Rockwell Automation 150 USE M User Manual
SMC Dialog Plus
Controller
Bulletin 150
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User Manual
5
Please Read!
This manual is intended to guide qualified personnel in the
installation and operation of this product.
Because of the variety of uses for this equipment and because of the
differ ences between this soli d-sta te equipmen t and electromecha nical
equipment, the user of and those respo nsible for applying this
equipment must satisfy thems elves as to the acceptability of each
application an d use of the equipment. In no event will Al len -Bradley
Company, Inc. be respons ible or liable for indirect or consequential
damages resulting fro m the use or applica tion of this equipment.
The illustrations shown in this manual are intende d solely to ill ustra te
the text of this manual. Because of the many variables and
requirements assoc iated with any particular inst allation, the AllenBradley Company, Inc. cannot assume responsibi lity or liability for
actual use based on the illustrative uses and applications.
No patent liability is ass umed by Allen-Bradley Company, Inc. with
respect to use of informati on, circuits, or equipment described in this
text.
Reproduction of the content of this manual, in whole or in part,
without written permission of the Allen-Bradley Company, Inc. is
prohibited.
Important User Information
The information in this manual is organized in numbered chapters.
Read each chapter in sequence and perform procedur es when you are
instructed to do so. Do not pr oceed to the next chapter until you have
completed all procedure s.
Throughout this manual attention statements make you aware of
safety considerations:
ATTENTION: Identifies information about pra ctices
or circumstances that can lead to personal injury or
!
Attentions help you:
• Identify a hazard
• Avoid the hazard
• Recognize the consequenc es
Importa nt: Identif ies information that is especially important for
SMC Dialog Plus, SMB, SCANport, and Accu-Stop are trademarks of Rockwell Automation.
DeviceNet is a trademark of the Open DeviceNet Vendors Association (O.D.V.A.)
death, property damage, or economi c loss .
successful applic ation and underst anding of thi s product.
For Bulletin 150 SMC Smart Motor Controller technical support on start-up or existing
installations, contact your Allen-Bradley representative. In the United States and Canada, you
can also call 1-800-765-SMCS (765-7627) for assistance Monday through Friday from 8:00
a.m. to 12:00 noon and 1:00 p.m. to 4:30 p.m. (central time zone). Areas outside the United
States and Canada can call 001-414-382-4650 for assistance.
Table of Contents
Chapter 1 Product Overview 1-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Starting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Energy Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Phase Rebalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Protection and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Stall Protection and Jam Detection . . . . . . . . . . . . . . . . . . . . . 1-8
Open Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Line Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Excessive Starts/Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Status Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Soft Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Pump Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Preset Slow Speed Option . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SMB‰ Smart Motor Braking Option . . . . . . . . . . . . . . . . . . 1-14
Accu-Stop‰ Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Slow Speed with Braking Option . . . . . . . . . . . . . . . . . . . . . 1-15
Chapter 2 Installation
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Ventilated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Non-ventilated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
toc–iv
Table of Contents
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Power Factor Correction Capacitors . . . . . . . . . . . . . . . . . . . . . . 2-9
Fast Acting Current-limiting Fuses . . . . . . . . . . . . . . . . . . . . . . 2-10
Protective Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Two-speed Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Multi-motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Connecting the Human Interface Module to the Controller . . . 2-13
Control Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Converter Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . 2-18
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Accessory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Chapter 3 Wiring
Chapter 4 Programming
Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Control Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Fan Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Fan Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Control Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Grounding Provision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Standard Controller Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 3-7
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Keypad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Programming Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Parameter Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Random Access Memory (RAM). . . . . . . . . . . . . . . . . . . . . . . . 4-6
Read-only Memory (ROM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Electrically Erasable Programmable
Read-only Memory (EEPROM) . . . . . . . . . . . . . . . . . . . . . . 4-6
Using Parameter Management . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Parameter Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Soft Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Advanced Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Table of Contents
toc–v
Example Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Jam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Chapter 5 Calibration
Chapter 6 Metering
Chapter 7 Options
Chapter 8 Serial Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Motor Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Viewing Metering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Control Wiring for SCANport Control . . . . . . . . . . . . . . . . . . . . . . 7-5
Soft Stop, Pump Control, and
SMB Smart Motor Braking Options . . . . . . . . . . . . . . . . . . . . . . . 7-6
Soft Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Pump Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
SMB Smart Motor Braking Option . . . . . . . . . . . . . . . . . . . . . . . 7-14
Preset Slow Speed and Accu-Stop Options . . . . . . . . . . . . . . . . 7-15
Preset Slow Speed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Accu-Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Slow Speed with Braking Option . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Logic Control Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Control Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
SMC Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Reference/Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Parameter Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Scale Factor Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Display Unit Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Datalinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Interfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Processing Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Remote I/O Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Example #1 – SLC 500 Controller without Block Transfer . . . . 8-5
1203-GD1 Communication Module Switch Settings . . . . . . . . 8-6
G File Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
I/O Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Example #1 - Ladder Logic Program . . . . . . . . . . . . . . . . . . . . 8-9
Example #2 - SLC 500 Controller with Block Transfer . . . . . . 8-10
1203-GD1 Communication Module Switch Settings . . . . . . . 8-10
Example #2 – Ladder Logic Program . . . . . . . . . . . . . . . . . . 8-15
toc–vi
Table of Contents
Example #3 – PLC 5/20, 5/40, 5/60, and 5/80 . . . . . . . . . . . 8-18
1203-GD1 Communication Module Switch Settings . . . . . . . 8-19
I/O Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Block Transfer Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Block Transfer Datafiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Example #3 Ladder Logic Program . . . . . . . . . . . . . . . . . . . . 8-23
DeviceNet Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Example #1 SLC Controller with Explicit Messaging. . . . . . . . 8-24
1203-GK5 Communication Module Switch Settings . . . . . . . . 8-24
Example Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
I/O Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
SMC Dialog Plus Controller Logic Command Addresses . . . . . 8-29
Explicit Messaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Explicit Message Request (Get Attribute Multiple) . . . . . . . . . 8-29
Explicit Message Response (Get Attribute Multiple) . . . . . . . . 8-29
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Setting up the Data File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Example Ladder Logic Program . . . . . . . . . . . . . . . . . . . . . . . 8-32
Chapter 9 Diagnostics
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Protection Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Clear Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Fault Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Fault Auxiliary Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Fault Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Line Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Phase Reversal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Overvoltage and Undervoltage Protection . . . . . . . . . . . . . . . . 9-3
Voltage Unbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Stall Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Open Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Excess Starts/Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Controller Temp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Comm Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Chapter 10 Troubleshooting
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Control Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
24–135 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
180–360 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
500–1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Protective Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
650–1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
MOV Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
500–1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Power Module and Interface Board Resistance Check . . . . . . 10-13
24–135 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
180-1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Appendix A Specifications
Appendix B Parameter Information
Appendix C Renewal Parts
Appendix D Accessories
Table of Contents
toc–vii
Figures
Figure 1.1 Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Figure 1.2 Selectable Kickstart . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1.3 Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1.4 Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1.5 Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1.6 Overload Trip Curves . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure 1.7 Restart Trip Curves after Auto Reset. . . . . . . . . . . . 1-7
Figure 1.8 Stall Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1.9 Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1.10 ScanPort Location . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Figure 1.11 Built-in Keypad and LCD . . . . . . . . . . . . . . . . . . . 1-11
Figure 1.12 Soft Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Figure 1.13 Pump Control Option . . . . . . . . . . . . . . . . . . . . . . 1-13
Figure 1.14 Preset Slow Speed Option . . . . . . . . . . . . . . . . . . 1-13
Figure 1.15 SMB Smart Motor Braking Option. . . . . . . . . . . . . 1-14
Figure 1.16 Accu-Stop Option . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Figure 1.17 Slow Speed with Braking Option . . . . . . . . . . . . . 1-15
Figure 2.1 Dimensions: 24, 35, and 54 Amp Controllers . . . . 2-4
Figure 2.2 Dimensions: 97 and 135 Amp Controllers . . . . . . . 2-5
Figure 2.3 Dimensions: 180 through 360 Amp Controllers . . . 2-6
Figure 2.4 Dimensions: 500 Amp Controller . . . . . . . . . . . . . . 2-7
Figure 2.5 Dimensions: 650-1000 Amp Controllers . . . . . . . . 2-8
Figure 2.6 Typical Wiring Diagram for Power
Factor Correction Capacitors . . . . . . . . . . . . . . . . . 2-9
Figure 2.7 SMC Dialog Plus Controller with
Human Interface Module . . . . . . . . . . . . . . . . . . . 2-13
Figure 2.8 SMC Dialog Plus Controller with
Communication Module . . . . . . . . . . . . . . . . . . . . 2-16
Figure 2.9 Converter Module Connection Interface . . . . . . . . 2-17
toc–viii
Table of Contents
Figure 2.10 Current Transformer Connection
to Converter Module . . . . . . . . . . . . . . . . . . . . . . 2-18
Figure 3.1 Wiring Terminal Locations (24 to 54 Amp) . . . . . . . 3-1
Figure 3.2 Wiring Terminal Locations (97 and 135 Amp) . . . . 3-1
Figure 3.3 Wiring Terminal Locations (180 to 360 Amp) . . . . . 3-2
Figure 3.4 Wiring Terminal Locations (500 Amp). . . . . . . . . . . 3-2
Figure 3.5 Wiring Terminal Locations (650 to 1000 Amp) . . . . 3-3
FIgure 3.6 97A and 135A Fan Terminations . . . . . . . . . . . . . . 3-5
Figure 3.7 180A to 500A Fan Terminations . . . . . . . . . . . . . . . 3-5
Figure 3.8 650A to 1000A Fan Terminations . . . . . . . . . . . . . . 3-5
Figure 3.9 SMC Dialog Plus Controller Control Terminals . . . . 3-6
Figure 3.10 Grounding Provision . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3.11 Typical Wiring Diagram for Standard Controller . . . 3-7
Figure 3.12 Typical Wiring Diagram for Two-Wire Control or
Programmable Control Interfacing . . . . . . . . . . . . . 3-8
Figure 3.13 Typical Wiring Diagram for
Dual Ramp Applications . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3.14 Typical Wiring Diagram for Start-Stop
Control via the SCANport . . . . . . . . . . . . . . . . . . . 3-10
Figure 3.15 Typical Wiring Diagram for
Retrofit Applications. . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3.16 Typical Wiring Diagram for
Isolation Applications . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3.17 Typical Wiring Diagram for
Bypass Applications . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3.18 Typical Wiring Diagram for Bypass
with Isolation Applications . . . . . . . . . . . . . . . . . . 3-14
Figure 3.19 Typical Wiring Diagram for
Shunt Trip Applications . . . . . . . . . . . . . . . . . . . . 3-15
Figure 3.20 Typical Wiring Diagram for Single
Speed Reversing Applications . . . . . . . . . . . . . . . 3-16
Figure 3.21 Typical Wiring Diagram for
Two-speed Applications . . . . . . . . . . . . . . . . . . . 3-17
Figure 3.22 Typical Wiring Diagram for
Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 3-18
Figure 4.1 Menu Structure Hierarchy . . . . . . . . . . . . . . . . . . . 4-2
Figure 4.2 Memory Block Diagram . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 7-1 Typical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 7-6
Figure 7.2 Typical Retrofit Wiring Diagram . . . . . . . . . . . . . . . 7-7
Figure 7.3 Typical Wiring Diagram for Applications
Requiring an Isolation Contactor . . . . . . . . . . . . . . 7-8
Figure 7.4 Typical Wiring Diagram for Applications
Requiring a Bypass Contactor . . . . . . . . . . . . . . . . 7-9
Figure 7.5 Typical Wiring Diagram for Two-wire Control
or Programmable Controller Interfacing . . . . . . . . 7-10
Figure 7.6 Typical Wiring Diagram for
Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 7-11
Figure 7.7 Soft Stop Option Sequence of Operation . . . . . . . 7-12
Figure 7.8 Pump Control Option Sequence of Operation . . . . 7-13
Table of Contents
toc–ix
Figure 7.9 SMB Smart Motor Braking Sequence
of Operation 7-14
Figure 7.10 Typical Wiring Diagram for the
Preset Slow Speed Option . . . . . . . . . . . . . . . . . . 7-15
Figure 7.11 Typical Retrofit Wiring Diagram . . . . . . . . . . . . . . 7-16
Figure 7.12 Typical Wiring Diagram for Applications
Requiring an Isolation Contactor . . . . . . . . . . . . . 7-17
Figure 7.13 Typical Wiring Diagram for Applications
Requiring a Bypass Contactor . . . . . . . . . . . . . . . 7-18
Figure 7.14 Typical Wiring Diagram for
Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 7-19
Figure 7.15 Preset Slow Speed Option
Sequence of Operation . . . . . . . . . . . . . . . . . . . . 7-20
Figure 7.16 Accu-Stop Option Sequence of Operation . . . . . . 7-21
Figure 7.17 Typical Wiring Diagram for the
Slow Speed with Braking Option . . . . . . . . . . . . . 7-22
Figure 7.18 Typical Retrofit Wiring Diagram for the
Slow Speed with Braking Option . . . . . . . . . . . . . 7-23
Figure 7.19 Typical Wiring Diagram for the Slow Speed
with Braking Option with an Isolation Contactor . . 7-24
Figure 7.20 Typical Wiring Diagram for the Slow Speed
with Braking Option with a Bypass Contactor . . . . 7-25
Figure 7.21 Slow Speed with Braking Option Sequence
of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Figure 9.1 Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Figure 10.1 Troubleshooting Flowchart. . . . . . . . . . . . . . . . . . 10-2
Figure 10.2 Removal of Control Module (24–135A) . . . . . . . . 10-7
Figure 10.3 Removal of Control Module (180–360A) . . . . . . . 10-9
Figure 10.4 Removal of Protective Cover (500–1000A) . . . . 10-12
Figure 10.5 Removal of Control Module (500–1000A) . . . . . 10-10
Figure 10.6 MOV Fuse Replacement . . . . . . . . . . . . . . . . . . 10-13
Figure 10.7 Pin Locations for Power Module
Resistance Check . . . . . . . . . . . . . . . . . . . . . . . 10-22
Figure 10.8 Pin Locations for Power Pole Resistance
Check (180–1000A) . . . . . . . . . . . . . . . . . . . . . 10-24
Figure 10.9 Gate and Thermistor Lead Identification
(180–1000A) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Tables
Table 2.A Maximum Heat Dissipation. . . . . . . . . . . . . . . . . . . 2-2
Table 2.B Minimum Ventilation Openings . . . . . . . . . . . . . . . 2-3
Table 2.C Recommended Fuses . . . . . . . . . . . . . . . . . . . . . 2-10
Table 2.D Converter Module Selection Guide . . . . . . . . . . . . 2-16
Table 3.A Lug Wire Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Table 3.B Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Table 3.C Lug Wire Capacity and Tightening Torque . . . . . . . 3-4
Table 3.D Heatsink Fan Control Power . . . . . . . . . . . . . . . . . . 3-4
Table 3.E Control Wiring and Tightening Torque . . . . . . . . . . 3-4
Table 4.A Parameter Linear List . . . . . . . . . . . . . . . . . . . . . . 4-4
Table 5.A Motor Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
toc–x
Table of Contents
Table 8.A Logic Control Data . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Table 8.B SMC Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Table 8.C Fault Code Cross-reference . . . . . . . . . . . . . . . . . . 9-2
Table 10.A SMC Fault Display Explanation . . . . . . . . . . . . . . 10-3
Table 10.B Motor Will Not Start — No Output Voltage
to the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Table 10.C Motor Rotates
(but does not accelerate to full speed) . . . . . . . . . 10-4
Table 10.D Motor Stops While Running . . . . . . . . . . . . . . . . . 10-4
Table 10.E Miscellaneous Situations . . . . . . . . . . . . . . . . . . . 10-5
Table B.1 Parameter Text/Display Unit Cross Reference. . . . . B-5
Product Overview
Chapter 1
Description
The SMC Dialog Plus controller offers a full range of starting modes
as standard:
• Soft Start with Selectab le Kickstart
• Current Limit Start with Selec table Kickstart
• Dual Ramp Start
• Full Voltage Start
Other features that offer further user benefit include:
• Expanded protective features
• Metering
• Communication capabil ity
Innovative starting and stopping options provide enhanced
performance:
• Soft Stop
• Pump Control
• Preset Slow Speed
Operation
• SMB™ Smart Motor Braking
• Accu-St op
• Slow Speed with Braking
These modes, features, and options are further describ ed in t his
chapter.
The SMC Dialog Plus controller can operate three-pha se squirrel cage
motors rated 1–1000A; 200–480V AC or 200–600V AC; 50/60 Hz.
Depending upon the catalog number ord ere d, the controller will
accept a control powe r input of either 100–240V AC or 24V AC/DC.
If the control power input option is 100–240V AC, the controller’s
microprocessor will se lf-adjust to the input control v oltage.
1-2
Start Run
Percent
Voltage
Initial
Torque
100%
Time (seconds)
Product Overview
Starting Modes
Soft Start
This mode has the most general application. The motor is given an
initial torque set ting, which is user-adjusta ble from 0 to 90% of
locked rotor torq ue. Fro m the init ial torque l e v el, t he output v olt age t o
the motor is steplessly inc rea sed during the acceleration ramp time.
The acceleration ramp time is user-adjustable from 0 to 30 seconds. If
the SMC Dialog Plus controller senses that the motor has reached the
up-to-speed condition during the voltage ramp operation, the output
voltage automatically switches to full voltage.
Figure 1.1 Soft Start
1-3
Selectable Kickstart
Product Overview
①
This feature pro vides a boost at startup to break away loads tha t
require a pulse of high torque to get started. This is intended to
provide a pulse of current that is 550% of full load current. Selectable
kickstart is user-adjustable from 0.0 to 2.0 seconds.
Figure 1.2 Selectable Kickstart
Percent
Voltage
Kickstart
100%
Initial
Torque
Current Limit Start
Start Run
②
Time (seconds)
This starting mode provides a fixed reduced voltage start; it is used
when limiting maximum starting current is necessary. The Current
Limit level is user-adjustable from 50 to 600% of the motor full loa d
ampere rating; and the current limit time is user-adjustable from 0 to
30 seconds. If the SMC Dialog Plus controller senses that the motor
has reached the up-to-speed condition during the current limit st arting
mode, the output voltage automatically switches to full voltage.
Figure 1.3 Current Limit Start
Percent
Full Load
Current
600%
50%
Start
Time (seconds)
①
Kickstart is also available with Current Limit Start.
②
The Current Limit Start mode design is based on a motor with a locked rotor current rating that is
600% of the full load current rating.
1-4
Percent
Voltage
Initial
Torque #1
100%
Start #1 Run #1
Ramp #2
Ramp #1
Start #2
Time (seconds)
Run #2
Initial
Torque #2
100%
Product Overview
Starting Modes (cont.)
Dual Ramp Start
①
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 Soft Start profiles
with separately adjustable ramp times and initial torque settings.
Figure 1.4 Dual Ramp Start
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
Percent
Voltage
Time (seconds)
①
Dual Ramp Start is available only with the standard controller.
Product Overview
1-5
Energy Saver
Phase Rebalance
The Energy Saver feature is typically use d in app lications where the
motor is lightly loaded or unloaded for extended periods of time.
With the Energy Saver f eature enabled, the SMC Dialog Plus
controller continuously monitors motor load with its interna l
feedback circuit ry. Because SCRs control the output voltage, motor
power losses may be redu ced by decreasing the motor terminal
voltage.
Notes: (1) The Energy Saver feature is not available when a bypass
contactor is used.
(2) When Energy Saver and Phase Rebalance are both
enabled, Phase Rebalance takes precedence in operation.
Wit h the Phase Rebalance feature enabled, the SMC Dialog Plus
controller continuously monitors the incoming three-pha se line
voltage and automatically adjusts the output voltage to balance the
three phase currents dr awn by the motor.
Notes: (1) Phase Rebalance requir es that the Bulletin 825 conv erter
module is utilized.
(2) Phase Rebalance is not active during byp ass ope r ation.
(3) When Phase Rebalance and Energy Saver are both
enabled, Phase Rebalance takes precedence in operati on.
Protection and
Diagnostics
The SMC Dialog Plus controller provides the protective and
diagnostic features described below.
Overload
The SMC Dialog Plus controller meets applicable requirements as a
motor overload protective device. T hermal memory provides added
protection and is maintained even when control po wer is removed . The
built-in o verload algorithm controls the value stored in P aramet er 11,
Motor Thermal Usage; an Overload Fault will occur when this value
reaches 100%. The programming parameters below provide
application flexibility and easy setup.
Paramete r Range
Overload Class Off, 10, 15, 20, 30
Overload Reset Manual – Auto
!
Motor FLC
Service Factor
ATTENTION: During slow speed and/or braking
operations, current waveforms exhibit non-sinusoidal
characteristics. These non-sinusoida l characteristics
inhibit the controller’ s current measure ment capability .
To compensate for additional motor heating that may
result, the controller uses motor thermal modeling,
which increments motor thermal usage . This
compensation take s place when these options are in use:
Preset Slow Speed, Smart Motor Braking, Accu-Stop,
and Slow Speed with Braking.
1.0
–
0.01
999.9 Amps
–
1.99
1-6
Product Overview
Protection and Diagnostics
(cont.)
Notes: (1) The factory default setting for Overload Class, which is
“Off,” disables overload protection. An overload trip
class and the motor’s full load current rating must be
programmed to enable overload protection.
(2) The current sensing capability of the SMC Dialog Plus
controller is disable d during bypass operation. Using a
Bulletin 825 converter module in these appli cations is
recommended to provi de curre nt feedback. Otherwise, a
separate overload relay is required.
(3) Motors with full load current ratings of 5 Amps and
below may requir e the use of the converter module
(Cat. No. 825-MCM20) for improved current
measurement accuracy.
(4) Automatic reset of an overload fault requires the start
input to be cycled in a 2-wire contr ol scheme. This
applies to the follo wing firmware relea ses: 1.07
(standard), 1A07L (Soft Stop) and 1B05L (Pump
Control) or earlier.
Figure 1.6 and Figure 1.7 provide the overload trip curves for the
ava ilable trip classes.
1000.0
100.0
Product Overview
Figure 1.6 Overload Trip Curves
Class 10 Class 15 Class 20 Class 30
10000.0
1000.0
10000.0
1000.0
10000.0
1000.0
1-7
10.0
1.0
Approximate Trip Time (seconds)
0.1
1 10 2 3 9 8 7 6 5 4
100.0
10.0
Approximate Trip Time (seconds)
1.0
1 10 2 3 9 8 7 6 5 4
100.0
10.0
Approximate Trip Time (seconds)
1.0
1 10 2 3 9 8 7 6 5 4
100.0
10.0
Approximate Trip Time (seconds)
1.0
1 10 2 3 9 8 7 6 5 4
Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC
Approximate trip time for 3-phase balanced
condition from cold start.
Approximate trip time for 3-phase balanced
condition from cold start.
Figure 1.7 Restart Trip Curves after Auto Reset
100000
1000
100
Seconds
10
1
0
100%
1000%
Percent Full Load Current Setting
Auto Reset Times:
Class 10 = 90s
Class 15 = 135s
Class 20 = 180s
Class 30 = 270s
Class 10
Class 15
Class 20
Class 30
1-8
Stall
600%
Percent
Full
Load
Current
Time (seconds)
Programmed Start Time
100%
Running Jam
Percent
Full
Load
Current
Time (seconds)
User Programmed Trip Level
Product Overview
Protection and Diagnostics
(cont.)
Stall Protection and Jam Detection
The SMC Dialog Plus controller provides both stall protection and
jam detection for enhanced moto r and syste m protection.
• Stall protection is user-adjustable from 0.0 to 10.0 seconds (in
addition to the ramp time programmed) .
• Jam detection allo ws the user to determine the jam lev el (up to
999% of the motor’s FLC rating) and the delay time (up to 10.0
seconds) for applica tion flexibility.
Figure 1.8 Stall Protection
Figure 1.9 Jam Detection
①
Jam detection is disabled during slow speed and braking operation.
①
Product Overview
1-9
Open Gate
An open gate fault indic ates tha t 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 Dialog Plus controller continually monitors line conditions
for abnormal factors. Pre-start protection includes:
• Power Loss (with phase indication)
• Line Fault (with phase indication)
– Po wer loss
– Missing load connection
– Shorted SCR
Running protection includes:
• Line Fault (no phase indi cation)
– Power loss
– Missing load connection
– Shorted SCR
Additional programmable parameters are provided for the foll owing
protective features:
①
• Undervoltage
can be adjust ed from 0 t o 99% of the programmed
line voltage and has a programmable delay time of 0 to 99
seconds.
①
• Overvoltage
can be adju sted fro m 0 to 199% of the programmed
line voltage and has a programmable delay time of 0 to 99
seconds.
②
• Phase reversal
• Voltage unbalance
protection can be toggled either On or Off.
①
protection can be programmed for trip levels
of 0 to 25% with a programmable delay time of 0 to 99 seconds.
Underload
③
Utilizing the underload pro tection of the SMC Dialog Plus controll er ,
motor operation can be halted if a sudden drop in current is sensed.
The SMC Dialog Plus controller provides an adjusta ble underload trip
setting from 0 to 99% of the programmed motor full load current
rating. Trip delay time can be adjusted from 0 to 99 seconds.
①
Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.
②
Phase reversal protection is functional only at pre-start.
③
Underload protection is disabled during slow speed and braking operations.
1-10
Product Overview
Protection and Diagnostics
(cont.)
Metering
Excessive Starts/Hour
The SMC Dialog Plus 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 Dialog Plus controller monitors the temperature of the
SCRs by using interna l thermistors. When the po wer poles’ maxi mum
rated temperature is reache d, S CR firing is inhibited.
An overtemper ature condition can indicate inadequate ventilation,
high ambie nt temper at ure, over l o a d in g, or exc essive cy cling. After
the SCR temperature is reduced to allowable levels, the fault c an be
cleared (see page 9-1 for instructions).
Power monitoring parameters include:
• Three-phase curren t
• Three-phase v oltage
• Power in kW
• Power usage in kWH
• Power factor
• Motor thermal capacity usage
• Elapsed time
Notes: (1) The current sensing capability of the SMC Dialog Plus
controller is disable d during bypass operation. A
Bulletin 825 converter module is required to maintain t he
three-phase current, kW, kWH, and motor thermal
capacity measurements.
(2) Current measurement is not available during the slow
speed and/or braking operations of the Preset Slow
Speed, SMB Smart Motor Braking, Accu-Stop and Slow
Speed with Braking control opti ons.
(3) Voltage measurement is not available during the braking
operation of the SMB Smart Motor Braking, Accu-St op,
and Slow Speed with Braking control options.
(4) The power fac tor parameter is pro vide d as a displacement
power fa ctor value. Powe r factor measurement is
disabled during bypass operation.
(5) The elapsed time and kWH values are automatically
saved to memory every 12 hours.
(6) Motor thermal capacity usage is deter mined by the built-
in electronic thermal overload protection system. An
overload fault occurs when this value reaches 100%.
Product Overview
1-11
Communication
A serial interface port (called SCANport™) is provided as standard,
which allows connection to the Bulletin 1201 human interface
modules and the Bulletin 1203 communication modules.
Figure 1.10 SCANport Location
SCANport
ATTENTION: Only one peripheral devic e can be
connected to the SCANport. The maximum output
!
current through the SCANport is 100 ma.
Programming
Status Indication
Setup is easy with the built-in keypad and two-line, sixteen character
backlit LCD. Parameters are organized in a four-level menu
structure, using a text format for straightforward programming.
Figure 1.11 Built-in Keypad and LCD
Three programmable hard conta ct outputs are provided as standard.
The first two contacts are Form C and programmable for Normal/Upto-speed. The third contact is programmable as Normal/Fault.
1-12
Start Run Soft Stop
Coast-to-rest
Soft
Stop
Kickstart
Initial
Torque
100%
Percent
Voltage
Time (seconds)
Product Overview
Control Options
The SMC Dialog Plus controller offers the control options described
below.
Importa nt: The options listed in this section are mutually exclusive
and must be specified whe n ordering. An existing
controller may be upgraded to anothe r control option by
replacing the c ontrol module. Consult yo ur nearest/local
Allen-Bradley sales office.
Soft Stop Option
This option can be used in applications that requir e an extended c oastto-rest. The voltage ramp down time is user-adjustable from 0 to 60
seconds and is adjusted indep endently from the starting time. The
load will stop when the output v olt age drops to a point where the load
torque is greater than the developed motor torque.
Figure 1.12 Soft Stop Option
ATTENTION: Soft Stop is not inten ded to be used as
an emergency stop. Refer to the applicable standards
!
for emergency stop requirements.
Product Overview
Pump Start Run Pump Stop
Motor
Speed
100%
Time (seconds)
1-13
Pump Control Option
This option reduces surges during the starting and stopping of a
centrifugal pump b y smoothly accelerating and decelerating the
motor. The microprocessor analyzes the motor variables and
generates commands that contr ol the motor and reduce the possibi lity
of surges occurring in the system.
The starting time is progra mmable from 0–30 seconds, and the
stopping time is programmable from 0–120 seconds.
Figure 1.13 Pump Control Option
ATTENTION: Pump stopping is not intended to be
used as an emergency stop. Refer to the applicable
!
!
standard for emergency stop requirements.
ATTENTION: 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.
Preset Slow Speed Option
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 (lo w) and 20% of base speed (high) set tings.
1-14
Forward
15% – High
7% – Low
10% – Low
20% – High
Reverse
Run Start Time (seconds)
Start
Motor
Speed
100%
Run
Automatic Zero Speed
Shut-off
Brake
Smart Motor Braking
Coast-to-rest
Time (seconds)
Product Overview
Figure 1.14 Preset Slow Speed Option
ATTENTION: Slow speed runni ng is not intended for
continuous operation due to reduced motor cooling.
!
Control Options (cont.)
SMB Smart Motor Braking Option
This option can be used in applications that require reduced stopping
times. The SMC Dialog Plus controller incorpor ates a
microprocessor-based system that applies braking current to a
standard squirrel cage induction 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 1.15 SMB Smart Motor Braking Option
Product Overview
Start
Run
Motor
Speed
100%
Slow
Speed
Accu-Stop
Braking
Slow
Speed
Slow Speed
Braking/Coast
7% or 15%
Time (seconds)
1-15
Note: All braking current settings in the range of 1–100% will
provide 100% braking current to the motor.
ATTENTION: SMB Smart Motor Braking is not
intended to be used as an emergency stop. Refer to
!
applicable standards fo r emer gency stop requirements.
Accu-Stop Option
This option combines the benefits of the SMB Smart Motor Braking
and Preset Slo w 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 1.16 Accu-Stop Option
1-16
Motor
Speed
100%
Start
Run Slow
Speed
Braking
7% or 15%
Stop
Coast-to-rest
Time (seconds)
Product Overview
Slow Speed with Braking Option
The Slow Speed with Bra king option pr o vides a jog spe ed for pr ocess
set-up and braking-t o-stop at the end of the cycle.
Figure 1.17 Slow Speed with Braking Option
!
ATTENTION: Accu-Stop and Slow Speed with
Braking are not intended to be used as an emergency
stop. Refer to applicable standards for emergency sto p
requirements.
Installation
Chapter 2
Receiving
Unpacking
Inspecting
Storing
It is the responsibili ty of the user to thorough ly inspect the equipment
before accepting the shipm ent from the freight company. Check the
item(s) received against the purchase order. If any items are
damaged, it is the responsibil ity of the user not to accept deli very until
the freight agent has note d the damage on the freight bill. Should any
concealed damage be found during unpac king, it is again the
responsibili ty of the user to notify the freight agent. The shipping
container must be left intact and the fr eight agen t should be requeste d
to make a visual inspection of the equipment.
Remove all packing material, wedges, or braces from within and
around the controlle r. Remove all packing material from the heat
sink.
After unpacking, check the it em(s’) nameplate catalog number
against the purchas e order.
The controller should remain in its shipping container prior to
installati on. If the equipment is not to be used for a period of time, it
must be stored according to the foll owing instructions in order to
maintain warranty c overage.
• 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
General Precautions
In addition to the precautions listed throughout this manual, the
following sta tements, which are general to the system, must be read
and understood.
ATTENTION: The controller contains ESD
(electrostatic di scharge) sensiti ve parts and assembl ies.
!
!
!
Static control precautions are require d when installing,
testing, servicing, or repa iring the assembly.
Component damage may result if ESD control
procedures are not follo wed. If you are not familiar with
static control procedures, refer to applicable ESD
protection handbooks.
ATTENTION: An incorrectly applied o r 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.
ATTENTION: Only personnel familiar with the
controller and associated machinery should plan or
implement the installation, start-up, and subsequent
maintenance of the sys tem. Failure to do this may r esult
in personal injury and/or equipment damage.
Heat Dissipation
SMC Rating
Max. Watts
24A 35A 54A 97A 135A 180A 240A 360A 500A 650A 720A 850A 1000A
110 150 200 285 410 660 935 1170 1400 2025 2250 2400 2760
Enclosures
The following table provides the maximum heat dissipation at rated
current for the controllers. For currents lower than rat ed value, heat
dissipation will be red uced.
Table 2.A Maximum Heat Dissipation
The open-style desig n of t he SMC Dialog Plus c ontroll er re quires t hat
it be installed in an enclosure. The internal temperature of the
enclosure must be kept within the range of 0°C to 50°C.
Installation
2-3
Ventilated Enclosures
For Type 1 (IP42) enclosures, the following guidelines are
recommended to limit the maximum controller ambient temperature.
There should be a clearance of at least six inc hes (15 cm) above and
below the contr oller. This area allows air to fl ow thro ugh the
heatsink. Ventilation openings are required above and below this air
space.
The ventilation outlet should be placed at least six inches (15 cm)
above the con troller with the ventilation inlet placed near the bottom
of the enclosure. A filter is required to preve nt contaminants from
entering the enclosu re.
Use the table below to det erm ine the minimum ventilation openings
and fan/blower requirements.
Table 2.B Minimum Ventilation Openings
SMC Rating Top Cutout
24–54A
97 and 135A
180A
240A
360A
500A
650A
720A
850A
1000A
65 cm
(10 in2)
233 cm
(36 in2)
13 × 51
(5 × 20)
13 × 51
(5 × 20)
13 × 51
(5 × 20)
13 × 41
(5 × 16)
②
②
②
②
①③
2
2
Bottom Cutout
2
65 cm
(10 in2)
2
233 cm
(36 in2)
②
②
②
②
13 × 76
(5 × 30)
13 × 76
(5 × 30)
13 × 76
(5 × 30)
13 × 76
(5 × 30)
①③
Fan Size
110 CFM
110 CFM
100 CFM
250 CFM
(2) 250 CFM
275 CFM
(3) 240 CFM
(3) 240 CFM
(3) 240 CFM
(3) 240 CFM
①
①
Cutout size assumes 50% blockage (filters, louvers, etc.)
②
Cutout size is the same as required for the particular fan or blower being used.
③
Dimensions are in centimeters (inches in parentheses).
Non-ventilated Enclosures
For Type 12 (IP54) or non-ventilated enclosures, it is recommended
that a bypass contactor be used. This will allow the SMC Dialog Plus
controller t o bring the m otor up- to-spee d. After the c ontroller is up to
full volta ge, it is bypassed. Note that the Energy Saver , Phase
Rebalance, some metering functions, and some protecti ve features of
the controller may no longe r be available. See Figure 3.17 on page 313 for this confi guration.
2-4
Installation
Mounting
D
C
The controller is c on v ect ion coole d. Additiona lly, units rated for 97A
and above 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 mus t be m ounted with he ats ink fins in a vertica l
plane and hav e a minimum of six inches ( 15 cm) free space above
and below the controller.
Dimensions
Figure 2.1 Dimensions: 24, 35, and 54 Amp Controllers
Ø .28 in.
(7.14 mm)
4 Mtg. Holes
Ø .22 in.
(5.56 mm)
4 Mtg. Holes
G F B
E
A
Unit
24A
Controller
35A
Controller
54A
Controller
All dimensions are approximate and are not intended for manufacturing purposes. Refer to the nearest Allen-Bradley sales office for complete dimension drawings.
mm 154 180 185 50 140 160 140 10 20 4.5 kg
in. 6-1/16 7-3/32 7-19/64 1-31/32 5-33/64 6-5/16 5-33/64 13/32 51/64 10 lbs.
mm 214 240 195 60 200 200 180 20 30 6.8 kg
in. 8-7/16 9-39/64 7-11/16 2-23/64 7-7/8 7-7/8 7-3/32 51/64 1-3/16 15 lbs.
mm 244 290 225 90 230 240 200 25 45 11.3 kg
in. 9-39/64 11-22/64 8-7/8 3-35/64 9-1/64 9-29/64 7-7/8 63/64 1-25/32 25 lbs.
A
Width
B
Height
C
Depth
DE F GHJ
Ground Screw
(10-32)
Approx.
Ship. Wt.
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