds)

Table 2.C Soft Stop (Available only with interface option)

Switch

Number

5 101525354555110

Time (seconds)

12 Off On Off On Off On Off On

11 Off Off On On Off Off On On

10 Off Off Off Off On On On On

SMC-2 Smart Motor Controller

Figure 2.6 SMC-2 Current Limit Selection

2-5

Time Select

Starting Time

Current Limit Level

NOTE:

The switches shown above are for a 15 second, 300 percent

Starting Time

Soft Stopping Time (Active only with interface option)

current limit start with a 25 second soft stop

Table 2.D Rotary Position % Current Limit

Position

OFF Position

Current Limit

Energy Saver Select (ON OFF)/

50/60 H (ON/OFF)

Auxiliary Contact (Up-to-Speed./Instant.) (Active only with interface option)

ON Positio

Stall Select (ON/OFF)

Soft Stop Selec (Active only with interface option) Must be OFF when Soft Stop not used

Soft Stop Select (Active only with interface option) Must be OFF when Soft Stop not used

0123456789

% of Full

Load Amps

25 50 100 200 250 300 350 450 500 550

Table 2.E Current Limit Start Time

Switch

Number

15 Off On

14 Off Off

13 Off Off

Time (seconds)

15 30

Table 2.F Soft Stop (Available only with interface option)

Switch

Number

5 101525354555110

12 Off On Off On Off On Off On

11 Off Off On On Off Off On On

Time (seconds)

10 Off Off Off Off On On On On

2-6

SMC-2 Smart Motor Controller

Adjustments (cont.)

Initial Torque Leve

Time Select

Figure 2.7 SMC-2 Full Voltage Selection

Full Voltage

Starting Time

Soft Stopping Time (Acti v only with interface option

Soft Stopping Time (Active only with interface option

Current Limit

Energy Saver Select (ON OFF)/

50/60 H (ON/OFF)

Auxiliary Contact (Up-to-Speed./Instant.) (Active only with interface option)

ON Positio

Stall Select (ON/OFF)

Soft Stop Selec (Active only with interface option) Must be OFF when Soft Stop not use

Soft Stop Select (Active only with interface option) Must be OFF when Soft Stop not use

Table 3.G Soft Stop (Available only with interface option)

Switch

Number

12 Off On Off On Off On Off On

11 Off Off On On Off Off On On

10 Off Off Off Off Off On On On

5 101525354555110

Time (seconds)

SMC-2 Smart Motor Controller

2-7

Wiring Diagram

Series Controller

The SMC-2 controller is designed to operate with an electromechanical starter. The series mode has the following features:

• Simplified initial installation – no need for additional wiring

• Easy retrofits – works with existing electromechanical starter

Figure 2.8 Wiring Diagram for Series Controller

T1/2

➀

L1/1

T2/4

L2/3

T3/6

L3/5

SMC-2

Controller

Existing Control Circuit

Power Input

3-Phase

Branch

Protection

Stop

Customer supplied.

➀

Start

➀

Overload Relay

(O.L.)

➀

O.L.

➀

Motor

➀

2-8

SMC-2 Smart Motor Controller

Options

Description of Interface Options

The SMC-2 controller is designed to be operated by an external device. An optional interface is available for the SMC-2 controller. This offers the following features:

• ON/OFF control directly to the controller through an external device. In many applications the interface ma y e l i mi nate the need for an additional contactor. This reduces the panel space required.

• A configurable auxiliary contact which operates as either an instantaneous or up-to-speed contact.

• Soft Stop. This extends stopping time to minimize load shifting or spillage d uring stopping.

Figure 2.9 Interface Option (5–16 Amps)

This option is available as a plug-in module for the 5–16 Amp devices. For 24–97 Amp devices, the interface is included as an integral part of the logic design. It is not a plug-in device like th 5–16 Amp interface option.

Soft Stop Option

This function can be used in applications that require an extended coast to rest. The voltage ramp downtime can be set from 5–110 seconds. The starting and stop ping times are independently adjusted. The load will stop when the voltage drops to a point where the load torque is greater than the motor torque.

Figure 2.10 Soft Start with Soft Stop

100

Percent

Voltage

Inititial Tor que

Start Run

Soft Sto

Coast

Soft Sto

Time (Seconds)

SMC-2 Smart Motor Controller

Wiring Diagram with Interface Option

Control power requirement for the interface option is 5VA at 120V and 15VA at 240V. Auxiliary contact rating is NEMA C300, 2.5 Amps, 20–250V AC: 1 Amp, 12–30V DC.

Figure 2.11 Wiring Diagram with Interface Option

L1/1

Power Input

3-Phase

Protection

Branch

➀

C.C.T.

Stop

➀ ➂

SMC-2 Controlle

➀

Start

➀

L2/3

L3/5

T1/2

T2/4

T3/6

Overload Relay

( O . L . )

O.L.

➀

Motor

➀

2-9

10 20 30 40 50 60

Interface Option

Customer supplied

➀

Maximum fuse size 10A, 250V.

➁

For two wire control, remove stop/start push buttons and

➂

connect two wire device between terminals 10 and 30

Auxiliar

Contact

2-10

SMC-2 Smart Motor Controller

Options (cont.)

Overload Relay Option

To save additional panel space, IEC overload relays may be mounted directly to the 5, 9, and 16 Amp SMC-2 controllers.

Figure 2.12 SMC-2 Controller with Bulletin 193 Overload Relay (5–16 Amps)

Applications In this section a few of many applications are described, as well as

why the particular control method was selected. For example, tumbler drum is described using a soft start feature. We will then “build” upon this application to describe how the SMC-2 controller options can be used to improve the tumbler drum performance and productivity.

Illustrations are included to he l p identify the particular application. Motor ratings are specified but this may vary in other typical applications.

SMC-2 Smart Motor Controller

Figure 2.13 Conveyor with Soft Start

2-11

480 Vol

7.5 HP

LOG

Motor

Chain

LOG

Problem: A conveyor is used to transport logs. The drive chain was

breaking due to uncontrolled start-up. This caused interruptions in the production schedule and lost productivity. Panel space was very limited.

Solution: Due to its compact design, the SMC-2 controller was

easily installed in the space vacated by the previous starter. A 10-second soft start was selected. This reduced the starting torque and the shock to the mechanical sy ste m.

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