Rockwell Automation 150 SMC-Flex User Manual

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SMC™-Flex

BULLETIN 150

USER MANUAL FOR SERIES B

Important User Information

ATTENTION

IMPORTANT

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited.

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

Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

Identifies information that is critical for successful application and understanding of the product.

Trademark List Accu-Stop, Allen-Bradley Remote I/O, RSNetworx, PLC, PowerFlex, SLC, SMC, SMC-2,

SMC-Flex, SMC PLUS, SMC Dialog Plus, SMB, and STC are trademarks of Rockwell Automation. ControlNet is a trademark of ControlNet International, Ltd. DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association (ODVA). Ethernet is a registered trademark of Digital Equipment Corporation, Intel, and Xerox Corporation. Modbus is a trademark or registered trademark of Schneider Automation Inc. Profibus is a registered trademark of Profibus International.

European Communities (EC) Directive Compliance

If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.

EMC Directive

This product is tested to meet the Council Directive 89/336/EC Electromagnetic Compatibility (EMC) per EN/IEC 60947-4-2.

This product is intended for use in an industrial environment.

Low Voltage Directive

This product is tested to meet Council Directive 73/23/EEC Low Voltage, per EN/IEC 60947-4-2.

This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection.

Notes

Table of Contents

Chapter 1 Product Overview

Other Related Documents ........................................................................... 1-1

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

Operation ....................................................................................................1-2

Modes of Operation (Standard) ....................................................................1-2

Soft Start ..............................................................................................1-2

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

Current Limit Start ................................................................................1-3

Dual Ramp Start ...................................................................................1-4

Full Voltage Start ..................................................................................1-4

Preset Slow Speed ...............................................................................1-5

Linear Speed Acceleration.....................................................................1-6

Soft Stop ..............................................................................................1-7

Control Options ...........................................................................................1-8

Modes of Operation (Pump Control) .............................................................1-8

Pump Control Option ............................................................................1-8

Modes of Operation (Braking Control) ..........................................................1-9

SMB Smart Motor Braking Option .........................................................1-9

Accu-Stop Option ...............................................................................1-10

Slow Speed with Braking Option .........................................................1-10

Protection and Diagnostics ........................................................................1-11

Overload ............................................................................................1-11

Underload ...........................................................................................1-11

Undervoltage ......................................................................................1-13

Overvoltage ........................................................................................1-13

Unbalance ..........................................................................................1-13

Stall Protection and Jam Detection .....................................................1-14

Ground Fault ......................................................................................1-15

Ground Fault Trip ...............................................................................1-16

Ground Fault Alarm ............................................................................1-16

Thermistor/PTC Protection ..................................................................1-17

PTC Trip .............................................................................................1-17

Excessive Starts/Hour .........................................................................1-18

Overtemperature ................................................................................1-18

Open Gate ..........................................................................................1-18

Line Faults .........................................................................................1-18

Metering ...................................................................................................1-19

I/O ............................................................................................................1-19

Communication .........................................................................................1-20

Programming ............................................................................................1-20

Status Indication .......................................................................................1-21

Chapter 2 Installation

Degree of Protection ...................................................................................2-1

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

Unpacking ...................................................................................................2-1

Inspecting ...................................................................................................2-1

Storing ........................................................................................................2-1

Lifting .........................................................................................................2-2

General Precautions .................................................................................... 2-3

Heat Dissipation ..........................................................................................2-3

Enclosures ..................................................................................................2-4

Mounting ....................................................................................................2-5

Power Factor Correction Capacitors .......................................................... 2-12

Protective Modules ................................................................................... 2-13

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

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

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

Electromagnetic Compatibility (EMC) ......................................................... 2-14

Enclosure ...........................................................................................2-14

Wiring ................................................................................................2-14

Additional Requirements ....................................................................2-14

Chapter 3 Wiring

Terminal Locations .....................................................................................3-1

Power Structure .......................................................................................... 3-3

Power Wiring .......................................................................................3-3

Line Connected ....................................................................................3-4

Delta Connected ..................................................................................3-4

Power Lugs ................................................................................................3-5

Control Power .............................................................................................3-7

Control Wiring ......................................................................................3-7

Controllers rated 5…480 A ..................................................................3-7

Controllers rated 625…1250 A ............................................................3-7

Control Wire Specifications ................................................................3-11

Fan Power ................................................................................................3-11

Fan Terminations ...............................................................................3-11

Control Terminal Designations ..................................................................3-12

Standard Controller Wiring Diagrams ........................................................ 3-13

Soft Stop, Pump Control, and SMB Smart Motor Braking ...........................3-24

Preset Slow Speed .................................................................................... 3-28

Slow Speed with Braking ..........................................................................3-30

Sequence of Operation ..............................................................................3-31

Special Application Considerations ............................................................3-36

Use of Protective Modules ..................................................................... 36

Multi-motor Applications ........................................................................... 3-38

SMC-Flex Controller as a Bypass to an AC Drive .......................................3-39

SMC-Flex Controller with a Bulletin 1410 Motor Winding Heater ...............3-40

Chapter 4 Programming

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

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

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

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

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

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

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

Electrically Erasable Programmable Read-only Memory (EEPROM)....... 4-6

Parameter Modification................................................................................ 4-7

Soft Start .................................................................................................... 4-8

Current Limit Start ......................................................................................4-8

Dual Ramp Start ..........................................................................................4-9

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

Linear Speed .............................................................................................4-10

Programming Parameters .........................................................................4-11

Standard ............................................................................................4-11

Pump Control .....................................................................................4-12

Braking Control ..................................................................................4-12

Basic Set Up .............................................................................................4-14

Motor Protection .......................................................................................4-15

Example Settings ......................................................................................4-16

Undervoltage ......................................................................................4-16

Overvoltage ........................................................................................4-16

Jam ...................................................................................................4-16

Underload ..........................................................................................4-16

Chapter 5 Metering

Chapter 6 Optional HIM Operation

Chapter 7 Communications

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

Viewing Metering Data ................................................................................5-1

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

Human Interface Module .............................................................................6-1

Standard .............................................................................................. 6-1

Pump Control .......................................................................................6-2

Braking Control ....................................................................................6-2

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

Communication Ports ..................................................................................7-1

Human Interface Module............................................................................. 7-2

Keypad Description .............................................................................. 7-2

Connecting the Human Interface Module to the Controller ....................7-4

HIM Control Enable ...............................................................................7-4

Control Enable .............................................................................................7-6

Loss of Communication and Network Faults ................................................7-6

SMC-Flex Specific Information ....................................................................7-6

Default Input/Output Configuration ..............................................................7-7

Variable Input/Output Configuration .............................................................7-7

SMC — Flex Bit Identification ..................................................................... 7-8

Reference/Feedback ...................................................................................7-9

Parameter Information ................................................................................7-9

Scale Factors for PLC Communication .........................................................7-9

Read Example ......................................................................................7-9

Write Example ......................................................................................7-9

Display Text Unit Equivalents ....................................................................7-10

Configuring DataLinks ...............................................................................7-10

Rules for Using DataLinks ..................................................................7-10

Updating Firmware ....................................................................................7-10

Chapter 8 Diagnostics

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

Protection Programming .......................................................................8-1

Fault Display ...............................................................................................8-1

Clear Fault ..................................................................................................8-2

Fault Buffer .................................................................................................8-2

Fault Codes ..........................................................................................8-3

Fault and Alarm Auxiliary Indication for Fault or Alarm ................................8-3

Fault Definitions .......................................................................................... 8-4

Chapter 9 Troubleshooting

Appendix A Specifications

Appendix B Parameter Information

Appendix C Renewal Parts

Appendix D Accessories

Introduction ................................................................................................9-1

Power Module Check ..................................................................................9-7

Shorted SCR Test .................................................................................9-7

Functional Design Specifications .................................................................A-1

Electrical Ratings ........................................................................................A-2

Short Circuit Protection ...............................................................................A-3

Environmental .............................................................................................A-5

Mechanical .................................................................................................A-5

Other ..........................................................................................................A-6

Approximate Dimensions and Shipping Weights ..........................................A-6

Open Type Controllers ..........................................................................A-6

Enclosed Type Line-Connected Controllers ...........................................A-7

Parameter Information................................................................................ B-1

Renewal Parts ............................................................................................C-1

Contactor Replacement Installation Instructions for 625…1250 A units

...................................................................................... D-1

Appendix E Accessories

Appendix F Renewal Parts Cross Reference

Accessories ................................................................................................ E-1

Renewal Part Cross Reference ....................................................................F-1

Product Overview

Chapter 1

Other Related Documents • Quick Start — Publication 150-QS001_

• Renewal Part Instructions — 41053-277-01 (5…85 A) 41053-328-01 (108…135 A) 41053-228-01 (201…480 A) 41053-367-01 (625…1250 A)

• Selection Guide — Publication 150-SG009_

• Application Guide — Publication 150-AT002_

①

-EN-P

①

-EN-P

①

-EN-P

Description The SMC™-Flex controller offers a full range of starting modes as

standard:

• Soft Start with Selectable Kickstart

• Current Limit with Selectable Kickstart

• Dual Ramp Start with Selectable Kickstart

• Full Voltage Start

• Preset Slow Speed

• Linear Speed Acceleration with Selectable Kickstart (requires

Tach feedback)

• Soft Stop

Other features that offer further user benefit include:

• Expanded protective features

• Metering

•I/O

• Communication capability

Innovative starting and stopping options provide enhanced performance:

• Pump Control

• Braking Control

• Smart Motor Braking (SMB™)

• Accu-Stop™

• Slow Speed with Braking

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

➀ Latest revision

1-2 Product Overview

Percent Voltage

100%

Initial

Torque

Time in Seconds

Start

Run

Ramp Time

Current Limit

Operation The SMC-Flex controller can operate standard squirrel-cage

induction motors rated 1…1250 A or Star-delta (wye-delta) type motors rated 1.8…1600 A; up to 690V AC, 50/60 Hz. Depending upon the controller type ordered, the control power input can range from 100…240V AC to 24V AC/DC. Please verify voltage on product, before applying power.

Modes of Operation (Standard) Soft Start

This mode has the most general application. The motor is given an initial torque setting, which is user-adjustable from 0…90% of locked rotor torque. From the initial torque level, the output voltage to the motor is steplessly increased during the acceleration ramp time. The acceleration ramp time is user-adjustable from 0…30 seconds. If the SMC-Flex controller senses that the motor has reached the up-tospeed condition during the voltage ramp operation, the internal bypass contactor will be pulled in.

Figure 1.1 Soft Start

①

➀ Kickstart is also available with Soft Start.

Product Overview 1-3

00%

que

)

600%

50%

)

Selectable Kickstart

This feature provides a boost at startup to break away loads that require a pulse of high torque to get started. This is intended to provide a pulse of current that is selectable from 0…90% of locked rotor torque. Selectable kickstart is user-adjustable from

0.0…2.0 seconds.

Figure 1.2 Selectable Kickstart

Percent Volta

Initial

Tor

electable Kickstar

oast-to-res

Soft Sto

tar

Current Limit Start

Time (seconds

➀

Soft Sto

This starting mode provides a true current limit start; it is used when limiting maximum starting current is necessary. The Current Limit level is user-adjustable from 50…600% of the motor full load ampere rating; and the current limit time is user-adjustable from 0…30 seconds. If the SMC-Flex controller senses that the motor has reached the up-to-speed condition during the current limit starting mode, the internal bypass contactor will be pulled in.

Figure 1.3 Current Limit Start

Percent Full

urren

Load

tar

Time (seconds

➀ Kickstart is also available with Current Limit Start.

1-4 Product Overview

Ramp #2

Ramp #1

Time in Seconds

Percent Voltage

100%

Initial

Torque #2

Initial

Torque #1

Start #1

Start #2

Run #1

Run #2

Current Limit 2

Current Limit 1

100%

Percent Voltage

Time in Seconds

Dual Ramp Start

➀

This starting mode is useful on applications that have varying loads (and therefore varying starting torque requirements). Dual Ramp Start allows the user to select between two separate start profiles with separately adjustable ramp times and initial torque settings.

Figure 1.4 Dual Ramp Start

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

Full Voltage Start

This starting mode is used for applications requiring across-the-line starting. The output voltage to the motor will reach full voltage within 1/4 second.

Figure 1.5 Full Voltage Start

Product Overview 1-5

00%

peed

)

ATTENTION

Preset Slow Speed

This option can be used in applications that require a slow speed jog for general purpose positioning. Preset Slow Speed provides either 7% of base speed (low) or 15% of base speed (high) settings in the forward direction. Reverse can also be programmed and offers 10% of base speed (low) and 20% of base speed (high) settings.

Figure 1.6 Preset Slow Speed

Motor

Forwar

15% - Hi

7% - Lo

10% - Lo

20% - Hi

Time (seconds

Rever

tar

Slow speed running is not intended for continuous operation due to reduced motor cooling.

1-6 Product Overview

00%

peed

)

Stop

ATTENTION

Linear Speed Acceleration

➀

The SMC-Flex has the ability to control the motor speed during starting and stopping maneuvers. A tach input (0…5V DC) is required to perform this start mode. The start time is selectable from 0…30 seconds and determines the time the motor will ramp from 0 speed to full speed. Kickstart is available with this option.

Figure 1.7 Linear Speed Acceleration

Percent

tar

Time (seconds

➀ Kickstart is also available with Linear Speed Acceleration.

Linear Stop is not intended to be used as an emergency stop. Refer to the applicable standards for emergency stop requirements.

The Linear Stop does not need to be set up even if the linear start has been programmed. The Linear Stop can not brake the motor/load and reduce the stopping time.

Product Overview 1-7

00%

que

)

ATTENTION

Soft Stop

This option can be used in applications that require an extended stop time. The voltage ramp down time is user-adjustable from 0…120 seconds and is adjusted independently from the starting time. The load will stop when the output voltage drops to a point where the load torque is greater than the developed motor torque.

Figure 1.8 Soft Stop

Percent

Volta

Initial

Tor

electable Kickstar

oast-to-res

Soft Sto

tar

Time (seconds

Soft Sto

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

1-8 Product Overview

100%

Motor Speed

Time in Seconds

Pump Start

Ramp Time

Run

Pump Stop

Stop Time

ATTENTION

Control Options The SMC-Flex controller offers the control options described below.

Important: The options listed in this section are mutually exclusive

and must be specified when ordering. An existing controller may be upgraded to another control option by replacing the control module. Consult your local Allen-Bradley distributor.

Modes of Operation (Pump Control)

Pump Control Option

This option reduces surges during the starting and stopping of a centrifugal pump by smoothly accelerating and decelerating the motor. The microprocessor analyzes the motor variables and generates commands that control the motor and reduce the possibility of surges occurring in the system.

The starting time is programmable from 0…30 seconds, and the stopping time is programmable from 0…120 seconds.

Figure 1.9 Pump Control Option

➀

➀ Kickstart is also available with Pump Control.

Pump stopping is not intended to be used as an emergency stop. Refer to the applicable standard for emergency stop requirements.

Pump stopping may cause motor heating depending on the mechanical dynamics of the pumping system. Therefore, select the lowest stopping time setting that will satisfactorily stop the pump.

Product Overview 1-9

100%

Motor Speed

Smart Motor Braking

Coast-to-Rest

Time in Seconds

Automatic Zero Speed Shut-Off

Start

Run

Brake

Stop Time

ATTENTION

Modes of Operation (Braking Control)

SMB™ Smart Motor Braking Option

This option can be used in applications that require reduced stopping times. The SMC-Flex controller incorporates a microprocessor-based system that applies braking current to a motor without any additional equipment. This option offers a user-adjustable braking current setting from 0% to 400% of the motor’s full load current rating. Further, it provides automatic shut-off at zero speed detection.

Figure 1.10 SMB Smart Motor Braking Option

Note: All braking current settings in the range of 1…100% will

provide 100% braking current to the motor.

SMB Smart Motor Braking is not intended to be used as an emergency stop. Refer to applicable standards for emergency stop requirements.

1-10 Product Overview

ATTENTION

Accu-Stop™ Option

This option combines the benefits of the SMB Smart Motor Braking and Preset Slow Speed options. For general purpose positioning, the Accu-Stop option provides a brake from full speed to the preset slow speed setting, then brakes to stop.

Figure 1.11 Accu-Stop Option

Accu-Stop and Slow Speed with Braking are not intended to be used as an emergency stop. Refer to applicable standards for emergency stop requirements.

Slow Speed with Braking Option

The Slow Speed with Braking option provides a jog speed for process set-up and braking-to-stop at the end of the cycle.

Figure 1.12 Slow Speed with Braking Option

Product Overview 1-11

Protection and Diagnostics The SMC-Flex controller provides the protective and diagnostic

features described below.

Overload

The SMC-Flex controller meets applicable requirements as a motor overload protective device. Thermal memory provides added protection and is maintained even when control power is removed. The built-in overload controls the value stored in Parameter 12, Motor Thermal Usage; an Overload Fault will occur when this value reaches 100%. The programming parameters below provide application flexibility and easy setup.

Parameter Range

Overload Class Off, 10, 15, 20, 30 Overload Reset Manual – Auto

Motor FLC

Service Factor

Notes: (1) The factory default setting for Overload Class, which is

10, enables overload protection. The motor’s full load current rating must be programmed to properly set overload protection.

(2) Automatic reset of an overload fault requires the start

input to be cycled in a 2-wire control scheme.

1.0

…2200 A

0.01…1.99

The trip rating is 117% of the programmed FLC.

Figure 1.13 and Figure 1.14 provide the overload trip curves for the available trip classes.

Underload

➀

Utilizing the underload protection of the SMC-Flex controller, motor operation can be halted if a sudden drop in current is sensed.

The SMC-Flex controller provides an adjustable underload trip setting from 0…99% of the programmed motor full load current rating. Trip delay time can be adjusted from 0…99 seconds.

➀ Underload protection is disabled during slow speed and braking operations.

1-12 Product Overview

Approximate trip time for 3-phase balanced

1.0

10.0

100.0

1000.0

10000.0

1 10 2 3 9 8 7 6 5 4

0.1

1.0

10.0

100.0

1000.0

1 10 2 3 9 8 7 6 5 4

10.0

100.0

1000.0

10000.0

2 3 9 8 7 6 5 4

10.0

100.0

1000.0

10000.0

1 10 2 3 9 8 7 6 5 4

Approximate trip time for 3-phase balanced condition from cold start.

Approximate trip time for 3-phase balanced condition from hot start.

100%

100

1000

100000

Percent Full Load Current Setting

Class 10 Class 15 Class 20

Class 30

Auto Reset Times:

Class 10 = 90s Class 15 = 135s Class 20 = 180s Class 30 = 270s

Class 10 Class 15 Class 20 Class 30

Figure 1.13 Overload Trip Curves

Approximate Trip Time (seconds)

1.0

Approximate Trip Time (seconds)

1.0 10

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

condition from cold start.

Figure 1.14 Restart Trip Curves after Auto Reset

Seconds

1000%

Product Overview 1-13

Undervoltage

➀

Utilizing the undervoltage protection of the SMC-Flex, motor operation can be halted if a sudden drop in voltage is detected.

The SMC-Flex controller provides an adjustable undervoltage trip setting from 0…99% of the programmed motor voltage. Trip delay time can be adjusted from 0…99 seconds.

An alarm (pre-fault) indication level can be programmed to indicate the unit is getting close to faulting. The alarm modification information is displayed through the LCD, HIM, Communication (if applicable) and alarm contact closing.

Overvoltage

➀

Utilizing the overvoltage protection of the SMC-Flex, motor operation can be halted if a sudden increase in voltage is detected.

The SMC-Flex controller provides an adjustable overvoltage trip setting from 0…199% of the programmed motor voltage. Trip delay time can be adjusted from 0…99 seconds.

Unbalance

➀

The SMC-Flex is able to detect an unbalance in line voltages. Motor operation can be halted if the unbalance is greater than the desired range.

The SMC-Flex controller provides an adjustable unbalance setting from 0…25% of the line voltages. Trip delay time can be adjusted from 0…99 seconds.

➀ Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.

1-14 Product Overview

Stall

600%

Percent

Full

Load

Current

Time (seconds)

Programmed Start Time

100%

Running Jam

Percent

Full

Load

Current

Time (seconds)

User Programmed Trip Level

Stall Protection and Jam Detection

The SMC-Flex controller provides both stall protection and jam detection for enhanced motor and system protection.

• Stall protection is user-adjustable from 0.0…10.0 seconds (in addition to the ramp time programmed).

Figure 1.15 Stall Protection

• An alarm (pre-fault) indication level can be programmed to indicate the unit is getting close to faulting. The alarm modification information is displayed through the LCD, HIM, Communication (if applicable) and alarm contact closing.

• Jam detection allows the user to determine the jam level (up to 1000% of the motor’s FLC rating) and the delay time (up to

99.0 seconds) for application flexibility.

Figure 1.16 Jam Detection

➀➁

➀ Jam detection is disabled during slow speed and braking operation. ➁ Unit will self-protect in a jam condition.

Product Overview 1-15

Ground Fault

In isolated or high impedance-grounded systems, core-balanced current sensors are typically used to detect low level ground faults caused by insulation breakdowns or entry of foreign objects. Detection of such ground faults can be used to interrupt the system to prevent further damage, or to alert the appropriate personnel to perform timely maintenance.

The SMC-Flex’s ground fault detection capabilities require the use of external sensor. Installation of this sensor allows the option of enabling Ground Fault Trip, Ground Fault Alarm, or both.

For the 5…480 Amp devices, the recommended sensor is a Cat. No. 825-CBCT core balance current transformer for 1…5 A corebalanced ground fault protection.

For the 625…1250 A devices, the recommended sensor is shown below and provides 5…25 A core-balanced ground fault protection.

• Manufacturer: Allen-Bradley

• Description: 600 Volt-Rated Current Transformer

• Catalog Number: 1411-126-252

• Ratio: 2500:5

Figure 1.17

BLACK WHITE SHIELD

SHIELD

BLACK

WHITE

➀ Customer supplied. ➁ Cat. No. 825-CBCT or Flex-Core Cat. No. 126-252

Note: When connecting the ground fault sensors, the secondary of

the CT should be shorted until the connection to the Flex control module is completed.

1-16 Product Overview

Ground Fault Trip

The SMC-Flex will trip with a ground fault indication if:

• No other fault currently exists

• Ground fault protection is enabled

• GF Inhibit Time has expired

• GF Current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay

Parameter 75, Gnd Flt Inh Time, allows the installer to inhibit a ground fault trip from occurring during the motor starting sequence and is adjustable from 0…250 seconds.

Parameter 74, Gnd Flt Delay, allows the installer to define the time period a ground fault condition must be present before a trip occurs. It is adjustable from 0.1…250 seconds.

Parameter 73, Gnd Flt Level, allows the installer to define the ground fault current at which the SMC-Flex will trip. It is adjustable from

1.0…5.0 A or 5.0…25 A, depending on the service size.

Important: The ground fault inhibit timer starts after the maximum

phase of load current transitions from 0 A to 30% of the device’s minimum FLA Setting or the GF Current is greater than or equal to 0.5 A. The SMC-Flex does not begin monitoring for a ground fault condition until the Gnd Flt Inh Time expires.

Ground Fault Alarm

The SMC-Flex will indicate a Ground Fault Alarm if:

• No warning currently exists

• Ground fault alarm is enabled

• GF Inhibit Time has expired

• GF Current is equal to or greater than the Gnd Flt A Lvl

Parameter 77, Gnd Flt A Lvl, allows the installer to define the ground fault current at which the SMC-Flex will indicate a warning. It is adjustable from 1.0…5.0 A or 5.0…25 A, depending on the service size.

Parameter 78, Gnd Flt A Dly, allows the installer to define the time period a ground fault alarm condition must be present before a trip occurs. It is adjustable from 0…250 seconds.

Product Overview 1-17

100

250

550

1330

4000

-20°C TNF-20K 0°C TNF- 5K

TNF+15K

TNF+ 5K

TNF

Thermistor/PTC Protection

The SMC-Flex provides terminals 23 and 24 for the connection of positive temperature coefficient (PTC) thermistor sensors. PTC sensors are commonly embedded in motor stator windings to monitor the motor winding temperature. When the motor winding temperature reaches the PTC sensor’s temperature rating, the PTC sensor’s resistance transitions from a low to high value. Since PTC sensors react to actual temperature, enhanced motor protection can be provided to address such conditions as obstructed cooling and high ambient temperatures.

The following table defines the SMC-Flex PTC thermistor input and response ratings:

Table 1.A PTC Input Ratings

Response resistance 3400 Ω ±150 Ω Reset resistance 1600 Ω ±100 Ω Short-circuit Trip Resistance 25 Ω ±10 Ω Maximum Voltage at PTC Terminals (R

Maximum Voltage at PTC Terminals (R Maximum Number of Sensors 6

Maximum Cold Resistance of PTC Sensor Chain 1500 Ω Response Time 800 ms

= 4kΩ) < 7.5V

PTC

= open) 30V

PTC

The following figure illustrates the required PTC sensor characteristics, per IEC-34-11-2.

Figure 1.18 PTC Sensor Characteristics per IEC-34-11-2

PTC Trip

The SMC-Flex will trip with a PTC indication if:

• No other fault currently exists

• PTC protection is enabled

1-18 Product Overview

• The resistance across terminals 23 and 24 is either greater than the relay’s response resistance or less than the short-circuit trip resistance.

Excessive Starts/Hour

The SMC-Flex controller allows the user to program the allowed number of starts per hour (up to 99). This helps eliminate motor stress caused by repeated starting over a short time period.

Overtemperature

The SMC-Flex controller monitors the temperature of the SCRs and Bypass by using internal thermistors. When the power poles’ maximum rated temperature is reached, the unit will shut down and restart is inhibited.

An overtemperature condition can indicate inadequate ventilation, high ambient temperature, overloading, or excessive cycling. After the temperature is reduced to allowable levels, the fault can be cleared.

Open Gate

An open gate fault indicates that improper SCR firing, typically caused by an open SCR gate, has been detected on one of the power poles. Before the controller shuts down, it will attempt to start the motor a total of three times.

Line Faults

The SMC-Flex controller continually monitors line conditions for abnormal factors. Pre-start protection includes:

• Line Fault (with phase indication) – Line voltage loss – Missing load connection – Shorted SCR

Running protection includes:

• Line Fault (no phase indication) – Line voltage loss – Missing load connection

Phase Reversal

➀

protection can be toggled either On or Off.

➀ Phase Reversal protection is functional only at pre-start.

Metering Power monitoring parameters include:

• Three-phase current

• Three-phase voltage

•Power in kW

• Power usage in kWH

•Power factor

• Motor thermal capacity usage

• Elapsed time

Notes: (1) Voltage measurement is not available during the braking

operation of the SMB Smart Motor Braking, Accu-Stop, and Slow Speed with Braking control options.

(2) The elapsed time and kWH values are automatically

saved to memory every 12 hours.

(3) Motor thermal capacity usage is determined by the built-

in electronic thermal overload. An overload fault occurs when this value reaches 100%.

Product Overview 1-19

I/O The SMC-Flex has the ability to accept up to two (2) inputs and

four (4) outputs controlled over a network. The two inputs are controlled at terminal 16 (Option Input #1), and terminal 15 (Option Input #2). For these two inputs, see Chapter 4 for the parameter settings and see Chapter 7 for the bit identification. By using these two terminals as inputs, the Stop Input will need to be programmed to meet the desired stop functionality.

The four (4) outputs are Aux #1, Aux #2, Aux #3, and Aux #4. All auxiliary contacts are programmable to the function found on page 4-14. If programmed to Network or Network NC, they can be controlled over a Network. Please see Table 7.H that defines the Logic Command Word (Control).

1-20 Product Overview

DPI

ATTENTION

Port 5 — DPI Communications

Port 2

Ports 2 and 3 when two HIMs are connected with a splitter

Communication A serial interface port (DPI) is provided as standard, which allows

connection to the Bulletin 20-HIM LCD interface modules.

Figure 1.19 DPI Location

Two peripheral devices can be connected to the DPI. The maximum output current through the DPI is 280 mA.

Programming Setup is easy with the built-in keypad and three-line, sixteen character

backlit LCD. Parameters are organized in a three-level menu structure, using a text format for straightforward programming.

Figure 1.20 Built-in Keypad and LCD

Product Overview 1-21

11 12

15 16

18 19 20

25 26

28 29

30 31 32 332234

Aux #3

Aux #2

Aux #4

Aux #1

SMC-Flex

Control Terminals

PTC Input

TACH

Input

Ground

Fault

Stop

Input Start Input

Opt

Input #2

Opt

Input #1

Status Indication Four programmable hard contact outputs are provided as standard. All

auxiliary contacts are programmable for the following states:

• Normal (N.O./N.C.)

• Up-to-Speed (N.O./N.C.)

• Alarm (N.O./N.C.)

• Fault (N.O./N.C.)

• Network Control (N.O./N.C.)

• External Bypass (N.O.)

Figure 1.21 Control Terminals

Network inputs can be obtained through proper programming of Option Input #1 and Option Input #2.

1-22 Product Overview

Notes

Chapter 2

Installation

Degree of Protection The SMC-Flex soft starters have an IP00 or IP2X protection rating,

depending on the size. Taking into account the ambient conditions, the device must be installed in IP54 (Type 2) switchgear cabinets. Make sure that no dust, liquids, or conductive parts can enter the soft starter. Soft starter operation produces waste heat (heat loss). See Table 2.A or Specifications on page A-9, for details.

Receiving It is the user’s responsibility to thoroughly inspect the equipment

before accepting the shipment from the freight company. Check the item(s) received against the purchase order. If any items are damaged, it is the responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill. Should any concealed damage be found during unpacking, it is again the responsibility of the user to notify the freight agent. The shipping container must be left intact and the freight agent should be requested to make a visual inspection of the equipment.

Unpacking Remove all packing material, wedges, or braces from within and

around the controller.

Inspecting After unpacking, check the item(s’) nameplate catalog number

against the purchase order.

Storing The controller should remain in its shipping container prior to

installation. If the equipment is not to be used for a period of time, it must be stored according to the following instructions in order to maintain warranty coverage.

• Store in a clean, dry location.

• Store within an ambient temperature range of –20°C to +75°C (–4°F to +167°F).

• Store within a relative humidity range of 0% to 95%, noncondensing.

• Do not store equipment where it could be exposed to a corrosive atmosphere.

• Do not store equipment in a construction area.

2-2 Installation

Lifting Points

Lifting For controllers rated 625…1250 A, the device should only be lifted

from designated lifting points. The lifting points are designed to accept a ½ -13 threaded hoist ring capable of lifting 2500 pounds. These points are identified in Figure 2.1.

Figure 2.1 Lifting Points

Installation 2-3

ATTENTION

General Precautions In addition to the precautions listed throughout this manual, the

following statements, which are general to the system, must be read and understood.

The controller contains ESD- (electrostatic discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing the assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to applicable ESD protection handbooks.

An incorrectly applied or installed controller can damage components or reduce product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures, may result in malfunction of the system.

Only personnel familiar with the controller and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage.

Hazardous voltages that can cause shock, burn, or death are present on L1, L2, L3, T1, T2, T3, T4, T5, and T6.

Power terminal covers can be installed to prevent inadvertent contact with terminals. Disconnect the main power before servicing the motor controller or associated wiring.

Heat Dissipation The following table provides the maximum heat dissipation at rated

current for the controllers. For currents lower than rated value, heat dissipation will be reduced.

Table 2.A Maximum Heat Dissipation

SMC

Rating

5 A 25 A 43 A 60 A 85 A 108 A 135 A 201 A 251 A 317 A 361 A 480 A 625 A 700 A 970 A 1250 A

Max.

Watts

70 70 81 97 129 91 104 180 198 225 245 290 446 590 812 1222

2-4 Installation

Enclosures The open-style design of the SMC-Flex controller requires that it be

installed in an enclosure. The internal temperature of the enclosure must be kept within the range of 0…50°C.

For Type 12 (IP54) enclosures, the following guidelines are recommended to limit the maximum controller ambient temperature.

There should be a clearance of at least 15 cm (6 in.) above and below the controller. This area allows air to flow through the heatsink.

Table 2.B Minimum Enclosure Size ➊

Controller Rating (A)

5 610 (24) 406 (16) 254 (10) 25 610 (24) 406 (16) 254 (10) 43 610 (24) 406 (16) 254 (10) 60 610 (24) 406 (16) 254 (10) 85 610 (24) 406 (16) 254 (10)

108 762 (30) 610 (24) 305 (12) 135 762 (30) 610 (24) 305 (12) 201 965 (38) 762 (30) 356 (14) 251 965 (38) 762 (30) 356 (14) 317 1295 (51) 914 (36) 356 (14) 361 1295 (51) 914 (36) 356 (14) 480 1295 (51) 914 (36) 356 (14) 625 2286 (90) 889 (35) 508 (20) 780 2286 (90) 889 (35) 508 (20)

5 610 (24) 406 (16) 254 (10) 25 610 (24) 406 (16) 254 (10) 43 610 (24) 406 (16) 254 (10) 60 610 (24) 406 (16) 254 (10) 85 610 (24) 406 (16) 254 (10)

108 965 (38) 762 (30) 356 (14) 135 965 (38) 762 (30) 356 (14) 201 965 (38) 762 (30) 356 (14) 251 965 (38) 762 (30) 356 (14) 317 1524 (60) 965 (38) 356 (14)

361 1524 (60) 965 (38) 356 (14) 480 ➊ 1524 (60) 965 (38) 356 (14) 480 ➋ 2286 (90) 889 (35) 508 (20)

625 2286 (90) 1397 (55) 508 (20)

780 2286 (90) 1397 (55) 508 (20)

5 610 (24) 406 (16) 254 (10) 25 610 (24) 406 (16) 254 (10) 43 610 (24) 406 (16) 254 (10) 60 610 (24) 406 (16) 254 (10) 85 610 (24) 406 (16) 254 (10)

108 965 (38) 762 (30) 356 (14) 135 965 (38) 762 (30) 356 (14) 201 965 (38) 762 (30) 356 (14) 251 965 (38) 762 (30) 356 (14) 317 1295 (51) 914 (36) 356 (14) 361 1295 (51) 914 (36) 356 (14) 480 1295 (51) 914 (36) 356 (14) 625 2286 (90) 1397 (55) 508 (20) 780 2286 (90) 1397 (55) 508 (20)

➊ Larger enclosure may be required based on options selected. Consult your local Rockwell

Automation Sales office or Allen-Bradley distributor.

➋ Use this row for 460V -58 and 575V -59. ➌ Use this row for 460V -59 and 575V -60 and -61.

B Height A Width C Depth

Non-Combination Controller [mm (in.)]

Combination Controllers with Fusible Disconnect

Combination Controllers with Circuit Breaker

IP65 (Type 4/12)

Installation 2-5

Mounting All units are fan cooled. It is important to locate the controller in a

position that allows air to flow vertically through the power module.

The controller must be mounted in a vertical plane and have a minimum of 15 cm (6 in.) free space above and below the controller.

When drilling or installing near the softstarter, make sure that adequate measures are taken to protect the device from dust and debris. See Figure 2.2.

Figure 2.2 SMC-Flex Mounting Protection

2-6 Installation

Figure 2.3 Dimensions: 5…85 A Controllers

5…85 A

Controller

Unit

mm 150.1 307 203.1 120 291 119.8 14.1 5.7 kg

WidthBHeightCDepth

DEFH

in. 5.91 12.09 8.00 4.72 11.46 4.72 0.56 12.6 lb.

All dimensions are approximate and are not intended for manufacturing purposes. Consult your local Allen-Bradley distributor for complete dimension drawings.

Approx.

Ship. Wt.

Figure 2.4 Dimensions: 108…135 A Controllers

Installation 2-7

Unit

108…135 A

Controller

mm 196.4 443.7 212.2 166.6 367 129.5 26 15 kg

in. 7.74 17.47 8.35 6.56 14.45 5.10 1.02 33 lb.

Width

Height

Depth

All dimensions are approximate and are not intended for manufacturing purposes. Consult your local Allen-Bradley distributor for complete dimension drawings.

DEFG

Approx.

Ship. Wt.

2-8 Installation

157.25

(6.2)

6.4

(.250)

253.8

(9.992)

40.9

(1.6)

1.000

13.5

(.531)

50.8

(2.0)

24.9

(.980)

(.984)

(1.890)

SCALE

#8-32 UNC-2B

M10 X 1.5

560

(22.047)

225

(8.858)

504.1

(19.847)

150

(5.906)

(.513)

11.5

(.453)

27.5

(1.083)

19.7

(.776)

91.189

(3.59)

164.126

(6.46)

152.749

(6.01)

44.311

(1.74)

79.811

(3.14)

245.689

(9.67)

(3.15)

SEE DETAIL AA

Figure 2.5 Dimensions: 201…251 A Controllers

201…251 A

Controller

Unit

WidthBHeightCDepth

DEFGHI

Approx.

Ship. Wt.

mm 225 560 253.8 150 504.1 157.25 91.189 44.311 79.811 30.4 kg

in. 8.858 22.047 9.992 5.906 19.847 6.2 3.59 1.74 3.14 67 lb.

All dimensions are approximate and are not intended for manufacturing purposes. Consult your local Allen-Bradley distributor for complete dimension drawings.

40.9

(1.6)

276.5

(10.89)

182.25

(7.18)

63.5

(2.50)

(.67)

22.5 (.89)

#8 - 32 UNC - 2B

12.522 (.49)

32.74

(1.29)

(1.89)

M12 x 1.75

30.5

(1.20)

Figure 2.6 Dimensions: 317…480 A Controllers

Installation 2-9

Unit

WidthBHeightCDepth

DEFGH I

Ship. Wt.

Approx.

317…480 A

Controller

mm 290 600 276.5 200 539.18 182.25 104.5 55.5 103.5 45.8 kg

in. 11.42 23.62 10.89 7.87 21.23 7.18 4.11 2.19 4.07 101 lb.

All dimensions are approximate and are not intended for manufacturing purposes. Consult your local Allen-Bradley distributor for complete dimension drawings.

2-10 Installation

23.5023.50 596,9596,9

[ ]

41.0041.00 1041,41041,4

[ ]

2.002.00 50,850,8

[ ]

4.004.00 101,6101,6

[ ]

1.201.20 30,530,5

[ ]

21.6921.69 550,9550,9

[ ]

1.641.64 41,641,6

[ ]

7.897.89 200,4200,4

[ ]

23.3923.39 594,1594,1

[ ]

38.4538.45 976,6976,6

[ ]

.90.90

2323

[ ]

13.6313.63 346,2346,2

[ ]

2X 2X .2525

6,46,4

[ ]

7878

19,819,8

[ ]

3.623.62 92,192,1

[ ]

8.468.46 214,9214,9

[ ]

3X 3X .2525

.05.05

[ ]

.39.39

1010

[ ]

13.8613.86 351,9351,9

[ ]

14.5414.54 369,4369,4

[ ]

19.5419.54 496,3496,3

[ ]

29.0229.02 737737

[ ]

.500.500

12,712,7

[ ]

.531.531

13,4913,49

[ ]

7.357.35 186,6186,6

[ ]

14.3514.35 364,4364,4

[ ]

8.258.25 209,5209,5

[ ]

7.007.00 177,8177,8

[ ]

4X 4X 2.752.75

69,869,8

[ ]

4X 4X 3.003.00

76,276,2

[ ]

.734.734

18,6418,64

[ ]

1.001.00 25,425,4

[ ]

SEE DETAIL ASEE DETAIL A

3X DETAIL A3X DETAIL A

#8-32 UNC-2B#8-32 UNC-2B

Figure 2.7 Dimensions: 625…780 A Controllers

625…780 A

Controller

Width

Height

Depth

DEFG

Approx.

Ship. Wt.

Unit

mm 596.9 1041.4 346.2 550.9 594.1 214.9 200.4 179 kg

in. 23.5 41.0 13.63 21.69 23.39 8.46 7.89 395 lb.

All dimensions are approximate and are not intended for manufacturing purposes. Consult your local Allen-Bradley distributor for complete dimension drawings.

41.0041.00 1041,41041,4[ ]

23.3923.39 594,1594,1[ ]

7.897.89 200,4200,4[ ]

1.641.64 41,641,6[ ]

.90.90

2323[ ]

21.6921.69 550,9550,9[ ]

23.5023.50 596,9596,9[ ]

3X 3X .15.15

3,83,8[ ]

13.8613.86 351,9351,9[ ]

14.5414.54 369,4369,4[ ]

19.5419.54 496,3496,3[ ]

29.0229.02 737737[ ]

4.574.57 116,2116,2[ ]

8.468.46 214,9214,9[ ]

2X 2X .25.25

6,46,4[ ]

13.6313.63 346,2346,2[ ]

.500.500

12,712,7[ ]

2.502.50 63,563,5[ ]

5.005.00

127127[ ]

.74.74

18,818,8[ ]

1.201.20 30,530,5[ ]

.28.28

7,27,2[ ]

.531.531

13,4913,49[ ]

38.4538.45 976,6976,6[ ]

4X 4X 2.252.25

57,157,1[ ]

4X 4X 2.002.00

50,850,8[ ]

.734.734

18,6418,64[ ]

8.258.25 209,5209,5[ ]

7.007.00 177,8177,8[ ]

7.357.35 186,6186,6[ ]

14.3514.35 364,4364,4[ ]

1.251.25 31,831,8[ ]

SEE DETAIL ASEE DETAIL A

3X DETAIL A3X DETAIL A

#8-32 UNC-2B#8-32 UNC-2B

Installation 2-11

Figure 2.8 Dimensions: 970…1250 A Controllers

970…1250 A

Controller

Unit

Width

Height

Depth

DEFG

Approx.

Ship. Wt.

mm 596.9 1041.4 346.2 550.9 594.1 214.9 200.4 224 kg

in. 23.5 41.0 13.63 21.69 23.39 8.46 7.89 495 lb.

All dimensions are approximate and are not intended for manufacturing purposes. Consult your local Allen-Bradley distributor for complete dimension drawings.

2-12 Installation

3/5

3/6

SMC

➀

➀ Customer Supplied

➁

➀

➁ Overload protection is included as a

standard feature of the SMC-Flex controller.

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

3-Phase

Input Power

Branch

Protection

SMC-Flex Controller

Power Factor

Correction Capacitors

➀

➀ Customer Supplied

➁

➀

➁ Overload protection is included as a standard feature of the SMC-Flex controller.

➂ Energize 1/2 second before start command to SMC.

➂

➃ Open contactor after stopping method is complete.

➂ Energize contactor after up-to-speed. ➃ Open contactor before initiating a stop.

Alternate

➃

Power Factor Correction Capacitors

The controller can be installed on a system with power factor correction (PFC) capacitors. The capacitors must be located on the line side of the controller. This must be done to prevent damage to the SCRs in the SMC-Flex controller.

When discharged, a capacitor essentially has zero impedance. For switching, sufficient impedance should be connected in series with the capacitor bank to limit the inrush current. One method for limiting the surge current is to add inductance in the capacitor’s conductors. This can be accomplished by creating turns or coils in the power connections to the capacitors.

• 250V — 15 cm (6 in.) diameter coil, 6 loops

• 480…690V — 15 cm (6 in.) diameter coil, 8 loops

Take care in mounting the coils so that they are not stacked directly on top of each other; stacking will cause a cancelling effect. Also, mount the coils on insulated supports away from metal parts so they will not act as induction heaters. If an isolation contactor is used, put capacitors in front of contactor.

Note: For further instructions, consult the PFC capacitor vendor.

Figure 2.9 Typical Wiring Diagram for Power Factor Correction Capacitors

-Phas

Input Powe

Prot

Branch

tio

Power Facto

Correction Capacitor

ontrolle

-Flex

Figure 2.10 Typical Wiring Diagram for Power Factor Correction Capacitors

and Contactor

Installation 2-13

ATTENTION

Protective Modules Protective modules containing metal oxide varistors (MOVs) can be

installed on controllers rated 5…1250 A and 200…600V, to protect the power components from electrical transients. The protective modules clip voltage transients generated on the lines to prevent such surges from damaging the SCRs.

When installing or inspecting the protective module, make sure that the controller has been disconnected from the power source. The protective module should be inspected periodically for damage or discoloration. Replace if necessary.

Motor Overload Protection

Thermal motor overload protection is provided as standard with the SMC-Flex controller. If the overload trip class is less than the acceleration time of the motor, nuisance tripping may occur.

Overload protection should be properly coordinated with the motor.

Two applications require special consideration: two-speed motors, and multi-motor protection.

Two-speed Motors

The SMC-Flex controller has overload protection available for single speed motors. When the SMC-Flex controller is applied to a twospeed motor, the Overload Class parameter must be programmed to OFF and separate overload relays must be provided for each speed.

Multi-motor Protection

If the SMC-Flex controller is controlling more than one motor, individual overload protection is required for each motor.

2-14 Installation

ATTENTION

Electromagnetic Compatibility (EMC)

This product has been designed for Class A equipment. Use of the product in domestic environments may cause radio interference, in which case, the installer may need to employ additional mitigation methods.

The following guidelines are provided for EMC installation compliance.

Enclosure

Install the product in a grounded metal enclosure.

Wiring

Wire in an industrial control application can be divided into three groups: power, control, and signal. The following recommendations for physical separation between these groups is provided to reduce the coupling effect.

• Different wire groups should cross at 90° inside an enclosure.

• Minimum spacing between different wire groups in the same tray should be 16 cm (6 in.).

• Wire runs outside an enclosure should be run in conduit or have shielding/armor with equivalent attenuation.

• Different wire groups should be run in separate conduits.

• Minimum spacing between conduits containing different wire groups should be 8 cm (3 in.).

• For additional guidelines, please refer to Wiring and Ground guidelines, publication DRIVES-IN001A-EN-P.

Additional Requirements

• If linear acceleration is used, a separate conduit or wire way should be used for the tachometer leads.

• Wire earth ground to control terminal 14.

• Use shielded wire for PTC, Tachometer, and ground fault input.

• Terminate shielded wires to terminal 14.

• Ground fault CT must be inside or within 3 m of metal enclosure.

To meet product susceptibility requirements, ferrite cores need to be added to the communication lines. When using an external HIM (or DPI interface), a core should be added to the HIM cable near the SMC-Flex control module. The recommended core is Fair-Rite no. 0431167281 or equivalent. When using a DeviceNet circuit, two cores need to be added to the DeviceNet cable near the SMC-Flex control module. The recommended cores are TDK ZCAT2023 0930H and TDK ZCAT2035 0930 or equivalent. All cores specified are the split type cores and can be added to existing connections.

Chapter 3

➀

Wiring

Terminal Locations The SMC-Flex controller wiring terminal locations are shown in

Figure 3.1 and Figure 3.2. Make wiring connections as indicated in the typical connection diagrams. Incoming three-phase power connections are made to terminals L1/1, L2/3, and L3/5. Load connections to Line motors are made to T1/2, T2/4, and T3/6, while load connections to Wye-Delta motors are made to T1/2, T2/4, T3/6, T4/8, T5/10, and T6/12.

Figure 3.1 Wiring Terminal Locations (5…85 A)

Table 3.A Wiring Terminal Locations

1 Incoming Line Termination

2 Line Motor Connections

3 Delta Motor Connections

4 Control Terminations

5 Fan Terminations

IP20 protective covers on Delta termination must be removed when connecting in a Delta

➀

configuration.

3-2 Wiring

Figure 3.2 Wiring Terminal Locations (108…480 A)

Table 3.A Wiring Terminal Locations

1 Incoming Line Termination

2 Line Motor Connections

3 Delta Motor Connections

4 Control Terminations

5 Fan Terminations

Figure 3.3 Wiring Terminal Locations (625…1250 A)

Wiring 3-3

Table 3.B Wiring Terminal Locations

1 Incoming Line Terminations

2 Line Motor Connections

3 Terminal Block CP1 - Common Control Power Connections

(Fans, Contactors, and Control Modules)

Power Structure The SMC-Flex product has an integrated mechanical run contactor on

each phase of the motor to minimize heat generation during run time. These contacts are pulled in sequentially in the 108…1250 A units. In the 5…85 A units, these contacts are pulled in, all at once. The SMC-Flex product also has a Current Transformer (CT), built in on each phase of the motor to provide current readings.

Power Wiring

Refer to the product nameplate or User Manual for power lug termination information including:

• Lug wire capacity

• Tightening torque requirements

• Lug kit catalog numbers (108…1250 A)

3-4 Wiring

ATTENTION

Use of an isolation contactor or shunt trip type circuit breaker on the line side of the SMC. This device should be capable of interrupting the motor’s lock rotor current.

Connection of this isolation device to an auxiliary contact on the SMC-Flex. The auxiliary contact should be programmed for the “normal” condition. See Chapter 4 for additional information on programming.

Failure of solid state power switching components can cause overheating due to a single-phase condition in the motor. To prevent injury or equipment damage, the following is recommended:

Line Connected

The SMC-Flex by default is programmed to be connected to a line controlled motor as shown in Figure 3.4. These motors typically have 3 leads and must be rated between 1…1250 amps. An optional isolation contactor can be added to the circuit to provide galvanic isolation of the motor and final electro-mechanical removal of power.

Figure 3.4

SMC-Flex

5/L3

6/T3

10/T5

3/L2

1/L1

4/T2

8/T4

2/T1

12/T6

Delta Connected

The SMC Flex can be programmed and connected to a delta controlled motor as shown in Figure 3.5. These motors typically have 6 or 12 leads and must be rated between 1.8…1600 amps. It is recommended that an isolation contactor be added to the circuit to provide galvanic isolation of the motor and final electro-mechanical removal of power.

Figure 3.5

Wiring 3-5

2/T1

4/T2

6/T3

12/T6

8/T4

10/T5

1/L1

5/L3

3/L2

SMC-Flex

ATTENTION

Power Lugs Power lugs are required for devices rated 108..1250 A. In some cases

these lugs are sold in kits. Each kit contains three lugs. The number and type of lugs required is listed in the following tables.

Table 3.C lists the recommended lugs for the SMC when configured as a line connection. Table 3.D lists the recommended lugs when using the SMC Flex with a delta connection. Note that devices rated 625…1250 A require the use of a power distribution block when used with a delta connection.

Terminal covers are available for units rated 108…480 A which can make the product deadfront (IP2X) safe. See Appendix D for the appropriate catalog numbers for ordering.

3-6 Wiring

Table 3.C SMC-Flex 5…1250 A, Line Connection Lug Information

SMC

Rating

Lug Kit

Cat. No.

Wire Strip

Length

5…85 A — 18…20 mm

108…135 A 199-LF1 18…20 mm

201…251 A 199-LF1 18…20 mm

317…480 A 199-LG1 18…25 mm

625…780 A 100-DL630 32 mm / 64 mm

970 A 100-DL860 26 mm / 48 mm

100-DL630 32 mm / 64 mm

1250 A

➀

100-DL860 26 mm / 48 mm

Conductor

Range

2.5…85 mm

(#14…3/0 AWG)

16…120 mm

(#6…250 MCM)

16…120 mm

(#6…250 MCM)

25…240 mm

(#4…500 MCM)

70…240 mm

(2/0…500 MCM)

120…240 mm

(4/0…500 MCM)

70…240 mm

(2/0…500 MCM)

120…240 mm

(4/0…500 MCM)

The 1250 A device requires one (1) each of the 100-DL630 and 100-DL860.

➀

Max. No. Lugs/Pole Tightening Torque

Line Side Load Side Wire — Lug Lug — Busbar

— — 11.3 N•m

(100 lb.-in.)

11 31 N•m

(275 lb.-in.)

22 31 N•m

(275 lb.-in.)

22 42 N•m

(375 lb.-in.)

22 45 N•m

(400 lb.-in.)

11 45 N•m

(400 lb.-in.)

45 N•m

(400 lb.-in.)

—

23 N•m

(200 lb.-in.)

23 N•m

(200 lb.-in.)

28 N•m

(250 lb.-in.)

68 N•m

(600 lb.-in.)

68 N•m

(600 lb.-in.)

68 N•m

(600 lb.-in.)

SMC

Rating

Suggested Lug

Cat. No.

108…135 A 1494R-N15

201…251 A 1494R-N14

317…480 A 150-LG5MC

625…780 A

970…1250 A

➀

—

Table 3.D SMC-Flex 108…1250 A, Delta Connection Lug Information (for

Inside-the-Delta applications)

Conductor

Pole

Range

Line Side ➁ Wire — Lug Lug — Busbar

Max. No. Lugs/

25…240 mm

1 42 N•m

(#4…500 MCM)

50…120 mm

2 31 N•m

(1/0…250 MCM)

95…240 mm

1 33.9 N•m

(3/0…500 MCM)

25…240 mm

2 42 N•m

(#4…500 MCM)

25…240 mm

4 42 N•m

(#4…500 MCM)

For 625

➀

➁ Load side lug information for inside-the-delta applications is contained in Table 3.C.

…1250 A inside-the-delta connections, terminal blocks are required for line side

connections. Required terminal blocks are as follows:

- Allen-Bradley Part# 1492-BG (625…780 A: 2 per phase, 970…1250 A: 4 per phase). Short-Circuit Protection = Fuses

- Cooper Bussmann Part# 16504-2 (625…780 A: 1 per phase, 970…1250 A: 2 per phase). ShortCircuit Protection = Circuit breaker

Tightening Torque

(375 lb.-in.)

(275 lb.-in.)

(300 lb.-in.)

(375 lb.-in.)

23 N•m

(200 lb.-in.)

23 N•m

(200 lb.-in.)

28 N•m

(250 lb.-in.)

N/A

Control Power Control Wiring

Refer to the product nameplate for control terminal wire capacity and tightening torque requirements. Each control terminal will accept a maximum of two wires. Refer to the product nameplate prior to applying control power. Depending on the specific application, additional control circuit transformer VA capacity may be required.

Controllers rated 5…480 A

The SMC-Flex controllers rated 5…480 A accept control power input of 100…240V AC or 24V AC/DC, (+10/–15%) single-phase, 50/ 60 Hz. A control power source of 125 VA is required. The control power requirement for the control module is 75 VA. The control power requirement for the fans is 20 or 50 VA. The control module and fans are separately wired. The control module requirements are shown in Table 3.E. The fans require additional power as defined in Table 3.G.

Table 3.E Control Module Requirements

120…240V AC Transformer 75 VA

24V AC Transformer 130 VA

24V DC

Wiring 3-7

Inrush Current 5 A Inrush Time 250 ms Transient Watts 60 W Transient Time 500 ms Steady State Watts 24 W Minimum Allen-Bradley Power Supply 1606-XLP50E

Controllers rated 625…1250 A

For controllers rated 625…1250 A, common control is required for proper operation. Control power is connected to the product through terminal block CP1, at terminals 1 and 4. This single connection point feeds the control module, contactors, and fans. Control power must be supplied as 110/120 VAC or 230/240 VAC, 50/60 Hz only. A control power source of at least 800 VA is required. The control power requirements include the control module (75 VA), bypass contactors (526 VA max), and fan power (150 VA).

Depending on the specific application, additional control circuit transformer VA capacity may be required.

3-8 Wiring

Figure 3.6 230V Control Undervoltage Relay Settings for 625…1250 A

Devices

SEE NAMEPLATE FOR STATUS

LED

TIME DELAY PICK-UP

TIME DELAY DROP-OUT

SEC.

0.1

220

SEC.

0.1

115%

PICK-UP % NOMINAL VOLTAGE

85%

240

NOMINAL VOLTAGE

208

95%

DROP OUT % PICK-UP

GENERAL NOTES:

1. SET ALL RELAY POTENTIOMETERS PER ILLUSTRATION.

178 2

CP1

CONTACTO R

UV. RELAY

SM C FLEX CONTROL

MODULE

141322

CONTACTO R

141322

CONTACTO R

15 16

262728

303132

243 1

F A N A

GND

F A N B FAN C

CONTACTO R/ FAN

IN P U T 230 V AC

GND

See Figure 3.6 for setting information.

Wiring 3-9

Figure 3.7 Internal Wiring and 230V Control Undervoltage Relay Connection

Diagram for 625…1250 A Devices

3-10 Wiring

CP1

CONTACTOR

SM C FLEX CONTROL

MODULE

CONTACTOR

F A N A F A N B FAN C

CONTACTOR/ FAN

IN P U T 120 V AC

15 16

262728

303132

243 1

GND

141322

Figure 3.8 Internal Wiring and 120V Control Connection Diagram for

625…1250 A Devices

Wiring 3-11

ATTENTION

110/120 VAC

Jumpers

Supply

Jumper

Factory Set

110/120 VAC

Jumpers

Supply

5…480 A

625…1250 A

Fan Terminations

Control Power/

CP1

110/120 VAC

50/60 Hz ONLY

230/240 VAC

Control Wire Specifications

Table 3.F provides the control terminal wire capacity, the tightening torque requirements, and the wire strip length. Each control terminal will accept a maximum of two wires.

Table 3.F Control Wiring and Tightening Torque

Wire Size Torque Wire Strip Length

0.75…2.5 mm

(#18…14 AWG)

0.6 N•m (5 lb.-in.) 5.6…8.6 mm (0.22…0.34 in.)

Fan Power Controllers rated 5…1250 A have heatsink fan(s). Refer to Table 3.G

for the control power VA requirements of the heatsink fans.

Fan Terminations

See Figure 3.1, Figure 3.2, and Figure 3.3 for fan power connection locations.

The fan jumpers have been factory installed for 110/120V AC input. Refer to Figure 3.9 for 220/240V AC fan wiring (5

…480A devices only).

Figure 3.9 Power Terminations

Factory Set

Optional

220/240 VAC

Supply

Table 3.G Heatsink Fan Control Power

SMC Rating Heatsink Fan VA

➀

5…135 A 20 201…251 A 40 317…480 A 60 625…780 A 150

970…1250 A 150

Internally wired.

➀

3-12 Wiring

Control Terminal Designations As shown in Figure 3.10, the SMC-Flex controller contains 24 control

terminals on the front of the controller.

Figure 3.10 SMC-Flex Controller Control Terminals

Terminal

Number

Description

Ter mi na l

Number

Description

11 Control Power Input ➀➃ 23 PTC Input ➁ 12 Control Power Common ➀➃ 24 PTC Input ➁ 13 Controller Enable Input ➁ 25 Tach Input 14 Control Module Ground 26 Tach Input 15 Option Input #2

➀➁ 27 Ground Fault Transformer Input ➁

16 Option Input #1 ➀➁ 28 Ground Fault Transformer Input ➁ 17 Start Input ➀➁ 29 Aux. Contact #2➀➂ 18 Stop Input ➀➁ 30 Aux. Contact #2➀➂ 19 Aux. Contact #1➀➂ 31 Aux. Contact #3➀➂ 20 Aux. Contact #1➀➂ 32 Aux. Contact #3➀➂ 21 Not Used 33 Aux. Contact #4➀➂ 22 Not Used 34 Aux. Contact #4➀➂

RC Snubbers are required on loads connected to auxiliary.

➀ ➁ Do not connect any additional loads to these terminals. These “parasitic” loads may cause problems

with operation, which may result in false starting and stopping.

➂ External Bypass operates an external contactor and overload relay once the motor reaches full

speed. The SMC-FLEX overload functionality, diagnostics and metering are disabled when the external bypass is activated. Proper sizing of the contactor and overload is required.

➃ Control power on units rated 625…1250 A is pre-wired internally, from terminal block CP1.

Wiring 3-13

Standard Controller Wiring Diagrams

3-Phase

Input Power

➀

Branch

Protection

Figure 3.11 through Figure 3.22 show typical wiring for the SMC-Flex controller.

Figure 3.11 Typical Wiring Diagram for Standard Controller

L1/1

L2/3

L3/5

➀

SMC-Flex

Controller

Stop

Start

T1/2

T2/4

T3/6

➀

➁

11 12

SMC-Flex

Control Terminals

PTC

Input

25 26

TACH

Input

15 16

Ground

Fault

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

28 29

18 19 20

Aux #1

30 31 32 332234

Aux #3Aux #2

Aux #4

3-14 Wiring

3-Phase

Input Power

Figure 3.12 Typical Wiring Diagram for Two-Wire Control with Stopping

Control (No DPI Control)

T1/2L1/1

L2/3

T2/4

➀

L3/5

T3/6

Branch

➀

Protection

➁

11 12

SMC-Flex

Control Terminals

➀

Two-Wire

Device

➀

15 16

SMC-Flex

Controller

18 19 20

Aux #1

PTC

Input

25 26

TACH

Input

28 29

Ground

Fault

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

Notes: (1) Programmable controller interfacing in this diagram refers to hard-wiring between the

(2) The OFF state leakage current for a solid-state device must be less than 6 mA.

30 31 32 332234

Aux #3Aux #2

PLC’s output contacts and the SMC-Flex controller’s control terminals.

Aux #4

Wiring 3-15

Figure 3.13 Typical Wiring Diagram for Dual Ramp Applications

3-Phase

Input Power

Branch

➀

Protection

➀

Ramp 1 Ramp 2

➀

L1/1

L2/3

L3/5

SMC-Flex

Controller

Stop

Start

T1/2

T2/4

T3/6

➀

➁

11 12

SMC-Flex

Control Terminals

PTC

Input

25 26

TACH

Input

15 16

Ground

Fault

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

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

28 29

18 19 20

Aux #1

30 31 32 33

Aux #3Aux #2

Aux #4

3-16 Wiring

Figure 3.14 Typical Wiring Diagram for Start-Stop Control via DPI

Communications

Note: Use this wiring diagram when start-stop will come from

either a Bulletin 20-HIM LCD interface module or a Bulletin 20-COMM communication module connected to the SMC-Flex.

Note: Logic mask must be properly configured, see Chapter 8.

3-Phase

Input Power

Branch

➀

Protection

➁

11 12

➀

15 16

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

SMC-Flex

Controller

18 19 20

➀

SMC-Flex

Control Terminals

PTC

Input

25 26

TACH

Input

Aux #1

28 29

Ground

Fault

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

30 31 32 332234

Aux #3Aux #2

Aux #4

11 12

15 16

18 19 20

25 26

28 29

30 31 32 332234

Start

Aux #3Aux #2

Aux #4

Aux #1

SMC-Flex

Control Terminals

Stop

Branch

Protection

L2/3

L3/5

Input Power

3-Phase

SMC-Flex Controller

T1/2L1/1

T2/4

T3/6

Existing Motor

Starter

PTC

Input

TACH

Input

Ground

Fault

➀

➀➀

➀

➃

➂

➀➁

➀

Wiring 3-17

Figure 3.15 Typical Wiring Diagram for Retrofit Applications

Customer supplied.

➀ ➁ Overload protection should be disabled in the SMC-Flex controller. ➂ Refer to the controller nameplate to verify the rating of the control power input voltage.

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➃ Aux #4 should be set for normal operation

3-18 Wiring

11 12

15 16

18 19 20

25 26

28 29

30 31 32 332234

SMC-Flex

Control Terminals

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

3-Phase

Input Power

Branch

Protection

SMC-Flex

Controller

Isolation

Contactor

(IC)

Aux #3

PTC

Input

TACH

Input

Ground

Fault

Aux #2

Aux #4

Aux #1

Stop

Start

➀

➂

➁

➀

Figure 3.16 Typical Wiring Diagram for Isolation Applications (DPI also)

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➂ Aux #4 should be set for normal operation.

Wiring 3-19

11 12

15 16

18 19 20

25 26

28 29

30 31 32 332234

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

3-Phase

Input Power

Branch

Protection

SMC-Flex

Controller

Aux #3Aux #2

Aux #4

Aux #1

SMC-Flex

Control Terminals

Start

Stop

PTC

Input

TACH

Input

Ground

Fault

➀

➂

➁

Figure 3.17 Typical Wiring Diagram for Shunt Trip Applications

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➂ Aux #2 should be set to fault operation.

3-20 Wiring

Figure 3.18 Typical Wiring Diagram for Single-Speed Reversing Applications

3-Phase

Input Power

➀

Branch

Protection

E-Stop

➃

➀

➀➀

OFF

FOR REV

Reversing Contactors

➀

L1/1

L2/3

T1/2

T2/4

➀

L3/5

SMC-Flex

Controller

T3/6

➀

➁

11 12

PTC

Input

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

SMC-Flex

Control Terminals

25 26

TACH

Input

15 16

Ground

Fault

28 29

18 19 20

Aux #1

30 31 32 332234

Aux #3Aux #2

Aux #4

Customer supplied.

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➂ No braking manuever allowed in wiring diagram. ➃ Maintained pushbutton.

Notes: (1) Minimum transition time for reversing direction is 1/2 second.

(2) Phase Reversal protection must be disabled in reversing applications.

Wiring 3-21

11 12

15 16

18 19 20

25 26

28 29

30 31 32 33

SMC-Flex

Control Terminals

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

3-Phase

Input Power

Branch

Protection

SMC-Flex

Controller

Two-Speed Motor Starter

High

Low

Stop

HOL

LOL

1 sec.

Aux #3

PTC

Input

TAC H

Input

Ground

Fault

Aux #2

Aux #4

Aux #1

➀

➁

➀

➂

➃

Figure 3.19 Typical Wiring Diagram for Two-speed Applications

Customer supplied.

➀ ➁ Two-speed, consequent pole installations. ➂ Refer to the controller nameplate to verify the rating of the control power input voltage.

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➃ Overload must be disabled in SMC-Flex.

3-22 Wiring

Figure 3.20 Typical Wiring Diagram for SMC-Off-Bypass Control

3-Phase

Input Power

Branch

➀

Protection

L1/1

L2/3

T1/2

T2/4

➀

L3/5

➀

T3/6

SMC-Flex

Controller

Bypass

OffSMC

➀

Stop

Start

Bypass

➀

Bypass

Connector (BC)

➀

➁

11 12

SMC-Flex

Control Terminals

PTC

Input

25 26

TAC H

Input

15 16

28 29

Ground

Fault

18 19 20

Aux #1

30 31 32 332234

Aux #3Aux #2

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

Aux #4

Wiring 3-23

Figure 3.21 Typical Wiring Diagram for Hand-Off-Auto Control with Stop

Option and Start/Stop Push Buttons

Control Power

➁

➀

Start

➀

H A

➀

Auto Device

➀

Stop

➀

11 12

15 16

18 19 20

SMC-Flex

Control Terminals

PTC

Input

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

25 26

TACH

Input

Ground

Fault

28 29

30 31 32 332234

Aux #1

Aux #3Aux #2

Aux #4

3-24 Wiring

Soft Stop, Pump Control, and SMB Smart Motor Braking

Figure 3.22 through Figure 3.25 show the different wiring for the Soft Stop, Pump Control, and SMB Smart Motor Braking options.

Figure 3.22 Typical Wiring Diagram

Control Power

➂

Stop

➀

Start

➀

18 19 20

11 12

Option Stop

➀➁

15 16

SMC-Flex

Control Terminals

PTC

Input

Customer supplied.

➀ ➁ Soft Stop, Pump Stop, or Brake. ➂ Refer to the controller nameplate to verify the rating of the control power input voltage.

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

Note: Refer to Chapter 3 for typical power circuits.

25 26

TACH

Input

Ground

Fault

28 29

Aux #1

30 31 32 332234

Aux #3Aux #2

Aux #4

Figure 3.23 Typical Retrofit Wiring Diagram

11 12

15 16

18 19 20

25 26

28 29

30 31 32 332234

Option Stop

Start

Aux #3Aux #2

Aux #4

Aux #1

SMC-Flex

Control Terminals

Control Power

Stop

PTC

Input

TACH

Input

Ground

Fault

➀

➄

➀

➂

➀➃

➀➁

Wiring 3-25

Customer supplied.

➀ ➁ Overload protection should be disabled in the SMC-Flex controller. ➂ Refer to the controller nameplate to verify the rating of the control power input voltage.

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➃ Soft Stop, Pump Stop, or Brake. ➄ Aux #4 should be set to normal operation.

Note: Refer to Chapter 3 for typical power circuits.

3-26 Wiring

11 12

15 16

18 19 20

25 26

28 29

30 31 32 332234

Option Stop

Aux #3Aux #2

Aux #4

Aux #1

SMC-Flex

Control Terminals

Control Power

Start

Stop

PTC

Input

TACH

Input

Ground

Fault

➀

➁

➀

➃

➀➂

Figure 3.24 Typical Wiring Diagram for Applications Requiring an Isolation

Contactor

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➂ Soft Stop, Pump Stop, or Brake. ➃ Aux #4 should be set to normal operation.

Note: Refer to Chapter 3 for typical power circuits.

Wiring 3-27

11 12

15 16

18 19 20

25 26

28 29

30 31 32 332234

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

3-Phase

Input Power

Branch

Protection

SMC-Flex Controller

H A

Control Power

100-240 VAC

Aux #3Aux #2

PTC

Input

TACH

Input

Ground

Fault

Aux #4

Aux #1

SMC-Flex

Control Terminals

X00

00X

➀

Figure 3.25 Typical Wiring Diagram for Hand-Off-Auto (DPI) Control (Soft

Stop, Braking, and Pump Control Only)

Customer supplied.

➀

3-28 Wiring

Preset Slow Speed Figure 3.26 and Figure 3.27 show the different wiring for the Preset

Slow Speed.

Figure 3.26 Typical Wiring Diagram for the Preset Slow Speed

Control Power

➁

Stop

➀

Option Command

11 12

SMC-Flex

Control Terminals

25 26

➀➂

15 16

28 29

Start

➀

18 19 20

Aux #1

30 31 32 332234

PTC

Input

TACH

Input

Ground

Aux #3Aux #2

Aux #4

Fault

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➂ Slow Speed.

Note: Refer to Chapter 3 for typical power circuits.

Wiring 3-29

11 12

15 16

18 19 20

25 26

28 29

30 31 32 332234

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

3-Phase

Input Power

Branch

Protection

SMC-Flex

Controller

H A

Aux #3Aux #2

Aux #4

Aux #1

SMC-Flex

Control Terminals

Option Command

Hand Start

Hand Stop

PTC

Input

TACH

Input

Ground

Fault

➀

➀➁

➂

➀

➃

Figure 3.27 Typical Slow Speed Wiring Diagram for Hand-Off-Auto (DPI)

Control

Customer supplied.

➀ ➁ Slow Speed. ➂ Refer to the controller nameplate to verify the rating of the control power input voltage.

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➃ Aux #4 should be set to normal operation.

3-30 Wiring

 





 



  







 



 

   





3LOW3PEED

3TOP

3TART

#ONTROL0OWER

"RAKE

!UX!UX

!UX

!UX

3-#&LEX

#ONTROL4ERMINALS

04#

)NPUT

4!#(

)NPUT

'ROUND

&AULT





➂

Slow Speed with Braking Figure 3.28 shows the wiring for the Slow Speed with Braking option.

Figure 3.28 Typical Wiring Diagram for the Slow Speed with Braking with an

Isolation Contactor

Customer supplied.

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

For units rated 625…1250 A, terminals 11 & 12 are factory pre-wired from terminal block CP1 - terminals 1 & 4.

➂ Aux #4 should be set to normal operation.

Note: Refer to Chapter 3 for typical power circuits.

Wiring 3-31

00%

(

)

ATTENTION

Sequence of Operation Figure 3.29 through Figure 3.34 show the different operation

sequences for the Soft Stop, Preset Slow Speed, Pump Control, SMB Smart Motor Braking, Accu-Stop, and Slow Speed with Braking options.

Figure 3.29 Soft Stop Sequence of Operation

oast-to-res

Soft Sto

Motor

eed

Push Button

tar

Sto

Soft Sto

Auxiliary Contact

Norm

lose

Ope

lose

Ope

lose

Ope

lose

Ope

Soft Sto

If Soft Stop Selecte

Time

Run

seconds

tar

The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine.

3-32 Wiring

00%

)

Mot

Spee

Figure 3.30 Preset Slow Speed Sequence of Operation

oast-to-res

Soft Sto

7 or 1

Push Button

tar

Sto

Slow Spee

Auxiliary Contact

Norm

Up-to-spee

lose

Ope

lose

Ope

lose

Ope

lose

Ope

lose

Ope

Slow Spee

tar

Time (seconds

oas

Figure 3.31 Pump Control Sequence of Operation

Coast-to-Rest

100%

Up-to-Speed

Normal

Pump Stop (Stop Option)

Stop

Motor Speed

Push Buttons

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Start

Auxillary Contacts

Time in Seconds

If the Pump Stop is Selected

If the Coast-to-Rest is Selected

Pump Stop

Run

Pump Start

ATTENTION

Wiring 3-33

The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine.

3-34 Wiring

100%

Up-to-Speed

Normal

Smart Motor Braking

Stop

Motor Speed

Push Buttons

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Start

Auxillary Contacts

Time in Seconds

Run

Coast-to-Rest

Smart Motor Braking

Start

Automatic Zero Speed Shut-Off

If Brake Selected

If Coast-to-Rest Selected

(Stop Option )

ATTENTION

Figure 3.32 SMB Smart Motor Braking Sequence of Operation

The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine.

Figure 3.33 Accu-Stop Sequence of Operation

Start Run

100 %

Motor

Speed

Time (seconds)

Accu-Stop

Braking

Slow Speed

Slow Speed Braking

Accu-Stop

Push Buttons

Auxiliary Contacts

Up-to-speed

Normal

Stop

Start

Closed

Open

Closed

Open

Closed

If Coast-to-rest

Selected

Slow Speed

Braking

Slow

Speed

Coast-to-rest

➀

ATTENTION

Wiring 3-35

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

➀

The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine.

3-36 Wiring

ATTENTION

Motor Speed

Push Buttons

Slow Speed

(Stop Option )

Auxillary Contacts

Up-to-Speed

Start

Stop

Normal

SMB

100%

Closed

Figure 3.34 Slow Speed with Braking Sequence of Operation

Coast

Brake

Open

Slow Speed

Start

Run

Time in Seconds

Coast-to-Stop

Braking

Brake

Coast

Brake

If the Coast-to-Rest

is Selected

Special Application Considerations Use of Protective Modules

The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine.

A protective module (see Figure 3.35) containing metal oxide varistors (MOVs) can be installed to protect the power components from electrical transients and/or electrical noise. The protective modules clip transients generated on the lines and prevent such surges from damaging the SCRs.

Wiring 3-37

MADE IN U.S.A

PROTECTIVE MODULE

MAX. LINE VOLTAGE

Figure 3.35 Protective Module

There are two general situations that may occur which would indicate the need for using the protective modules.

1. Transient spikes may occur on the lines feeding the SMC-Flex

controller (or feeding the load from the SMC-Flex controller). Spikes are created on the line when devices are attached with current-carrying inductances that are open-circuited. The energy stored in the magnetic field is released when the contacts open the circuit. Examples of these are lightly loaded motors, transformers, solenoids, and electromechanical brakes. Lightning can also cause spikes.

2. The second situation arises when the SMC-Flex controller is

installed on a system that has fast-rising wavefronts present, although not necessarily high peak voltages. Lightning strikes can cause this type of response. Additionally, if the SMC-Flex controller is on the same bus as other SCR devices, (AC/DC drives, induction heating equipment, or welding equipment) the firing of the SCRs in those devices can cause noise.

Note: protective modules may be placed on the line, load, or both

sides of the SMC. However, protective modules must NOT be placed on the load side of the SMC when using inside-thedelta motor connections or with pump, linear speed, or braking control.

3-38 Wiring

Branc

otection

SMC

y (

)

y (

)

➀ Customer Supplied

➀

Multi-motor Applications The SMC-Flex controller will operate with more than one motor

connected to it. To size the controller, add the total nameplate amperes of all of the connected loads. The stall and jam features should be turned off. Separate overloads are still required to meet the National Electric Code (NEC) requirements.

Note: The SMC-Flex controller’s built-in overload protection

cannot be used in multi-motor applications.

Figure 3.36 Multi-Motor Application

-Phas

Input Powe

Mot

No.

-Flex

ontrolle

Rela

verload

O.L.

Mot

No.

verload

Rela

O.L

Wiring 3-39

3/5

3/6

SMC

O.L.

➁➁➁

➁

➃

➁

➂

SMC-Flex Controller as a Bypass to an AC Drive

-Phas

Input Powe

VFD Branch

Prot

tio

By using the controller as shown in Figure 3.37, a soft start characteristic can be provided in the event that an AC drive is nonoperational.

Note: A controlled acceleration can be achieved with this scheme,

but speed control is not available in the bypass mode.

Figure 3.37 Typical Application Diagram of a Bypass Contactor for an AC

Drive

➀➀

➀ Mechanical interlock required ➁ Customer supplied ➂ Many VF drives are rated 150% FLA. Because the SMC-Flex controller can be used for 600% FLA startin

separate branch circuit protection may be required. ➃ Overload protection is included as a standard feature of the SMC-Flex controller.

-Flex

ontrolle

3-40 Wiring

3/5

3/6

SMC

O.L.

➀

➁

➀

SMC-Flex Controller with a Bulletin 1410 Motor Winding Heater

-Phas

Input Powe

Figure 3.38 Typical Application Diagram of SMC-Flex Controller with a

Bulletin 1410 Motor Winding Heater

Bulletin 1410 MW

-Flex Controlle

➀ Customer supplied. ➁ Overload protection is included as a

standard feature of the SMC-Flex controller.

Chapter 4

Lang

Programming

Overview This chapter provides a basic understanding of the programming

keypad built into the SMC-Flex controller. This chapter also describes programming the controller by modifying the parameters.

Keypad Description The keys found on the front of the SMC-Flex controller are described

below.

Esc

Sel

Escape Exit a menu, cancel a change to a parameter value, or

acknowledge a fault/alarm.

Select Select a digit, select a bit, or enter edit mode in a

parameter screen. Will get to menu to change the language being displayed.

Up/Down Arrows

Enter Enter a menu, enter edit mode in a parameter screen, or

Scroll through options increase/decrease a value, or toggle a bit.

save a change to a parameter value.

Note: For ease of programming values, after using the Enter key to

edit, use the Sel key to jump to the digit that needs to be modified, then use the arrow keys to scroll through the digits.

Programming Menu Parameters are organized in a three-level menu structure for

straightforward programming. Figure 4.1 details the programming menu structure and the three-level hierarchy.

In order to change parameters, the controller must be in the STOP mode, and the control voltage must be present.

4-2 Programming

Device

Power-up and

Status Display

Parameter

Memory

Storage

Preferences

Diagnostics

Select

Monitoring Set Up Motor Protection Communications Utility Linear LIst

SMC-FLEX

Reset to Defaults

Change Password User Dspl Line User Dspl Time User Dspl Video Reset User Display

Alarms Faults Device Revision

Choose Mode

OPERATION LEVEL

MAIN MENU

➀

➁

Parameter menu continued in Figure 4.2

GROUP MENU

or oror or

Esc

Select language being displayed

Lang

Log-In

Enter Password

➂

Figure 4.1 Menu Structure Hierarchy

Sel

Esc

The SMC-Flex controller does not support EEPROM, Link, Process, or Start-up modes.

➀ ➁ Steps back one level. ➂ Only displayed if a password other than “0” is entered.

Figure 4.2 Parameter Menu Structure

Parameter

Metering Basic Overload Jam Comm Masks Language Linear List Volts Phase A-B SMC Option Overload Class Jam F Lvl Logic Mask Language All parameters

Volts Phase B-C Motor Connection Service Factor Jam F Dly

Parameter Mgt

➃ Parameter Mgt ➃ Parameter Mgt ➃

Volts Phase C-A Line Voltage Motor FLC Jam A Lvl Current Phase A Starting Mode Overload Reset Jam A Dly

DataLinks Motor Data

Current Phase B Ramp Time Overload A Lvl

Parameter Mgt

➃

Current Phase C Initial Torque

Parameter Mgt

➃

Data In A1 MotorFLC

Watt Meter Cur Limit Lvl

Stall

Data In A2 Motor ID

Kilowatt Hours Kickstart Time

Underload

Data In B1

Parameter Mgt

➃

Elapsed Time Kickstart Lvl Stall Dly Data In B2 Meter Reset Stop Input Underload F Lvl

Parameter Mgt

➃

Data In C1 Power Factor Option 1 Input Underload F Dly Data In C2 Mtr Therm Usage Option 2 Input Underload A Lvl

Ground Fault

Data In D1 Motor Speed Stop Mode Underload A Dly Data In D2

Stop Time

Parameter Mgt

➃

Gnd Flt Enable Data Out A1 Braking Current Gnd Flt Lvl Data Out A2 Overload Class

Undervoltage

Gnd Flt Dly Data Out B1 Service Factor Gnd Flt Inh Time Data Out B2 Motor FLC Undervolt F Lvl Gnd Flt A Enable Data Out C1 Overload Reset Undervolt F Dly Gnd Flt A Lvl Data Out C2 Aux1 Config Undervolt A Lvl Gnd Flt A Dly Data Out D1 Aux2 Config Undervolt A Dly

Parameter Mgt

➃

Data Out D2

Aux3 Config

Parameter Mgt

➃ Parameter Mgt ➃

Aux4 Config

PTC Backspin Timer

Overvoltage

Parameter Mgt

➃

PTC Enable

Overvolt F Lvl

Parameter Mgt ➃ Dual Ramp (Option

2 Input = Dual Ramp)

Overvolt F Dly Overvolt A Lvl

Phase Reversal

Overvolt A Dly

Starting Mode 2

Parameter Mgt

➃

Phase Reversal Ramp Time 2

Parameter Mtg

➃

Initial Torque 2

Unbalance

Cur Limit Lvl 2

Restart Kickstart Time 2 Unbalance F Lvl

Kickstart Lvl 2 Unbalance F Dly Starts Per Hour Parameter Mgt

➃

Unbalance A Lvl Restart Attempts Unbalance A Dly Restart Dly

Preset SS (Option 2 Input = Preset SS)

Parameter Mgt

➃ Parameter Mtg ➃

Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cur Parameter Mgt

➃

(Option 2 Input = Accu-Stop) Slow Speed Sel Slow Accel Cur Slow Running Cur Braking Current Stopping Current

Parameter Mgt

➃

Motor

Set Up

Utility Linear List⑤

Protection

Parameter

Monitoring

Communications

➀➂

➁

Esc

Programming 4-3

➀ Depending upon SMC option selected, some parameters may not appear in product display. ➁ Steps back one level. ➂ For further information on parameters, see Appendix B. ➃ For further information on parameter management, see page 4-6. ⑤ See page 4-4 for all SMC-Flex parameters available by the Linear List.

4-4 Programming

Parameter No. Description Parameter No. Description Parameter No. Description

Table 4.A Parameter Linear List

1 Volts Phase A-B 49 OL Trip Enable/Disable 97 Data Out A2 2 Volts Phase B-C 50 Overload A Lvl 98 Data Out B1 3 Volts Phase C-A 51 Underload F Lvl 99 Data Out B2 4 Current Phase A 52 Underload F Dly 100 Data Out C1 5 Current Phase B 53 Underload A Lvl 101 Data Out C2 6 Current Phase C 54 Underload A Dly 102 Data Out D1 7 Watt Meter 55 Undervolt F Lvl 103 Data Out D2 8 Kilowatt Hours 56 Undervolt F Dly 104 Motor ID

9 Elapsed Time 57 Undervolt A Lvl 105 CT Ratio 10 Meter Reset 58 Undervolt A Dly 106 MV Ratio 11 Power Factor 59 Overvolt F Lvl 107 Aux1 Config 12 Mtr Therm Usage 60 Overvolt F Dly 108 Aux3 Config 13 Motor Speed 61 Overvolt A Lvl 109 Aux4 Config 14 SMC Option 62 Overvolt A Dly 110 Aux2 Config 15 Motor Connection 63 Unbalance F Lvl 111 Language 16 Line Voltage 64 Unbalance F Dly 112 Timed Start 17 Starting Mode 65 Unbalance A Lvl 113 I Shut Off Level 18 Ramp Time 66 Unbalance A Dly 114 UTS Level 19 Initial Torque 67 Jam F Lvl 115 Parameter Mgmt 20 Cur Limit Start 68 Jam F Dly 116 Backspin Timer 21 Reserved 69 Jam A Lvl 117 VShut Off Level 22 Kickstart Time 70 Jam A Dly 118 OL Reset Level 23 Kickstart Level 71 Stall Delay 119 Ambient Temp 24 Option Input 2 72 Gnd Flt Enable 120 Notch Position 25 Starting Mode 2 73 Gnd Flt Level 121 Notch Maximum 26 Ramp Time 2 74 Gnd Flt Delay 122 Start Delay 27 Initial Torque 2 75 Gnd Flt Inh time 123 By-pass Delay 28 Cur Limit Level 2 76 Gnd Flt A Enable 124 Fault 1 29 Reserved 77 Gnd Flt A Level 125 Fault 2 30 Kickstart Time 2 78 Gnd Flt A Delay 126 Fault 3 31 Kickstart Level 2 79 PTC Enable 127 Fault 4 32 Stop Mode 80 Phase Reversal 128 Fault 5 33 Stop Time 81 Start Per Hour 129 Ramp Time E 34 Pump Pedestal 82 Restart Attempts 130 Ramp Time 2E 35 Braking Current 83 Restart Delay 131 Stop Time E 36 Braking Time 84 Line Fault Disable 132 Option Input 1 37 Load Type 85 Emergency Run 133 Stop Input 38 High Eff Brake 86 Current Loss 134 Elapsed Time 2 39 Slow Speed Sel 87 Logic Mask 40 Slow Speed Dir 88 Data In A1 41 Slow Accel Cur 89 Data In A2 42 Slow Running Cur 90 Data In B1 43 Stopping Current 91 Data In B2 44 Overload Class 92 Data In C1 45 Service Factor 93 Data In C2 46 Motor FLC 94 Data In D1 47 Overload Reset 95 Data In D2 48 OL Shunt Time 96 Data Out A1

Programming 4-5

Esc

Password The SMC-Flex controller allows the user to limit access to the

programming system through password protection. This feature is disabled with a factory-set default of 0. To modify the password, complete the procedure below.

Description Action Display

——

1. Press the ESC key to go from the status display to the Main menu.

2. Scroll with the Up/Down keys until the Preferences option is highlighted.

3. Press the Enter key to access the Preferences menu.

4. Scroll with the Up/Down keys until the Change Password option is highlighted.

0.0 Amps 0 Volt 0 %MTU

Main Menu

Preferences Diagnostics

Main Menu

Preferences

Diagnostics

Preferences: Change Passwor

User Dspy lines

Preferences:

Change Password

User Dspy lines

5. Press the Enter key.

6. Press the Up/Down keys to enter the desired number. If you are modifying the password, make a note of it as

Prefs: Password

New Code:

Verify: 83

displayed. Use the Sel key to highlight a single digit.

7. Verification of the new password is required. Press the Enter key.

8. Press the Enter key after you have completed modifying the password.

To complete the programming process, re-enter the Main Menu mode to log out. This will eliminate

➀

unauthorized access to the programming system.

➀

Preferences:

Change Password

User Dspy lines

Note: If you lose or forget the password, contact your local

Allen-Bradley distributor.

4-6 Programming

EEPROM RAM ROM

Esc

Parameter Management Before you begin programming, it’s important to understand how the

controller memory is:

• structured within the SMC-Flex controller

• used on power-up and during normal operation

Refer to Figure 4.3 and the explanations below.

Figure 4.3 Memory Block Diagram

Sel

Random Access Memory (RAM)

This is the work area of the controller after it is powered up. The SMC-Flex uses an Auto Store feature when programming parameters. When parameters are modified in the program mode, the new values are stored immediately in RAM and then in EEPROM, once the enter key has been pressed. If control power is lost prior to the enter key being pressed, these values will be lost. When the device first powers up, the values from the EEPROM area of memory are copied into RAM.

Read-only Memory (ROM)

The SMC-Flex controller comes with factory default parameter values. These settings are stored in non-volatile ROM and are displayed the first time you enter the Program mode. At any time you can restore defaults by accessing the memory storage menu.

Description Action Display

Recalling Defaults

After parameter values have been modified, factory default settings can still be re-initialized.

Memory Storage:

Reset to Defaults

Electrically Erasable Programmable Read-only Memory (EEPROM)

The SMC-Flex controller provides a non-volatile area for storing user-modified parameter values in the EEPROM.

Programming 4-7

0.0 Amps 0 Volt 0 %MTU

Esc

Main Menu

Parameter

Memory Storage

GP : File

Monitoring

Set Up

GP : File

Set Up

Motor Protection

F P: Group

Basic Set Up

FG : Parameter

Starting Mode

Ramp Time

FG :P#17

Starting M

ode

Current Lim

FG :P#18

Ramp Ti

10 Secs

Parameter Modification All parameters are modified using the same method. The basic steps

to performing parameter modification are described below. Notes: (1) Parameter values modified while the motor is operating

are not valid until the next time that operation occurs.

(2) If the password is set, parameters cannot be adjusted

without logging in.

(3) Use the Sel key to highlight a single digit.

Description Action Display ➁

——

1. Press the ESC key to go from the

—

status display to the Main menu.

2. Scroll with the Up/Down keys until the Parameter option is highlighted.

3. Press the Enter key to access the Parameter menu.

4. Scroll with the Up/Down keys until the option you want to use (Monitoring, Motor Protection, etc.) is highlighted. For this example, Set Up will be used.

5. Press Enter to select the Set Up

—

group.

6. Scroll to Basic Set Up and press

➀

Enter.

7. Scroll to the Starting Mode parameter by using the Up/Down keys, and press Enter.

8. Press Enter to select the option. Scroll to the option of your choice by using the Up/Down keys. For this example, we will choose Current Limit.

9. Press the Enter key to accept the

—

new setting.

10. Scroll to the next parameter by using the Down key. Continue the process until all desired settings are entered.

The SMC Option advises the user if any control option (i.e., Pump Control) is resident. This parame ter

➀

is factory set and cannot be modified by the user.

➁ The display will indicate that the second line is now active by highlighting the first character. If the

LCD display does not provide a highlighted cursor, then the controller is in the Display mode.

4-8 Programming

Soft Start The following parameters are specifically used to adjust the voltage

ramp supplied to the motor.

Parameter Option

Starting Mode

This must be programmed for Soft Start.

Ramp Time

This programs the time period that the controller will ramp the output voltage up to full voltage from the Initial Torque level programmed.

Initial Torque

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

Kickstart Time

A boost of current is provided to the motor for the programmed time period.

Kickstart Level

Adjusts the amount of current applied to the motor during the kickstart time.

➀

If the controller senses that the motor has reached full speed before completing the Soft Start, it will automatically switch to providing full voltage to the motor.

Soft Start

0…30 s

0…90% locked rotor torque

0.0…2.0 s

0…90% locked rotor torque

Current Limit Start To apply a current limit start to the motor, the following parameters

are provided for user adjustment:

Parameter Option

Starting Mode

This must be programmed for Current Limit.

Ramp Time

This programs the time period that the controller will hold the fixed, reduced output voltage before switching to full voltage.

Current Limit Level

This parameter provides adjustability for the reduced output voltage level provided to the motor.

Kickstart Time

A boost of current is provided to the motor for the programmed time period.

Kickstart Level

Adjusts the amount of current applied to the motor during the kickstart time.

➀

If the controller senses that the motor has reached full speed before completing the current limit start, it will automatically switch to providing full voltage to the motor.

Current Limit

0…30 s

50…600% full load current

0.0…2.0 s

0…90% locked rotor torque

Programming 4-9

Dual Ramp Start The SMC-Flex controller provides the user with the ability to select

between two Start settings. The parameters below are available in the Set Up programming mode. To obtain Dual Ramp control, Ramp #1 is located in the Basic Set Up and Ramp #2 is located in the Option 2 Input (Dual Ramp).

Parameter Option

Set Up

The user must select the Set Up programming mode to obtain access to the Dual Ramp parameters.

Basic Set Up/Starting Mode

Set Up as stated in previous pages.

Option 2 Input (Dual Ramp)

This allows the user the option to choose between two Soft Start profiles defined by:

1. Start Mode/Ramp Time/Initial Torque and

2. Start Mode 2/Ramp Time 2/Initial Torque 2.

When this feature is turned on, the ramp time/initial torque combination is determined by a hard contact input to terminal 15. When this input signal is low, ramp time/initial torque are selected. When this input is high, ramp time 2/initial torque 2 are selected. Once the Option 2 Input has been set to Dual Ramp, you must ESC back to the Parameter (File) menu. Re-enter into the Set Up menu to show both Basic Set Up and Dual Ramp.

Basic Set Up/Start Mode

This selects the start mode for option #1.

Basic Set Up/Ramp Time

This programs the time period during which the controller will ramp the output voltage up to full voltage for the first Start setup.

Basic Set Up/Initial Torque

This parameter establishes and adjusts the initial reduced output voltage level for the first Soft Start setup.

Dual Ramp/Start Mode 2

This selects the start mode for option #2.

Dual Ramp/Ramp Time 2

This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Start setup.

Dual Ramp/Initial Torque 2

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

➀

➁

—

0…30 s

0…90% locked rotor torque

—

0…30 s

0…90% locked rotor torque

➀ The Dual Ramp feaure is available on the standard controller. ➁ Kickstart can be programmed for both start modes.

4-10 Programming

Full Voltage Start The SMC-Flex controller may be programmed to provide a full

voltage start (output voltage to the motor reaches full voltage within 1/4 second) with the following programming:

Parameter Option

Starting Mode

This must be programmed for Full Voltage.

Full Voltage

Linear Speed The SMC-Flex provides the user the ability to control the motor speed

during starting and stopping maneuvers. A tach input is required as specified in Linear Speed Acceleration on page 1-6

Parameter Option

Starting Mode

This must be programmed for Linear Speed.

Ramp Time

This programs the time period that the controller will ramp from 0 speed to full speed.

Kickstart Time

A boost of current is provided to the motor for the programmed time period.

Kickstart Level

Adjusts the amount of current applied to the motor during the kickstart time.

Linear Speed

0…30 s

0.0…2.2 s

0…90% locked rotor torque

Programming 4-11

Programming Parameters The following table provides the option-specific parameters that are

provided with each control option. These parameters are in addition to those already discussed in the Basic Set Up and Metering groups. Diagrams supporting the options described below are shown later in this chapter.

Option Parameter Range

Standard

Soft Stop SMC Option

This parameter identifies the type of control present and is not user programmable.

Soft Stop Time

Allows the user to set the time period for the soft stopping function.

Preset Slow

Speed

SMC Option

This parameter identifies the type of control present and is not user programmable.

Slow Speed Select

Allows the user to program the slow speed that best fits the application.

Slow Speed Direction

This parameter programs the slow speed motor rotational direction.

Slow Accel Current

Allows the user to program the required current to accelerate the motor to slow speed operation.

Standard

0…120 s

Standard

Low: 7% – forward, 10% – reverse High: 15% – forward, 20% – reverse

Forward, Reverse

0…450% of full load current

Slow Running Current

Allows the user to program the required current to operate the motor at the slow speed setting.

0…450% of full load current

4-12 Programming

Option Parameter Range

Pump Control

Pump Control SMC Option

This parameter identifies the type of control present and is not user programmable.

Pump Stop Time

Allows the user to set the time period for the pump stopping function.

Starting Mode

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

Braking Control

SMB Smart

Motor Braking

Accu-Stop SMC Option

SMC Option

This parameter identifies the type of control present and is not user programmable.

Braking Current

Allows the user to program the intensity of the braking current applied to the motor.

This parameter identifies the type of control present and is not user programmable.

Pump Control

0…120 s

Pump Start, Soft Start, Current Limit Start

Braking Control

➀

0…400% of full load current

Braking Control

Slow Speed Select

Allows the user to program the slow speed that best fits the application.

Slow Accel Current

Allows the user to program the required current to accelerate the motor to slow speed operation.

Slow Running Current

Allows the user to program the required current to operate the motor at the slow speed setting.

Braking Current

Allows the user to program the intensity of the braking current applied to the motor.

Stopping Current

Allows the user to program the intensity of the braking current applied to the motor from slow speed operation.

➀

Low:7% High:15%

0…450% of full load current

0…400% of full load current

Programming 4-13

Option Parameter Range

Slow Speed

with Braking

SMC Option

This parameter identifies the type of

Braking Control

control present and is not user programmable.

Slow Speed Select

Allows the user to program the slow

Low:7% High:15%

speed that best fits the application.

Slow Accel Current

Allows the user to program the

0…450% of full load

current required current to accelerate the motor to slow speed operation.

Slow Running Current

Allows the user to program the

0…450% of full load

current required current to operate the motor at the slow speed setting.

Braking Current

➀

Allows the user to program the

0…400% of full load

current intensity of the braking current applied to the motor.

All braking/stopping current settings in the range of 1…100% will provide 100% braking current

➀

to the motor.

4-14 Programming

Basic Set Up The Basic Set Up programming group provides a limited parameter

set, allowing quick start-up with minimal adjustment. If the user is planning to implement some of the advanced features (e.g., Dual Ramp, or Preset Slow Speed), then the Setup programming group should be selected. It provides all the Basic Set Up parameter set plus the advanced set.

Parameter Option

SMC Option

Displays the type of controller. This is factory set and not adjustable.

Motor Connection

Displays the motor type to which the device is being connected.

Line Voltage

Displays the system line voltage to which the unit is connected.

Starting Mode

Allows the user to program the SMC-Flex 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.

Current Limit Level

The current limit level that is applied for the Ramp Time selected.

Kickstart Time

A boost current is provided to the motor for the programmed time period.

Kickstart Level

Adjusts the amount of current applied to the motor during kickstart.

Stop Input

Allows the user to select the operation of terminal 18, Stop Input.

Option 1 Input

Allows the user to select the operation of terminal 16, Option Input #1.

Option 2 Input

Allows the user to select the operation of terminal 15, Option Input #2.

Stop Mode

Allows the user to program the SMC-Flex controller for the type of stopping that best fits the application.

Stop Time

This sets the time period which the controller will ramp the voltage during a stopping maneuver.

Overload Class Disable, 10, 15, 20, 30 Service Factor 0.01…1.99 Motor FLC 1.0…2200 OL Reset Auto, Manual Aux1 Config

Contact is provided as standard with the SMC-Flex controller. This contact is located at terminals 19 and 20. Aux Contacts 1 allows the user to configure the operation of the contacts.

Aux2 Config

Contact is provided as standard with the SMC-Flex controller. This contact is located at terminals 29 and 30. Aux Contacts 2 allows the user to configure the operation of the contacts.

Aux3 Config

Contact is provided as standard with the SMC-Flex controller. This contact is located at terminals 31 and 32. Aux Contacts 3 allows the user to configure the operation of the contacts.

Aux4 Config

Contact is provided as standard with the SMC-Flex controller. This contact is located at terminals 33 and 34. Aux Contacts 4 allows the user to configure the operation of the contacts.

Parameter Mgmt

Recall of factory default parameter values.

➀

➁

Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter.

➀ ➁ Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level

parameter.

Standard

Line or Delta

Soft Start, Current Limit, Full Voltage, Linear Speed 0…30 s

0…90% of locked rotor torque

50…600% FLC

0.0…2.0 s

0…90% of locked rotor torque

Coast, Stop Option

Disable, Coast, Stop Option, Fault, Fault NC, Network Disable, Slow Speed, Dual Ramp, Fault, Fault NC, Network, Clear Fault Disable, Soft Stop, Linear Speed

0.0…120 s

Normal, Up-to-speed, Fault, Alarm, Network Control, External Bypass: (N.O./N.C.)

Ready, Load Default

Programming 4-15

ATTENTION

For overload protection, it is critical that the data be entered as it appears on the motor nameplate.

Motor Protection While the Basic Set Up group allows the user to get started with a

minimum number of parameters to modify, the Motor Protection group allows full access to the SMC-Flex controller’s powerful parameter set. Following is a listing of the additional setup parameters provided.

Note: The majority of parameters have a Fault and an Alarm

setting.

Parameter Option

Overload

Allows the user to select the operation of the overload:

Underload

Undervoltage ➀

Overvoltage

Unbalance

Jam

Determines the trip level as a percentage of motor full load current and delay period.

Stall

Ground Fault

Motor PTC

Phase Reversal

Restarts

➁

Determines the trip level as a percentage of the motor’s FLA, and the delay period.

Determines the trip level as a percentage of the line voltage and the delay period.

➀

Determines the trip level as a percentage of line voltage and delay period.

➀

Allows the user to set the current unbalance trip level and delay period.

➁

Allows the user to set the stall delay time.

➂

Allows the user to enable the ground fault level in amps, delay time, and inhibit time.

➃

Allows the user to connect a PTC to the SMC and enable a fault when it becomes active.

Determines the proper orientation of line connections to the SMC. If Enabled and phases are out of sequence, a fault will be indicated.

Allows the user to determine the maximum number of restarts per hour the unit can experience, and delay time between consecutive starts.

Trip Class, Service Factor, Motor FLC, Overload Reset, Overload Alarm Level Underload Fault Level, Underload Fault Delay, Underload Alarm Level, Underload Alarm Delay

Undervoltage Fault Level, Undervoltage Fault Delay, Undervoltage Alarm Level, Undervoltage Alarm Delay

Overvoltage Fault Level, Overvoltage Fault Delay, Overvoltage Alarm Level, Overvoltage Alarm Delay

Unbalance Fault Level, Unbalance Fault Delay, Unbalance Alarm Level, Unbalance Alarm Delay Jam Fault Level, Jam Fault Delay, Jam Alarm Level, Jam Alarm Delay Stall Delay

Ground Fault Enable, Ground Fault Level, Ground Fault Delay, Ground Fault Inhibit Time, Ground Fault Alarm Enable, Ground Fault Alarm Level, Ground Fault Alarm Delay PTC Enable

Phase Reversal

Restarts Per Hour, Restart Attempts, Restart Delay

➀ The delay time must be set to a value greater than zero when Undervoltage, Overvoltage, and

Unbalance are enabled.

➁ For Jam and Underload detection to function, the Motor FLC must be programmed in the Motor

Protection group. See Chapter 5 for instructions.

➂ See details in Ground Fault on page 1-15. ➃ See details in Thermistor/PTC Protection on page 1-17.

4-16 Programming

Example Settings Undervoltage ➀

With Line Voltage programmed for 480V and the Undervoltage level programmed for 80%, the trip value is 384V.

Overvoltage ➀

With Line Voltage programmed for 240V and the Overvoltage level programmed for 115%, the trip value is 276V.

Jam ➁➂

With Motor FLC programmed for 150 A and the Jam level programmed for 400%, the trip value is 600 A.

Underload ➁

With Motor FLC programmed for 90 A and the Underload level programmed for 60%, the trip value is 54 A.

The average value of the three phase-to-phase voltages is utilized.

➀ ➁ The largest value of the three phase currents is utilized. ➂ The SMC-Flex will self-protect.

Rockwell Automation 150 SMC-Flex User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual