Rockwell Automation 150 MNL User Manual

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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.

2-12

SMC-2 Smart Motor Controller

Applications (cont.)

Figure 2.14 Tumbler with Soft Start

480 Volts 50 HP

Loading Door

Tumbler D rum

Motor

Drive Chain

Problem: A tumbler used in a na il finishing process was breaking

the drive chain due to the uncontrolled acceleration from the across-the-line start. In addition, a reversing starte was needed to position the drum to the top position for loading the product. Due to lack of co ntrolled acceleration, numerous jogs were used to position the drum. The stopping time was not a con cer n in this application. In addition, single phasing of the motor was a frequent problem, causing premature motor failure.

Solution: The SMC-2 controller was installed after the reversing

contactor to control the starting torque of the motor. This prevented the snapping of the drive chain on the start up which increased the life of the chain and reduced th downtime on the tumbler. In addition, the SMC-2 controller made it easier to jog the drum into position for loading and unloading. (The SMC-2 controller slowed the acceleration rate to prevent overshoot.) This helped improve the prod uctivity of the l oad ing and unloading process. In addition, the SMC-2 controller could quickly detect the phase failure during starting. The controller would prevent starting until the line had been corrected. This added additional s tandard protection to the motor and system.

SMC-2 Smart Motor Controller

Figure 2.15 Power Walk with Soft Start and Soft Stop Option

240 Volts 15 HP

Motor

2-13

Problem: A power walk at an a ir po rt req u ire d a soft star t to prevent

damage to the drive chain gearbox on start-up. A soft stop was also required in case the power walk would b shut off while people were still on the belt. There would be multiple units at the site, and a controller that could be quickly installed and adjusted was required.

Solution: The SMC-2 controller with the Interface option was

designed into the system. A 10-second soft start with the Energy Saver enabled was selected. A 10-second soft stop was also selected. This allowed the power walk to have a controlled start and stop. D ur ing p eriods where the walk was unloaded, the SMC-2 controller Energy Saver reduced the voltage to the motor, minimizing the magnetic losses of the motor.

2-14

SMC-2 Smart Motor Controller

Applications (cont.)

Pallet

Figure 2.16 Towline Conveyor with Soft Start and Soft Stop Option

480 Volts 15 HP

Load Load

Gearbox

Motor

Problem: A towline conveyor at the en d of a production line had

frequent damage to the gearbox due to the starting torque from acr oss -the -li ne starting of the motor. There were frequent spills on both starting and stopping of the conveyor system.

Solution: The SMC-2 controller with the Interface option was

installed. Starting and stopping times of 15 seconds were selected. The reduced torque starting prevented shock to the gearbox and kept the load from shifting on st art-up. The soft stop prevented the load shifts while stopping. The SMC-2 c on t ro ller met the application requirements and was a cost effective solution.

SMC-2 Smart Motor Controller

Figure 2.17 Bottle Filler with Soft Start and Soft Stop Option

480 Volts 1 HP

Filler

2-15

Problem: A bottle filler line had product spillage upon starting and

stopping. An across-the-line starter w as used to start th motor. In addition, the application required an auxiliary contact that would energize when the motor was up to speed.

Solution: The SMC-2 controller was installed and set for a 10-

second soft start with a 20-second soft stop. This controlled the starting torque a n d prevented the sudden start that w ould cause t h e bottles to spi ll. The soft stop extended the stopping time eliminating load shift while stopping. T h e auxiliar y conta c t was configured to change state when the motor was up to speed.

2-16

SMC-2 Smart Motor Controller

Applications (cont.)

Motor

Figure 2.18 Grinder with Soft Start

575 Volts 20 HP

Grinding Wheel

Gearbox

Problem: Due to the high starti ng torque developed from starting

the motor across-the-line, the gears driving a grinding wheel were frequently damaged. T his resulted in unscheduled downtime for repair. T his application required a rugged device because vibration at the control panel was a problem.

Solution: The SMC-2 controller was installed and set for a

20-second acceler ation time. This reduced the starting torque and the downtime for repairs on the grinder. In addition, the benefit of the Energy Saver was realized when the motor was running lightly loaded. The SMC-2 controller meets the same shock and vibration requirements as electromechanical devices, therefore it met the durability requirements.

SMC-2 Smart Motor Controller

Figure 2.19 Passenger Elevator

2-17

Problem: A passenger e l evator i n a parking structure r equ ired a soft

start to el imin ate the jolt w hi ch occurred during an across-the-line start. Due to the size of the en closure, the soft starter must fit in the space vacated by the electromechanical motor starter.

Solution: An SMC-2 c o nt rolle r with the Int erfa ce o p t ion was

installed. The starting time was set for 10 seconds. This reduced the starting torque and eliminated the jolt during the start. The Interface option allowed all control wiring to be connected directly to the SMC-2 controller, thereby eliminating the need for the electromechanical motor starter. The small size of the SMC-2 controller allowed it to fit easily into the space vacated by th electromechanical motor starter.

2-18

SMC-2 Smart Motor Controller

Chapter 3

SMC Dialog Plus Smart Motor Controller

Description

When the Smart Motor Controller (SMC) was first introd uced in 1986, its modular design, digital set-up, and microprocessor control set the standard for soft starters. Since its launch in 1989, the SMC PLUS controller has been in a class by itself, providing unmatched performance with innovative starting and stopping options. Now, the SMC Dialog Plus controller achieves a higher level of sophistication with greatly enhanced protection, expanded diagnostics, a nd t he a b ility to log the motor’s operation (amps, kW, and power factor), as well as the option to “dialog” with various network protocols.

While the SMC Dialog Plus controller incorporates many new features into its design, it remai ns easy to set-up and operate. You can make use of as few or as many of the features as your application requires.

The SMC Dialog Plus controller is a compact, modular, multifunctional solid-state controller used in starting three-phase squirrel cage induction motors and controlling resistive loads. The SMC Dialog Plus product line includes current ratings from 24 to 1000 Amps, 200 to 600V, 50/60Hz. This covers applications up to 1000 horsepower. The SMC Dialog Plus c on troller meets applicab l standards and requirements.

Figure 3.1 SMC Dialog Plus Controller (24–1000 Amps)

3-2

SMC Dialog Plus Smart Motor Controller

Starting Methods

The following starting methods are standard within the controller:

• Soft Start with Selectable Kickstart

• Current Limit Start

• Dual Ramp Start

• Full Voltage Start

Optional fea tu res include:

• Soft Stop

• Pump Control

• Preset Slow Speed

•SMB Smart Motor Brake

• Accu-Stop/Slow Speed with Braking

Soft Start with Selectable Kickstart

This meth od h a s the m o st general app li c a tion. 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 voltag to the motor is steplessly increased during the acceleration ramp time, which is user adjustable from 0 to 30 seconds. If, during the voltag ramp operation, the SMC Dialog Plus controller senses that the moto has reached an up-to-speed condition, the output voltage will automatically switch to full voltage.

The kickstart feature provides a boost at start-up to break away loads that may require a pulse of high torque to get started. It is intended to provide a current pulse of 550% of full load current and is user adjustable from 0.0 to 2.0 seconds.

Figure 3.2 Soft Start with Selectable Kickstart

Percent Voltage

Kickstart

100%

Initial

Torque

Start Run

Time (seconds)

SMC Dialog Plus Smart Motor Controller

Percent

Voltage

Initial

Torque #1

100

Start #1 Run #1

Ramp #2

Ramp #1

Start #2

Time (seconds)

Run #2

Initial

Torque #2

3-3

Current Limit Start

This starting method provides a fixed reduced voltage start and is used when it is necessary to limit the maximum starting current. Th starting current is user adjustable from 50 to 600% of full load amperes. The current limit starting time is user adjusta ble from 0 to 30 seconds.

Figure 3.3 Current Limit Start

600%

Percent

Full Load

Current

50%

Start

Time (seconds)

Dual Ramp Start

This starting method is useful on applications with varying loads and varying starting torque requirements. Dual Ramp Start offers the user the ability to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings.

Figure 3.4 Dual Ramp Start

3-4

10 0

Percent Voltage

Time (seconds)

SMC Dialog Plus Smart Motor Controller

Starting Methods (cont.)

Full Voltage Start

This meth od is used in appli c ations requ iring across-the- l ine starting. The SMC Dialog Plus controller perf orms like a solid-state contactor. Full inrush current and locked rotor torque are realized.

Figure 3.5 Full Voltage Start

Features

LCD Display

A two line, sixteen character b acklit LCD display provides parameter definition with straightforward text so that controller set-up may be accomplished without a reference manual. Parameters are arranged in an organized four level menu structure for ease of programming and fast access to parameters.

Keypad Programming

Programming of param et ers is accomplished through a five button keypad on the fro nt of the SMC Di alog P lu s controller. The five buttons include up and down arro ws, an Enter button, a Select button, and an Escape button. The user needs only to enter the correct sequence of keystrokes for programming the SMC Dialog Plus controller.

Figure 3.6 LCD Display with Keypa

SMC Dialog Plus Smart Motor Controller

3-5

Electronic Overload

The SMC Dialog Plus controller meets applicable requirements as motor overload protective device. Overload protection is

accomplished electronically through an I

algorithm.

The overload is programmable, providing the user with flexibility. The overload trip class is selectable for class 10, 15, 20, or 30 protection. The tr i p current is set by entering th e motor’s full load current rating and the service factor.

Thermal memory i s i n cl u de d t o a ccurately model motor operating temperature. Ambient insensitivity is inherent in the electronic design of the o v er lo ad .

Note: The current sensing capability of the SMC Dialog Plus

controller i s d i sa b le d du ring b y pass operat ion. The Bulletin 825 Converter Module is required to provide current feedback in these applications.

Built-in Communication Port

A serial interface port is furnished as standard with the SMC Dialog Plus controller. This communication port allows for connection to a Bulletin 1201 Hu m an Interface Module. It a l so allows fo r a variety of other communications, including Allen-Bradley’s Remote I/O, DH485, RS 232/422/485-DF1, and DeviceNet network through the connection to the Bulletin 1203 communication modules.

3-6

Stall

60 0

Percent

Full

Load

Current

Time (seconds)

Programmed Start Time

100%

Running Jam

Percent

Full

Load

Current

Time (seconds)

User Programmed Trip Level

SMC Dialog Plus Smart Motor Controller

Features (cont.)

Stall Protection and Jam Detection

Motors can experience locked rotor currents and develop maximum torque in the event of a stall (during start) or a jam (after full speed is reached). These conditions can result in winding insulation breakdown or mechanical damage to the connected load.

The SMC Dialog Plus controller prov ides both sta ll and jam detection for enhanced motor and system protection. Stall protection allows the user to program a maximum stall time of up to 10 seconds. Jam detection allows the user to determine the jam level as a percentage o the motor’s full load current rating, and a trip delay time of up to 10 seconds.

Note: The stall trip delay time is in addition to the programmed

start time.

Figure 3.7 Stall Protection

Figure 3.8 Jam Detection

SMC Dialog Plus Smart Motor Controller

SMC Dialog Plus

Supply Voltage

501V 480V

462V

Motor

3-7

Phase Rebalance

As little a s 4% supply vo l ta ge un balanc e ca n resul t in a 20% current unbalance a n d a 25% in cr e ase in motor tem p era t u re, possibly triggering a premature failure of the motor. The SMC Dialog Plus controller continuously monitors the incoming three-phase line voltage balance and adjusts the output voltage automatically to balance the three-phase currents drawn by the motor.

Figure 3.9 Phase Rebalance

Notes: (1) Phase Rebalance is not active during bypass operation.

(2) Phase rebalance requires the use of the converter modul

(Bulletin 825) and fanning strip (Cat. No. 150-NFS).

Metering

The SMC Dialog Plus controller contains several power monitoring parameters as standard. These parameters include:

• Three-phase Current • Three-phase Voltage

• Power in kW • Power Usage in kWH

• Power Factor • Elapsed Time

• Motor Thermal Capacity Usage

Fault Indication

The SMC Dialog Plus controller monitors both the pre-start and running modes. If the controller senses a fault, the SMC Dialog Plus controller shuts down t h e motor and displays the appropriate fault condition in the LCD display. The controller monitors the following conditions:

• Open Gate • L i ne Fault

• Undervoltage • Underload

• Overvoltage • Excessive Starts/Hour

• Voltage Unbalance • Overtemperature

• Phase Reversal • Stall

• Power Loss • Jam

• Overload • System

Any fault condition will ca u se t he auxiliary co ntacts to change state and the hold- in circuit to release.

3-8

SMC Dialog Plus Smart Motor Controller

Features (cont.)

Auxiliary Contacts

Three hard contacts are provided as standard with the SMC Dialog Plus controller. The first two contacts are programmable for Normal/ Up-to-sp ee d . The third con tact is program mable for Normal/Fault.

Energy Saver

The built-in Energy Saver feature is integral to the SMC Dialog Plus controller and may be applied to applications whe re the motor is lightly loade d or unloaded for long periods of time. With the Energy Saver feature enabled, the SMC Dialog Plus controller continuously monitors the l oading of the motor wi th its internal feedback circuitry. Because the output voltage is SCR control led, moto r power losses can be reduced by decreasing the motor terminal voltage.

Note: The Energy Saver feature is not available when a bypass

contactor is used.

Modular Design

The SMC Dialog Plus controller packaging is designed for industrial environments. The mod u lar i ty of co n tr ol and power modules featur plug-in functionality. There are no gate wires to remove and no soldering is required. Common control modules reduce inventory requirements.

Figure 3.10 Exploded View of the 24 Amp SMC Dialog Plus Controller

SMC Dialog Plus Smart Motor Controller

3-9

Control Terminal Description

The SMC Dialog Plus controller contains 20 control terminals on the front of the controller. These control terminals are described below. See Figure 3.11.

Power Supply Board

Terminal Number Description

11 Control Power Input

12 Control Power Common

13 Controller Enable Input

14 Logic Ground

15 Dual Ramp/Option Input

16 Start Input

17 Stop Input

18 Auxiliary Relay Common

19 N.O. Auxiliary Contact 1 (Normal/Up-to-speed)

20 N.C. Auxiliary Contact 2 (Normal/Up-to-speed)

Logic Board

Terminal Number Description

21 Not Used

22 Not Used

23 Not Used

24 Not Used

25 Common (Converter Module)

26 Phase A Input (Converter Module)

27 Phase B Input (Converter Module)

28 Phase C Input (Converter Module)

29 N.O./N.C. Auxiliary Contact 3 (Normal/Fault)

30 N.O./N.C. Auxiliary Contact 3 (Normal/Fault)

Figure 3.11 SMC Dialog Plus Controller Control Terminals

3-10

SMC Dialog Plus Smart Motor Controller

Adjustments

Soft Start without Options

The following parameters are specifically used to provide and adjust the voltage ramp supplied to the motor

Para mete r Range

Starting Mode

This must be programmed for “Soft Start.”

Ramp Time #1

This sets the time period during which the controller will ramp the output voltage.

Initial Torque #1

The initial output voltage level for the voltage ramp is established and adjusted with this parameter.

Kickstart Time

A boost of 550% of full load current is provided to the motor for the programmed time period.

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Soft Start, Current Limit

0 to 30 seconds

0 to 90% of locked rotor torque

0.0 to 2.0 seconds

0 to 10 seconds

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19, and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

A third auxiliary contact is provided between terminals 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

Contact 3 Config

This parameter provides the user with the ability to program the “powered-up” state of the third auxiliary contact.

Parameter Mgmt

The newly programmed parameters values can be saved to memory, or the factory default parameter values can be recalled.

Off, On

Normal, Up-to-speed

Normal, Fault

N.O., N.C.

Ready, Default Init., Recll Frm EE, Store In EE

SMC Dialog Plus Smart Motor Controller

3-11

Current Limit Start without Options

To apply a fixed reduced voltage o utput to the motor, the following parameters are provided for user adjustment.

Para mete r Range

Starting Mode

This must be programmed for “Current Limit.”

Ramp Time #1

This sets the time period during which the controller will hold the fixed reduced voltage output before switching to full voltage.

Current Limit Level

This provides adjustability for the reduce voltage output level to the motor.

Kickstart Time

A boost of 550% of full load current is provided to the motor for the programmed time period.

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19, and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Soft Start, Current Limit

0 to 30 seconds

50 to 600% of full load current

0.0 to 2.0 seconds

0 to 10 seconds

Off, On

Normal, Up-to-speed

Aux Contact 3

A third auxiliary contact is provided between terminals 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

Contact 3 Config

This parameter provides the user with the ability to program the “powered-up” state of the third auxiliary contact.

Parameter Mgmt

The newly programmed parameters values can be saved to memory, or the factory default parameter values can be recalled.

Normal, Fault

N.O., N.C.

Ready, Default Init., Recll Frm EE, Store In EE

3-12

SMC Dialog Plus Smart Motor Controller

Adjustments (cont.)

Dual Ramp Start without Options

The SMC Dialog Plus controller provides the user with the ability to select between two soft start profiles. To obtain Dual Ramp Start control, the following parameters are available in the “Advanced Setup” progr ammi ng mode.

Note: The Dual Ramp Start feature is only a va ila ble with the

standard control module.

Parameter Range

Advanced Setup

The user must select the “Advanced Setup” programming mode in order to obtain access to the Dual Ramp Start parameters

Starting Mode

This must be programmed for “Soft Start.”

Dual Ramp

This allows the user to choose between two soft start profiles defined by: Ramp Time #1 and Initial Torque #1 Ramp Time #2 and Initial Torque #2 When the Dual Ramp feature is selected, the ramp time/initial torque combination is determined by a hard contact to input terminal

15. A low input signal to terminal 15 signifies that ramp time/initial torque #1 are selected. A high input signal to terminal 15 signifies that ramp time/initial torque #2 are selected.

—

Soft Start, Current Limit

No, Yes

Ramp Time #1

This determines the time period in which the controller will ramp the output voltage to the motor for the first soft start setup.

Initial Torque #1

The initial reduced voltage output level for the first soft start setup is established and adjusted with this parameter.

Ramp Time #2

This determines the time period in which the controller will ramp the output voltage to the motor for the second soft start setup.

Initial Torque #2

The initial reduced voltage output level for the second soft start setup is established and adjusted with this parameter.

Kickstart Time

A boost of 550% of full load current is provided to the motor for the programmed time period.

0 to 30 seconds

0 to 90 % of locked rotor torque

0 to 30 seconds

0 to 90 % of locked rotor torque

0.0 to 2.0 seconds

SMC Dialog Plus Smart Motor Controller

Dual Ramp Start without Options (cont.)

Parameter Range

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19, and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

A third auxiliary contact is provided between terminals 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

3-13

0 to 10 seconds

Off, On

Normal, Up-to-speed

Normal, Fault

Contact 3 Config

This parameter provides the user with the ability to program the “powered-up” state of the third auxiliary contact.

Parameter Mgmt

The newly programmed parameters values can be saved to memory, or the factory default parameter values can be recalled.

N.O., N.C.

Ready, Default Init., Recll Frm EE, Store In EE

3-14

SMC Dialog Plus Smart Motor Controller

Adjustments (cont.)

Full Voltage Start without Options

The SMC Dialog Plus controller may be programmed to provid full voltage start in whi ch t he o u tput vol ta g e to th e mot or re aches full voltage in 1/4 second.

Parameter Range

Start Mode

This must be programmed for “Soft Start.”

Ramp Time #1

This must be programmed for “0” seconds.

Initial Torque #1

This must be programmed for 90% of locked rotor torque.

Kickstart Time

This must be programmed for “0” seconds.

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Soft Start, Current Limit

0 to 30 seconds

0 to 90% of locked rotor torque

0.0 to 2.0 seconds

0 to 10 seconds

Off, On

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19, and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

A third auxiliary contact is provided between terminals 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

Contact 3 Config

This parameter provides the user with the ability to program the “powered-up” state of the third auxiliary contact.

Parameter Mgmt

The newly programmed parameters values can be saved to memory, or the factory default parameter values can be recalled.

Normal, Up-to-speed

Normal, Fault

N.O., N.C.

Ready, Default Init., Recll Frm EE, Store In EE

SMC Dialog Plus Smart Motor Controller

3-15

Typical Wiring Diagrams (without options)

Figure 3.12 Typical Wiring Diagram for Standard Controller

L1/1

T1/2

3-Phase

Input Power

Protection

Fast-acting

➀

Branch

➀

➁

11 12 13 14 15 16 17 18 19 20

SCR Fuses (optional)

➀

Stop

➀

Start

➀

L2/3

L3/5

T2/4

T3/6

➀

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

Internal Auxiliary Contacts

3-16

SMC Dialog Plus Smart Motor Controller

Typical Wiring Diagrams (without options)

Figure 3.13 Typical Wiring Diagram for Dual Ramp Applications

Control Power

Ramp 1 ➀Ramp 2

11 12 13 14 15 16 17 18 19 20

➁

Start

SMC Dialog Plus

Control Terminals

Stop

➀

Internal

Auxiliary

Contacts

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

Note: The Dual Ramp feature is only available with the standard control module.

SMC Dialog Plus Smart Motor Controller

3-17

Figure 3.14 Typical Wiring Diagram for Start-Stop Control via the SCANport

Control Power

➁

➂

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

If Soft Stop, Pump Control, or SMB Smart Motor option is installed, place additional jumper to

③

terminal 15.

3-18

SMC Dialog Plus Smart Motor Controller

Typical Wiring Diagrams (without options) (cont.)

Figure 3.15 Typical Wiring Diagram for Retrofit Applications

L1/1

3-Phase

Input Power

Branch

Protection

➀

Fast-acting

SCR Fuses

(Optional)

➀

Starter

Existing Motor

L2/3

L3/5

T1/2

T2/4

T3/6

Start

Stop

➀

➁

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

SMC Dialog Plus Smart Motor Controller

Start Run Soft Stop

Coast-to-rest

Soft Stop

Kickstart

Initial

Torque

100%

Percent Voltage

Time (seconds)

3-19

Control Options

The SMC Dialog Plus controller offers a variety of unique control options that provide enhanced motor starting and stopping capabilities. Please note that the options are mutually exclusive and must be specified at the time of order entry.

• Soft Stop

• Pump Control

• Preset Slow Speed

•SMB Smart Motor Braking

• Accu-Stop/Slow Speed with Braking

Soft Stop Option

The Soft Stop option can be used in applications requiring an extended coast-to-rest. The voltage ramp down time is use adjustable from 0 to 60 seconds. The Soft Stop time is adjusted independently from the start time. The load will stop when the voltage drops to a point where the load torque is greate r th an th motor torque.

Figure 3.16 Soft Stop Option

ATTENTION: Soft Stop is not intended to be used as an emergency stop. Refer to the applicable standards for

emergency stop requirements

3-20

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Soft Stop Option (cont.)

Figure 3.17 Typical Wiring Diagram for Soft Stop Option

Control Power

11 12 13 14 15 16 17 18 19 20

➁

Soft Stop

Stop

➀

Start

➀

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

SMC Dialog Plus Smart Motor Controller

Programming - Soft Start with Soft Stop Option

The basic parameter set-up for Soft Start selection with Soft Stop option follows:

Para mete r Range

3-21

SMC Option

“Soft Start” will be displayed.

Starting Mode

Allows the user to program the SMC Dialog Plus controller for the type of starting that best fits the application.

Ramp Time

This sets the time period during which the controller will ramp the output voltage.

Initial Torque

The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter.

Kickstart Time

A boost of 550% of full load current is provided to the motor for the programmed time period.

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19 and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

A third auxiliary contact is provided between terminals 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

Contact 3 Config

This parameter provides the user with the ability to program the “powered up” state of the third auxiliary contact.

Soft Stop Time

This parameter allows the user to program the soft stop (voltage ramp down) time that best fits the application.

Parameter Mgmt

The newly programmed parameters values can be saved to memory, or the factory default parameter values can be recalled.

—

Soft Start, Current Limit

0 to 30 seconds

0 to 90% of locked rotor torque

0.0 to 2.0 seconds

0 to 10 seconds

Off, On

Normal, Up-to-speed

Normal, Fault

N.O., N.C.

0 to 60 seconds

Ready, Default Init., Recll Frm EE, Store In EE

3-22

Motor Speed

Push Button

Start

Stop

Soft Stop

Auxiliary Contacts

Norma

Up-to-speed

Start Run

Open

Closed

100

Coast-to-rest

If Soft Stop Selected

If Coast-to-rest Selected

Soft Stop

Time (seconds)

Soft Stop

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Soft Stop Option (cont.)

Figure 3.18 Soft Stop Option Sequence of Operation

ATTENTION: The user has the ultimat

responsibil ity to determine whic h stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine.

SMC Dialog Plus Smart Motor Controller

Pump Start Run Pump Stop

Motor Speed

100

3-23

Pump Control Option

The SMC Dialog Plus controller’s unique interactive Pump Control is designed to reduce fluid surges in pumping systems. It provides closed loop acceleration and deceleration control of centrifugal pump motors without the need for feedback devices.

Figure 3.19 Pump Control Option

Time (seconds)

ATTENTION: Pump Stop is not intended to be used as an emergency stop. Refer to the applicable st andards

for emergency stop requirements.

3-24

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Figure 3.20 Typical Wiring Diagram for Pump Control Option

Control Power

11 12 13 14 15 16 17 18 19 20

➁

Pump Stop

➀

Stop

Start

➀

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

SMC Dialog Plus Smart Motor Controller

Programming - Pump Control Starting and Stopping

The basic parameter set-up for the Pump Control Starting and Stopping follows:

Para mete r Range

3-25

SMC Option

“Pump Control” will be displayed.

Starting Mode

Allows the user to program the SMC Dialog Plus controller for the type of starting that best fits the application.

Ramp Time

This sets the time period during which the controller will ramp the output voltage.

Initial Torque

The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter.

Kickstart Time

A boost of 550% of full load current is provided to the motor for the programmed time period.

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19 and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

A third auxiliary contact is provided between terminal 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

Contact 3 Config

This parameter provides the user with the ability to program the “powered up” state of the third auxiliary contact.

Pump Stop Time

This parameter allows the user to program the Pump Stop time that best fits the application.

Parameter Mgmt

The newly programmed parameters values can be saved to memory, or the factory default parameter values can be recalled.

—

Soft Start, Current Limit, Pump Start

0 to 30 seconds

0 to 90% of locked rotor torque

0.0 to 2.0 seconds

①

0 to 10 seconds

Off, On

Normal, Up-to-speed

Normal, Fault

N.O., N.C.

0 to 120 seconds

Ready, Default Init., Recll Frm EE, Store In EE

Kickstart is not available if “Pump Start” is selected.

①

3-26

Motor Speed

Push Button

Start

Stop

Soft Stop

Auxiliary Contacts

Normal

Up-to-speed

Start Run

Open

Closed

100

Coast-to-rest

If Pump Stop Selected

If Coast-to-rest Selected

Soft Stop

Time (seconds

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Pump Control Option (cont.)

Figure 3.21 Pump Control Option Sequence of Operation

ATTENTION: The user has the ultimat

responsibil ity to determine whic h stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine.

SMC Dialog Plus Smart Motor Controller

Forward

15% – Hig

7% – Low

10% – Low

20% – High

Reverse

Run Start Time (seconds)

3-27

Preset Slow Speed Option

The Preset Slo w Speed option can be used on applications t hat require a slow speed for positioning material. The Preset Slow Speed can be set for either Low, 7% of base speed, or Hi gh, 1 5% of ba s e speed. Reversing is also possible through programming. Speeds provided during reverse operation are Low, 10% of base speed, or High, 20% of base speed.

Figure 3.22 Preset Slow Speed Option

ATTENTION: Slow speed run ning is not in tended fo continuous operation due to reduced motor cooling.

3-28

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Preset Slow Speed Option (cont.)

Figure 3.23 Typical Wiring Diagram for Preset Slow Speed Option

Control Power

11 12 13 14 15 16 17 18 19 20

➁

Slow Speed

➀

Stop

Start

➀

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

SMC Dialog Plus Smart Motor Controller

3-29

Programming - Soft Start with Preset Slow Speed Option

The basic parameter set-up for Soft Start selection with Preset Slow Speed Option follows:

Parameter Range

SMC Option

“Preset Slow Speed” will be displayed.

Starting Mode

Allows the user to program the SMC Dialog Plus controller for the type of starting that best fits the application.

Ramp Time

This sets the time period during which the controller will ramp the output voltage.

Initial Torque

The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter.

Kickstart Time

A boost of 550% of full load current is provided to the motor for the programmed time period.

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19 and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

A third auxiliary contact is provided between terminal 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

Contact 3 Config

This parameter provides the user with the ability to program the “powered up” state of the third auxiliary contact.

Slow Speed Sel

This parameter allows the user to program the Preset Slow Speed that best fits the application.

Slow Speed Dir

Allows the user to select the Preset Slow Speed direction.

—

Soft Start, Current Limit

0 to 30 seconds

0 to 90% of locked rotor torque

0.0 to 2.0 seconds

0 to 10 seconds

Off, On

Normal, Up-to-speed

Normal, Fault

N.O., N.C.

High, Low

Forward, Reverse

3-30

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Programming - Soft Start with Preset Slow Speed Option (cont.)

Parameter Range

Slow Accel Cur.

Allows the user to program the Preset Slow Speed acceleration current.

Slow Running Cur.

Allows the user to program the Preset Slow Speed running current.

Parameter Mgmt

The newly programmed parameters values can be saved to memory, or the factory default parameter values can be recalled.

0 to 450% of full load current

Ready, Default Init., Recll Frm EE, Store In EE

SMC Dialog Plus Smart Motor Controller

Preset Slow Speed Option (cont.)

Figure 3.24 Preset Slow Speed Option Sequence of Operation

100%

7 or 15%

Motor Speed

3-31

Push Buttons

Start

Closed

Open

Stop

Closed

Open

Slow Speed

Closed

Open

Auxiliary Contacts

Normal

Up-to-speed

Speed

Start Coast

Time (seconds)

Run Slow

3-32

Start

Motor

Speed

100

Run

Automatic Zero Speed

Shut-off

Brake

Smart Motor Braking

Coast-to-rest

Time (seconds)

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)



SMB

The SMB Smart Motor Braking option provides motor braking for applications which require the motor to stop quickly. It is a microprocessor based braking system which applies braking current to a standard squirrel cage induction motor. The strength of the braking current is adjustable from 150 to 400% of full load current.

Figure 3.25 SMB Smart Motor Braking Option

Smart Motor Braking Option

ATTENTION: Braking may cause motor heating and equipment vibration depending on braking current,

frequency of braking, and duration of braking cycle. Select the lo west brake current setting that will brake satisfactorily.

ATTENTION: SMB Smart Motor Braking is not intended to be used as an emergency stop. Refe r to the applicable standards for emergency stop requirements.

SMC Dialog Plus Smart Motor Controller



SMB

Smart Motor Braking Option (cont.)

Figure 3.26 Typical Wiring Diagram for SMB Smart Motor Braking Option

3-33

Control Power

11 12 13 14 15 16 17 18 19 20

➁

Brake

➀

Stop

Start

➀

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

3-34

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Programming - Soft Start with SMB



Smart Motor Braking

Option

The basic parameter set-up for Soft Start selection with SMB Smart Motor Braking option follows:

Parameter Range

SMC Option

“SMB Smart Motor” Braking will be displayed.

Starting Mode

Allows the user to program the SMC Dialog Plus controller for the type of starting that best fits the application.

Ramp Time

This sets the time period during which the controller will ramp the output voltage.

Initial Torque

The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter.

Kickstart Time

A boost of 550% of full load current is provided to the motor for the programmed time period.

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19, and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

A third auxiliary contact is provided between terminal 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

Contact 3 Config

This parameter provides the user with the ability to program the “powered up” state of the third auxiliary contact.

Braking Current

Allows the user to program the percentage of braking current applied to the motor during the stop sequence. With the SMB Smart Motor Braking option, this is the current applied to bring the motor to zero speed.

Parameter Mgmt

The newly programmed parameters values can be saved to memory, or the factory default parameter values can be recalled.

—

Soft Start, Current Limit

0 to 30 seconds

0 to 90% of locked rotor torque

0.0 to 2.0 seconds

0 to 10 seconds

Off, On

Normal, Up-to-speed

Normal, Fault

N.O., N.C.

0 to 400% full load current

Ready, Default Init., Recll Frm EE, Store In EE

SMC Dialog Plus Smart Motor Controller

Motor Speed

Push Button

Start

Stop

Soft Stop

Auxiliary Contacts

Normal

Up-to-speed

Start Run

Open

Closed

100

Smart Motor Braking



SMB

Figure 3.27 SMB Smart Motor Braking Option Sequence of Operation

Smart Motor Braking Option (cont.)

Smart Motor Braking

Coast-to-rest

Brake

Time (seconds)

3-35

If Brake Selected

If Coast-to-rest Selected

ATTENTION: The user has the ultimat e responsibility to determine which stopping mode is best suited to th

applicati on and will meet applicable standards for operator safety o n a parti cular machine.

3-36

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Accu-Stop/Slow Speed with Braking Option

The Accu-Stop portion of this option provides rapid braking to a slow speed, and then braking to stop, facilitating cost-effective general positioning control.

Figure 3.28 Accu-Stop Option

100

Motor

Speed

7% or 15%

Slow

Speed

ATTENTION: Slow speed runnin g is not in tended for continuous operation due to reduced motor cooling.

Start

Time (seconds)

Run

Braking

Slow

Speed

Accu-Stop

ATTENTION: Braking may cause motor heating and

equipment vibration depending on braking current,

frequency of braking, and duration of braking cycle. Select the lo west brake current setting that will brake satisfactorily.

ATTENTION: Accu-Stop is not int ended to be used as an emergency stop. Refer to the applicable standards for emergency stop requirements.

SMC Dialog Plus Smart Motor Controller

Accu-Stop Option

Figure 3.29 Typical Wiring Diagram for Accu-Stop Option

3-37

Control Power

➁

Accu-Stop

➀

Stop

Start

➀

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

3-38

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Programming - Soft Start with Accu-Stop Option

The basic parameter set-up for Soft Start selection with Accu-Stop option follows:

Para mete r Range

SMC Option

“Accu-Stop” will be displayed.

Starting Mode

Allows the user to program the SMC Dialog Plus controller for the type of starting that best fits the application.

Ramp Time

This sets the time period during which the controller will ramp the output voltage.

Initial Torque

The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter.

Kickstart Time

A boost of 550% of full load current is provided to the motor for the programmed time period.

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19, and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

A third auxiliary contact is provided between terminal 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

Contact 3 Config

This parameter provides the user with the ability to program the “powered up” state of the third auxiliary contact.

Slow Speed Sel

This parameter allows the user to program the Preset Slow Speed that best fits the application.

Slow at Start

This parameter allows the user to activate or deactivate the Preset Slow Speed.

Slow Accel Cur.

This parameter allows the user to program the Preset Slow Speed acceleration current.

—

Soft Start, Current Limit

0 to 30 seconds

0 to 90% of locked rotor torque

0.0 to 2.0 seconds

0 to 10 seconds

Off, On

Normal, Up-to-speed

Normal, Fault

N.O., N.C.

High, Low

Off, On

0 to 450% of full load current

SMC Dialog Plus Smart Motor Controller

Programming - Soft Start with Accu-Stop (cont.)

Parameter Range

Slow Running Cur

This parameter allows the user to program the Preset Slow Speed running current.

Brake to Stop

This parameter allows th

the controller to brake from full speed to zero speed.

Braking Current

Allows the user to program the percentage of braking current applied to the motor during the stop sequence. With the SMC Smart Motor Braking option, this is the current applied to bring the motor to zero speed.

Stopping Current

Allows the user to program the percentage of braking current applied to bring the motor from Preset Slow Speed to zero speed.

Parameter Mgmt

The newly programmed parameters values can be saved to memory or the factory default parameter values can be recalled.

e user to program

0 to 450% of full load current

No, Yes

0 to 450% full load current

0 to 400% of full load current

Ready, Default Init., Recll Frm EE, Store In EE

3-39

3-40

①

②

Slow Speed Braking

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Accu-Stop Option (cont.)

Figure 3.30 Accu-Stop Option Sequence of Operation

100%

Motor Speed

Push Button

Start

Closed

Open

Stop

Closed

Open

Accu-Stop

Closed

Open

Auxiliary Contacts

Slow

Speed

Start

Slow Speed

Run

Time (seconds)

Braking

Slow Speed Braking/Coast

Accu-Stop

Norma

If Coast-to-rest Selected.

Up-to-speed

① ②

Slow Speed Start Select “On .”

When Accu-Stop push button is closed, start/stop function is disabled.

ATTENTION: The user has the ultimat e responsibility to determine which stopping mode is best suited to th

applicati on and will meet applicable standards for operator safety o n a parti cular machine.

SMC Dialog Plus Smart Motor Controller

Motor

Speed

100%

Start

Run Slow

Speed

Braking

7% or 15%

Stop

Coast-to-rest

Time (seconds)

3-41

Accu-Stop/Slow Speed with Braking Option

The Slow Speed with Braking portion of this option combi nes the benefits of the SMB Smart Motor Braking and Preset Slow Speed options for a pplications th at require slow set-up speeds and braking to a stop.

Figure 3.31 Slow Speed with Braking Option

ATTENTION: Slow speed runnin g is not in tended for continuous operation due to reduced motor cooling.

ATTENTION: Braking may cause motor heating and

equipment vibration depending on braking current,

frequency of braking, and duration of braking cycle. Select the lo west brake current setting that will brake satisfactorily.

ATTENTION: Slow Speed with Braking is not intended to be used as an emergency stop. Refer to th applicable standards for emergency stop requirements.

3-42

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Slow Speed with Braking Capability

Figure 3.32 Typical Wiring Diagram for Slow Speed with Braking Capability

Control Power

Stop

➀

11 12 13 14 15 16 17 18 19 20

➁

Slow Speed

➀

Brake

Start

➀

21 22 23 24 25 26 27 28 29 30

Customer supplied.

①

Refer to the controller nameplate to verify the rating of the control power input voltage.

②

SMC Dialog Plus Smart Motor Controller

3-43

Programming - Soft Start with Slow Speed with Braking Capability

The basic parameter set-up for Soft Start Selection with Slow Speed with Brak ing capa bility follows:

Para mete r Range

SMC Option

“Accu-Stop” will be displayed.

Starting Mode

Allows the user to program the SMC Dialog Plus controller for the type of starting that best fits the application.

Ramp Time

This sets the time period during which the controller will ramp the output voltage.

Initial Torque

The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter.

Kickstart Time

A boost of 550% of full load current is provided to the motor for the programmed time period.

Stall Delay

Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out.

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded for an extended period of time.

Aux Contacts 1&2

Two form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19, and

20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

A third auxiliary contact is provided between terminal 29 and 30. Aux Contact 3 allows the user to program the operation of the contact.

Contact 3 Config

This parameter provides the user with the ability to program the “powered up” state of the third auxiliary contact.

Slow Speed Sel

This parameter allows the user to program the Preset Slow Speed that best fits the application.

Slow at Start

This parameter allows the user to activate to deactivate the Preset Slow Speed.

Slow Accel Cur.

This parameter allows the user to program the Preset Slow Speed acceleration current.

—

Soft Start, Current Limit

0 to 30 seconds

0 to 90% of locked rotor torque

0.0 to 2.0 seconds

0 to 10 seconds

Off, On

Normal, Up-to-speed

Normal, Fault

N.O., N.C.

High, Low

Off, On

0 to 450% of full load current

3-44

SMC Dialog Plus Smart Motor Controller

Control Options (cont.)

Programming - Soft Start with Slow Speed with Braking Capability (cont.)

Para meter Range

Slow Running Cur

This parameter allows the user to program the Preset Slow Speed running current.

Brake to Stop

This parameter allows the user to program the controller to brake from full speed to zero speed.

Braking Current

Stopping Current

Allows the user to program the percentage of braking current applied to bring the motor from Preset Slow Speed to zero speed.

Parameter Mgmt

The newly programmed parameters values can be saved to memory. or the factory default parameter values can be recalled.

0 to 450% of full load current

No, Yes

0 to 400% full load current

0 to 450% of full load current

Ready, Default Init., Recll Frm EE, Store In EE

SMC Dialog Plus Smart Motor Controller

Start Brake

Motor Speed

100%

Push Button

Start

Stop

Slow Speed

Auxiliary Contacts

Normal

Up-to-speed

Open

Closed

Braking

Run Slow

Speed

Time (seconds)

Slow Speed with Braking Capability (cont.)

Figure 3.33 Slow Speed with Braking Capability Sequence of Operation

3-45

ATTENTION: The user has the ultimate responsi bility to determine which stopping mode is best suited to th

applicati on and will meet applicable standards for operator safety o n a parti cular machine.

Chapter 4

Application Profiles for the SMC Dialog Plus Controller

n this chapter, a few of the many possible applications for the SMC Dialog Plus controller are described. The basis for selecti ng particular control method is also de tailed. Illustrations are included to help iden t if y the pa rticular applicat ion. Motor rating s a re specified, but the ratings may vary in other typical applications.

For example, a tumbler drum is described as requiring the Soft Start feature. The application is examined further to determine how the SMC Dialog Plus controller options can be used to improve the tumbler drum performance and productivity.

4-2

Air Filter

Application Profiles for the SMC Dialog Plus Controller

Figure 4.1 Compressor with Soft Start

Inlet Valve

Tur n Valve Ports

208-480 Volts 50-250 HP 50/60 Hz

Motor

Problem: A compressor OEM shipped its equipment into overseas

markets. There were many different voltage and frequency req u irements to me e t because o f the compressor’s final destination. Due to power company requirements and mechanical st r ess on the compressor, reduced voltag e starter was requ ired. This made ordering and stocking spare parts difficult. Energy savings was desired because this is typically one of the larger motors in the plant and it frequently runs lightly loaded. Also, because of the size of the motor, the incoming line voltage unbalance was causing excessive heating in th motor.

Solution: The SMC Dialog Plus controller was installed and set for

an 18-second Soft Start, which reduced the voltage to the motor during starting and met the power company requirements. By reducing the voltage, the starting torque was also reduced, minimizing the shock to the compressor. Panel space was saved because the SMC Dialog Plus controller has a built-in overload feature. The Phase Rebalance feature automatically adjusted the voltage out put to balance th e thre e- ph as e c u rre nts drawn by the motor. In addition, the Energy Saver feature optimized the voltage to the motor while it was running unloaded.

Application Profiles for the SMC Dialog Plus Controller

Figure 4.2 Tumbler with Dual Ramp Start

Loading Door

4-3

480 Volts 25 HP

Tumbler Drum

Motor

Drive Chain

Problem: A tumbler used in a na il finishing process was breaking

the drive chain because of uncontrolled acceleration from the across-the-line start. In addition, a reversing starte was needed to position the drum to the top position for loading the product . Because o f the l a ck of controlled acceleration, numerous jogs were used to position the drum. The stopping time was not a con cer n in this application. When in maintenance mode, the tumbl e started unloaded, reaching full speed very quickly. A second starting ramp, for unloaded conditions, was desired. Additionally, single phasing of the motor was a frequent problem , causing prem a ture m o tor f ailure.

Solution: The SMC Dialog Plus controller was installed after the

reversing contactor to control the starting torque of th motor . This decreased the sn apping of the drive chain on start up, which in t ur n i ncreased the life of the ch a in and reduced the downtime on the tumbler. In addition, the SMC Dialog Plus controller made i t eas ie r t o j o g the drum into position for loading and unloading. (The SMC Dialog Plus controller slowed the acceleration rate to prevent overshoot.) When in maintenance mode, the Dual Ramp Start feature of the SMC Dialog Plus controller was utilized to provide a soft start specifically for no lo ad con ditions. Thi s improved the productivity of the loading and unloading process. Further, the SMC Dialog Plus controller quickly detected a phase failure during either t he st ar ting or r u nn i ng mo d es. The controller would shut off with a “line fault” condition and prevent restarting t he m o tor until the line had been corrected. This provided additional protection to the motor and system.

4-4

Application Profiles for the SMC Dialog Plus Controller

Figure 4.3 Tumbler with Soft Start and SMB Smart Motor Braking Option

480 Volts 150 H

Loading Door

Tumbler Drum

Motor

Drive Chain

Problem: A tumbler drum used in the de-burring pro cess was

breaking the drive c h ain becau se of the uncontrolled acceleration from the across-the-line starte r. To increase production on the drum, the coasting time on stop had to be reduced. Previous solutions were a separate soft start package plus a motor brake, which required additional panel space and power wiring. A small enclosure siz and simplified power wiring were needed to reduce the cost of the controls. Because a PLC was controlling several other processes i n t he facility, communi cation capabilities were desired.

Solution: The SMC Dialog Plus controller with the SMB Smart

Motor Braking option was installed on the process. The Soft Start provided a smooth acceleration of the drive chain, which reduce d downtime. The controlled acceleration made positioning for loading/unloading easier. The SMB Smart Motor Braking option allowed the system to be stopped quickly, improving productivi ty. Further, the SMB Smart Motor Braking option did not require additional panel space or wiring. The SMC Dialog Plus controller’s built-in o verload elim inated the need to mount an external overload relay in the enclosure, saving further pan el space. The communic a tion feature of the SM C Dialog P lus controller allowed for remote starting and stopping of th process f rom a PLC.

Application Profiles for the SMC Dialog Plus Controller

Figure 4.4 Tumbler with Accu-Stop Option

Loading Door

4-5

480 Volts 150 H

Tumbler Drum

Motor

Drive Chain

Problem: A tumbler drum used in a hide processing plant required

a controlled acceleration to prevent the drive chain from breaking. In addition, it was desirable to minimize the loading and unloading time. The drum would coast for a long period of ti me before stop pi ng for unloading. Previously, a soft start with electronic brake had been applied. This method still required excessive jogging for loading and unloading, which resulted in extended production times. It also required additio nal panel space and wiring for the brake. Consequently, higher installation costs were incurred.

Solution: The SMC Dialog Plus controller with the Accu-Stop

option was installed. This allowed the dr um t o b positioned fo r loading using th e Pres et Slow Speed. For unloading, the drum was rotated at Preset Slow Speed and then accurately stopped. This in crea s ed the productivity of the loading/unloading cycle. The SMC Dialog Plus controller required no additional panel space or power wiring, facilitating a smooth retrofit and reducing the installation costs.

4-6

Application Profiles for the SMC Dialog Plus Controller

Figure 4.5 Pump with Soft Start

Ground Level

Check Valve

Motor

480 Volts 30 HP

Pump

Problem: A municipal water company was experiencing problems

with pump i mpellers b ei n g damag ed. The damage occurred during an across-the-line start and was caused by the heavy shock to the impeller. The pumping station motor was over 100 feet below ground, making repair costly. For maintenance scheduling purposes, an elapsed time meter measuring motor running time had to b installed in the enclosure. Additional concerns were energy consumption and frequent line failures, which resulted in single phasing the motor.

Solution: The SMC Dialog Plus controller was installed, providing

a controlled acceleration of the motor. By decreasing the torque during start-up, the shock to the impeller was reduced. The SMC Dialog Plus controller’s built-in Energy Saver feature was automatically activated whenev er the pump was lightly l oade d for long periods of time. Panel space was saved by employing the built-in elapsed time meter. The SMC Dialog Plus controller’s line diagnostics detected the pre-start and running single phase condition and shut off the motor, thereby protecting against motor damage.

Application Profiles for the SMC Dialog Plus Controller

Figure 4.6 Pump with Pump Control Option

480 Volts 150 HP

Motor

4-7

Check Valve

Intake

Outlet

Pump Housing

Problem: A municipal pump wa s uti lizing a soft start co n tr oller

with soft stop to control the pump motor. The soft stop was controlling the motor in an open loop fashion by reducing the voltage to the motor. Because there was not enough torque provided t o the motor to dr ive the load, the motor’s stall point was quickly reached. During the stop mode, severe surges were causing pipe vibration and breakage.

Solution: The SMC Dialog Plus controller with the Pump Control

option was installed. The Pump Control option removed the surges by controlling the speed of the motor during starting and stopping. The microprocessor inside the SMC Dialog Plus controller analyzed the motor variables and generated control commands to reduce the surges in the system.

4-8

Application Profiles for the SMC Dialog Plus Controller

Figure 4.7 Bandsaw with Soft Start

480 Volts 300 HP

Saw Blade

Log

Carriage

Motor

High Inertia Wheels

Problem: Because of the remote location of the facility and powe

distribution limit a tio ns, a reduced voltag e starter was needed on a ba ndsaw applicat i on. The saw was turned off only during shift changes. When the saw b lade became dull, the curre nt drawn by the motor increased. Therefore, an ammeter was required. Metering th application for jam con diti on s w as a necessity. In addition, single phasing of the motor was a problem because of distribution limitations.

Solution: The SMC Dialog Plus controller was installed to provid

a reduced voltage start. This minimized the starting torque shock to the system. The Energy Saver feature was activated whenever the bandsaw was running lightly loaded. The current monitoring and jam detection features of the SMC D ial og Plu s con troll e r w ere implemented, saving valuable panel space and the cost o purchasing dedicated monitoring devices. The controller’s built-in programmable ove rl oad protection was utilized. The SMC Dialog Plus controller’s diagnostic capabilities would detect single phasing and shut the motor off accordingly.

Saw Blade

Motor

Application Profiles for the SMC Dialog Plus Controller

Figure 4.8 Bandsaw with Soft Start and SMB Smart Motor Braking Option

480 Volts 250 HP

Log

Carriage

High Inertia Wheels

4-9

Problem: A bandsaw application required a reduced voltage start

because o f power company res trictions. A brake package was required to reduce the stopping time of the saw. Previously, an autotransformer had been used to start the saw. The saw was stopped by sawing down. Sawing down is accomplished by running logs through the saw after the motor has been de-energized, which results in large amount of scrap lumber . Other stopping methods using de d ic ated b raking devic es were investigated but were unacceptable because of overly complex installation. Additionally, other stopping methods required panel space for the brake module, brak contactors and time rs , and they offered no z er o s peed detection.

Solution: The SMC Dialog Plus controller with the SMB Smart

Motor Braking option was installed. It provided the reduced voltage start needed to meet the po wer company restrictions. The SMB Smart Motor Braking option did not require additi onal panel space or DC braking contactors. The starting and stopping control was furnished in a single modular design, providing ease of installation.

4-10

Application Profiles for the SMC Dialog Plus Controller

Figure 4.9 Bandsaw with Soft Start and Slow Speed with Braking Option

480 Volts 300 HP

Saw Blade

Log

Carriage

Motor

High Inertia Wheels

Problem: A bandsaw required 25 minutes to coast to a stop to

routinely c ha nge the saw blade. A braking package was required to reduce the stopp in g time. Othe r me thods using de d ic ated b raking devic es were investigated but were unacceptable because of overly complex installation. These methods required additional panel space for the brake module, brake contactors, and timers. Because of p ot e nt ia l alignment problems, it was dangerous to bring the saw up to full speed afte installing a new blade.

Solution: The SMC Dialog Plus controller with the Slow Speed

with Braking option was installed. It provided a Preset Slow Speed, allowing the saw blade tracking to b inspected before the motor was brought to full speed. The brakin g option of the SMC Dialog P l us controlle did not require additional panel space or DC braking contactors. Starting and stopping control was furnished in a single modular unit, p roviding ease of installation.

Application Profiles for the SMC Dialog Plus Controller

Figure 4.10 Trolley with Dual Ramp Start

240 Volts 10 HP

Motor

4-11

Tow Chai n

Problem: A trolley carrying ceramic tiles entered a kiln for heating.

When heated, the trolley exited the kiln and entered th production area. Any abrupt mov e ment caused the tiles to fall over, resulting in damaged product. An across-theline starter, gearbox, and fluid coupling were used to perform this work, with some lost production expected.

Solution: The SMC Dialog Plus controller was installed to utiliz

acceleration control, which resulted i n improved productivity and a reduction i n damaged product. Th maintenance ti me for the fluid coupling was also minimized. Further, the Dual Ramp Start feature allowed for two separate acceleration ramps to be programmed; one ramp for a start w ith a heavy load, and on e for a start with the lighter tiles loaded.

4-12

Application Profiles for the SMC Dialog Plus Controller

Figure 4.11 Trolley with Soft Start and Preset Slow Speed Option

240 Volts 10 HP

Tow Chai n

Motor

Problem: A trolley application required a slow speed, as well as

soft start, to eliminate product tipping while accelerating from rest. A variable frequency drive was considered. However, variable speed was not required during the run cycle. A cost-effective solution was desired.

Solution: The SMC Dialog Plus controller with the Preset Slow

Speed option was i ns ta lle d . The Pr eset Slow Speed of 15% of rated speed was selected. After running at 15 of full speed for a few seconds, a 25-second ramp start was selected to acc elerate the m o to r to full s pe ed. The SMC Dialog Plus controller with Preset Slow Speed helped protect against product tipping during start-up. In addition, the desired accel erati on cont rol was provi ded at a reasonable cost.

Application Profiles for the SMC Dialog Plus Controller

Figure 4.12 Exhaust Fan with Soft Start

Exhaust Intake

Belts

Motor

4-13

480 Volts 60 HP

Problem: The belts on an exhaust fan were frequently breaking,

causing maintenance problems. In addition to the high cost of the belts, the fan belt guard was cumbersome to remove. The high starting torque from the motor was major contr ibu tor to t h e belt wear. Also, re mote st ar ting and stoppin g of the fan f ro m a PLC w as desired. Panel space was limit ed, re qu i ring a compact device.

Solution: The SMC Dialog Plus controller was installed as a

retrofit to the existing starter. The ramp time was set for 28 seconds, facilitating a smooth acceleration while reducing the starting torque of the motor and minimizing the mechani ca l shock to th e be lts. The SMC Dialog Plus controller ha s commu ni c ation capabilities built-in, allowing for remote control via a PLC. It also has builtin overload protection, which saved valuable panel space.

4-14

Application Profiles for the SMC Dialog Plus Controller

Figure 4.13 Palletizer with Dual Ramp Start

480 Volts 1-1/2 HP

Motor

Problem: A palletizer moved ce r eal boxes throu gh a pac kaging

process to a shrink wrap machine. Across-the-line starting caused unwanted product spillage, as well as an interruption of production due to the uncontrolled torque from the motor on start-up. Since several types of cereals, in different size boxes , wer e produced on the same line, the ability to match the acceleration ramp to the cereal was desired. The facility was standardized on Allen-Bradley’s Motor Control Centers. Therefore, the installation of the soft start in an MCC plug-in bucket was required.

Solution: The SMC Dialog Plus controller was installed , furnishing

a controlled acceleration, reducing the shock to the load, and eli minating product spillage. The Dual Ramp Start feature al lowed the controller to be programmed with two separate acceleration ramps, more closely matching the motor acceleration with the cereal produced. The SMC Dialog Plus controller was installed in a Motor Control Center plug-in bucket, maki ng the packaging attractive t o the customer and eliminating the need for a stand-alone enclosure.

Application Profiles for the SMC Dialog Plus Controller

Figure 4.14 Palletizer with Soft Start and Preset Slow Speed Option

240 Volts

7.5 HP

Bander

Paper Stacks

Motor

4-15

Problem: Stacks of paper on a conveyor were moved to a bander

and then moved through the bander process onto a skid. When the papers were loose, a cont ro lled low speed acceleration into the bander was required. After the papers were bound, a soft start was needed t o keep the bundles from falling off the palletizer. The expense of a variable frequency drive to control the motor speed was not feasible.

Solution: The SMC Dialog Plus controller with the Preset Slow

Speed option was insta lled, eliminat ing the need for frequent jogging of the conveyor to align the load with the bander . The loose papers were moved into the bander at 15% of full speed. A Soft Start was used to accelerat the motor to full speed, and load the bound stacks on th skid. The SMC D ia l og Plus controller was a cost effective method of achieving the results required by the application.

4-16

Application Profiles for the SMC Dialog Plus Controller

Figure 4.15 Rock Crusher with Soft Start

Motor: 250

480 Volts

Starts: Unloaded

Gearbox

Motor

Discharge

Problem: Because of the remote location of a rock quarry, the

power company requi red a reduced voltag e start on all motors over 150 HP. The starting current on these larg motors strain ed the capacity of the p o we r sy st em, causing severe voltage dips. When the rock crusher became overloaded, th e c urrent drawn by th e motor incr eased. Therefore, current monitoring capabilities within the soft starter were required. Because the conveyor feeding the rock crusher was controlled by a PLC, communications between the soft star ter and a PLC w a s n ec es sary. The rock crusher ran unloaded at times, and occasionally stall or jam would occur.

Solution: The SMC Dialog Plus controller was installed, meeting

the power company requirements. The metering capabilities of the SMC Dialog Plus controller allowed the current draw n by t he motor to be monitored . With the built-in communications capabilities, the motor current could then be communicated to the PLC. When the motor current reached a specified limit, the conveyor feeding the rock cr us her could be slowed. By slowing the conveyor, a jam condition in the rock crusher was avoided. The Energy Saver feature of the controlle reduced the voltage to the motor when the system was running lightly loaded. The stall and jam detection capabilities of the SMC Dialog Plus controller would shut off the motor when a stall or jam condition oc curred.

Input

Shredder Teeth

Application Profiles for the SMC Dialog Plus Controller

Figure 4.16 Shredder with Soft Start

Scrap

4-17

480 Volts 200 HP

Motor

Output

Gearbox

Problem: Because of power company restrictions, a metal shredder

required a reduced voltage start. Occasionally, a jam would occur during the shredding process. Additionally, the equipment ran unloaded for long periods. An autotransformer-type starter had been used in the past.

Solution: The SMC Dialog Plus controller was installed,

facilitating a re duced vo lta ge start. The controller also provided jam detection, which helped protect against excessive motor heating when a ja m condition was encounter ed. Th e Energy Saver feature o f t he SMC Dialog Plus controller reduced the volt ag e to the motor when the motor was running lightly loaded. The built-in overload feature of the control ler saved valuable panel space.

4-18

Application Profiles for the SMC Dialog Plus Controller

Figure 4.17 Hammermill with Current Limit Start

480 Volts 250 HP

Hammer

Feed

Belts

Motor

Problem: A hammermill with a high inertia load required a reduced

voltage sta rt be cause of pow er comp any restrictions. High torque on start-up was causing belt wear. Panel space was very limited. Traditional reduced voltage starters would not fit in the available space.

Solution: The SMC Dialog Plus controller was installed and set for

a 23-second, 425% current limit start, which met the power company’s requirement for the reduced voltage start. The belt life was extended since the starting torque was re duced. A current limit start was selected to quickly break away the high inertia load and still provide a reduced volt age start . The Energ y Saver feature was used when the mill was running lightly loaded. The compact size of the SMC Dialog Plus controller, along with th built-in overload feature, enabled the controller to fit into the available panel space.

Rockwell Automation 150 MNL User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read!

Important User Information

Table of Contents

Description

Modes of Operation

Features

Adjustments

Wiring Diagrams

Suitable Replacement

Applications

Applications (cont.)

Applications (cont.)

Applications (cont.)

Description

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

Modes of Operation (cont.)

Features

Adjustments

Wiring Diagram

Options

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

Description

Starting Methods

Features

Adjustments

Typical Wiring Diagrams (without options)

Control Options