Rockwell Automation 150 USE M User Manual

Download

SMC Dialog Plus Controller

Bulletin 150

172718

152516

112112



User Manual

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.

Figure 1.7 Restart Trip Curves after Auto Reset

100000

1000

100

Seconds

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 × 41 (5 × 16)

② ②

②

①③

Bottom Cutout

65 cm (10 in2)

233 cm

(36 in2)

②

13 × 76 (5 × 30)

①③

Fan Size

110 CFM

100 CFM

250 CFM

(2) 250 CFM

275 CFM

(3) 240 CFM

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

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

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.

Width

Height

Depth

DE F GHJ

Ground Screw

(10-32)

Approx.

Ship. Wt.

Installation

Figure 2.2 Dimensions: 97 and 135 Amp Controllers

2-5

Power Terminal M10 Bolt 6 Places

D H

Ground

Screw (M6)

Fan

.281 in.

Termina ls (Ø 7.14 mm) 4 Mtg. Holes

Unit

97A

Controller

135A

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 248 336 256.2 128 220 250 40.4 14 10.4 kg

in. 9-49/64 13-15/64 10-3/32 5-3/64 8-21/32 9-27/32 1-39/64 9/16 23 lbs.

mm 248 336 256.2 128 220 250 40.4 14 11.8 kg

in. 9-49/64 13-15/64 10-3/32 5-3/64 8-21/32 9-27/32 1-39/64 9/16 26 lbs.

Width

Height

Depth

DE F GH

Approx.

Ship. Wt.

2-6

Installation

Mounting (cont.)

.281 (7.1)

Dia.

6 Mtg. Holes

.281 (7.1)

Rad.

2 Key Holes

180, 240, and 360 Amp

Dbl. Lug Mtg.

Figure 2.3 Dimensions: 180 through 360 Amp Controllers

Ground Nut

(1/4-20)

Terminal Detail

.136 (3.5) Dia. #8-32 UNC-2B

.413 (10.5) Dia.

1.02

.984

(25.9)

(25)

.531

(13.5)

2.250

1.161 (29.5)

(57)

Unit

WidthBHeightCDepth

mm 273 580 294.2 245 5 81 221 361 453 56 251 167 35 19.3 8.4 28 4.7 25 kg

180A Cont.

in. 10.750 22.063 11.583 9.647 .207 3.195 8.695 14.195 17.817 2.213 9.880 6.562 1.375 .76 .250 1.1 .187 55 lbs.

mm 273 580 294.2 245 5 81 221 361 453 56 251 167 35 19.3 8.4 28 4.7 30 kg

240– 360A Cont.

All dimensions are approximate and are not intended for manufacturing purposes. Refer to the nearest Allen-Bradley sales office for complete dimension drawings.

10.750 22.063 11.583 9.647 .207 3.195 8.695 14.195 17.817 2.213 9.880 6.562 1.375 .76 .250 1.1 .187 65 lbs.

in.

D E F G H J K L M N P QRS

Approx.

Ship.

Wt.

.531 in. (13.5 mm)

for 1/2 Bolts Typ.

Installation

Figure 2.4 Dimensions: 500 Amp Controller

2-7

.312 in. (7.9 mm)

6 Mtg. Holes

Unit

HeightBWidthCDepth

Q Q

DEFGHJKLMNPQ

Ground Nut

(1/4-20)

Approx.

Ship.

Wt.

mm 588.4 508 310.7 183 51.4 50.8 469.9 489 19 196.9 393.7 38.9 18.6 17.5 136 40.8 kg

in. 23-11/64 20 12-15/64 7-13/16 2-1/32 2 18-1/2 19-1/4 3/4 7-3/4 15-1/2 1-17/32 47/64 11/16 5-11/32 90 lbs.

All dimensions are approximate and are not intended for manufacturing purposes. Refer to the nearest Allen-Bradley sales office for complete dimension drawings.

2-8

Installation

Mounting (cont.)

2.0

(50.8)

.688

(17.5)

1.312 (33.3)

4.0

(101.6)

650–720 Amp

.515

(13.1)

Dia. Typ.

1.312 (33.3)

.56 Dia. (Ø 14.2)

2 – Lifting Holes

.5 Dia. (Ø 12.7)

6 – Holes

Figure 2.5 Dimensions: 650-1000 Amp Controllers

R R

.75 Dia. (Ø 19.1) 2 – Holes

.105 Steel

Sheet (2.67)

(63.5)

.64

(16.3)

Typ.

.64

(16.3)

850–1000 Amp

Typical Line and Load Bus

Unit

650 and

720A

Controller

850 and

1000A

Controller

All dimensions are approximate and are not intended for manufacturing purposes. Refer to the nearest Allen-BradleyAllen-Bradley sales office for complete dimension drawings.

mm 32.0 60.0 15.83 30.25 6.0 12.13 .875 .875 2.0 58.25 9.935 5.475 .75 329 317.5 246.1

in. 812.8 1524.0 402.1 768.35 152.4 308.0 22.22 22.23 50.8 1479.55 252.35 139.06 19.05 13 12.5 9.69

mm 32.0 60.0 15.83 30.25 6.0 12.13 .875 .875 2.0 58.25 9.935 5.475 .75 383 375 246.1

in. 812.8 1524.0 402.1 768.35 152.4 308.0 22.22 22.23 50.8 1479.55 252.35 139.06 19.05 15 14.75 9.69

.688

(17.5)

.67

(17)

.64

(16.3)

WidthBHeightCDepth

(wide range: #6 solid to 250 MCM stranded)

DEFGHJ K L MNPQR

Grounding Lug

5.0

2.5 (127)

Installation

2-9

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 c ontroll er. This must be done to pr e v ent damage to the SCRs in the SMC Dialog Plus 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 – 6 inch diameter coil, 6 loops

• 480–600V – 6 inch diameter coil, 8 loops T ak e care in mounting the coils so that they are not stack ed directly on

top of each other; stacking will cause a canceling ef f ect. Also, mount the coils on ins ulated supports away from metal parts so they will not act as induction heater s. If an isolation contactor is used, put capacitors in front of contactor.

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

Figure 2.6 Typical Wiring Diagram for Power Factor Correction Capacitors

➀

➁

L1/1 T1/2

Branch Circuit

Protection

➀

➀➀➀

Power Factor

Correction Capacitors

L2/3 T2/4

L3/5 T3/6

SMC Dialog

Plus

➀ ➁

➀

Motor

➀

Customer supplied Not required

2-10

Installation

Fast Acting Current-limiting Fuses

SMC

Rating

24A

35A

54A

97A

135A

180A

240A

360A

500A

650A

720A

850A

1000A

Short-circui t protec tion g uidelines are provided in Appendix A of this manual. Enhanced SCR protection may be obtained with the use of fast acting current-limiting fuses. Table 2.C provides a listing of fuses that are coordinate d to protect the controller SCRs in the event of a ground fault or short- circui t at the connected loa d. If SCR fusing is not used, the controller power modules may be damaged and require replacement. Supplementary SCR fusing, however, is not required by the NFPA 70 (National Electric Code).

Table 2.C Recommended Fuses

Fuse Manufacturer Cat. No.

Bussman Shawmut Edison (Brush) Ferraz Littlefuse

SPP-4F60

170M 3610-63

SPP-4F100

170M 3612-100

SPP-4F150

170M 3614-160

SPP-4F300

170M 3617-315

SPP-4F300

170M 3617-315

SPP-4F400

170M 3619-400

SPP-6F400

170M 5608-400

SPP-6F600

170M 5612-630

SPP-6F800

170M 6613-900

SPP-6F800

170M 6613-900

SPP-5F600

170M 5612-630

SPP-7F1200

170M 6615-1100

SPP-6F800

170M 6613-900

②

A70P70 XL70F080 A070F060 L70S60

A70P100 XL70F125 A070F100 L70S100

A70P200 XL70F200 A070F150 L70S150

A70P300 XL70F300 A070F300 L70S300

A70P400 XL70F400 A070F400 L70S400

A70P500 XL70F500 A070F400 L70S400

A70P800 XL70F600 A070F800 L70S600

A70P1000 XL70F500

A70P1200 XL70F600

A70P1000

Note: Fuse size listed is for 230V, 460V, or 575V.

①

Fuse manufacturer’s cross reference of the fuse Cat. Nos. listed here may not provide proper coordination.

②

Two fuses per phase are required for these controller ratings.

②

— A070F1200 L70S800

①

②

A070F800 L70S800

A070F800 L70S500

ATTENTION: The fast acting current- limiting fuses

specified in Table 2.C may not provide branch circuit protection. Branch circuit pro tection in accordance with applicable electr ical codes may require add itional fusing (or a circuit breaker) even though fast acting current-limiting fuses are used.

ATTENTION: Applications requiring extended acceleration times or high duty cycle s may experience nuisance trippi ng of the co ordinated fa st acti ng currentlimiting fuses. This type of fuse has a limited thermal capacity that is less than that of the SCRs they are designed to protect. This makes them susceptible to thermal fatigue.

Installation

2-11

Protective Modules

Motor Overload Protection

Prot ective modules containing metal oxide varistors (MOVs) and capacitors c an be ins talle d on controlle rs r ated 24A to 360A to prote ct the powe r component s f rom elec tric al tra nsients and/or high elec trical noise. The pr otective modules clip voltage transients generated on the lines to pre vent such surges from damaging the SCRs. The capa c i tors i n the protective modules are used to shunt noise energy away from the contr oller electronics. Surge protection is provide d as standard for controlle r s rated 500–1000A.

ATTENTION: When installing or inspecting the protective module, make sure that the controller has

Thermal motor ov erload protection is provided as standard (though it must be programmed) with the SMC Dialog Plus controller. If the overl oad trip class is less than the accelerati on time of the motor, nuisance tripping may occur.

been disconnected from the po wer source. The protectiv e modul e should be inspecte d periodi cally for damage or discoloration. Replace if nece ssary.

ATTENTION: Overload protecti on should be properly coordinated with the motor.

Three special applic ations require consideration: bypass, two-speed motors, and multi-motor protection.

Bypass

In a bypass configuration, the SMC Dialog Plus controller lose s

current sensing capability. It is recommended that a Bulletin 825 converter module be used to provide curr ent feedback to the SMC Dialog Plus controller for these applications to maintain the thermal memory and to maintain the SMC Dialog Plus controller’s power monitoring capability. It is possible, however, to use a traditional electromechani cal overload relay for b ypass configurations.

Two-speed Motors

The SMC Dialog Plus controller has ov er load prot ection a va il able for

single speed motors. Whe n th e SMC Dial og Plus contr oller i s a pplie d

to a two-speed 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 Dialog Plus contr oller is c ont rolling mor e than one motor,

individual overload protection is required for each motor.

2-12

Installation

Human Interface Module

The Bulletin 1201 human interface modules may be used to program

and control the SMC Dialog Plus controlle r. The human interface

modules have two sections: a display pa nel and a control panel. The

display panel duplicate s the 2-line, 16-character backlit LCD display

and programming keypa d found on front of the SMC Dialog Plus

controller. Refer to Chapter 4 for a description of the programming

keys; refer to Appendix D for a listing of human interface module catalog numbers that are compatible with the controller.

The control panel pro vides the operator interface to the controller.

Start

The green start b utton, when presse d, will be gi n motor operation.

Stop

The red stop button, when pressed, will halt motor operation.

JOG

Jog

The jog button is active only when a control option is present. Pressing the jog but ton wi ll ini tiate the opt ion maneuver (for example: Pump Stop).

ATTENTION: The Bulletin 1201 human interface module’ s stop push b utt on i s not inte nded to be us ed a s

All other contro ls available with the various human interface modules are non-functional with the SMC Dialog Plus controller .

an emergency stop. Refer to the applicable standards for emergency stop requirements.

SMC Dialog Plus Controller

Installation

2-13

Connecting the Human Interface Module to the Controller

Figure 2.7 sho ws th e connection of the S MC Dialog Plus c ontroller to

a human interface module. S ee Figure 3.14 on page 3-10 for the

control wiring diagra m that enables start-stop control from a human

interface module.

Figure 2.7 SMC Dialog Plus Controller with Human Interface Module

172718

Latching

Mechanism

Pull back moving part (connector body) to disconnect

Bulletin 1202

Cable

cable from the SCANport connection.

Human Interface Module

Control Enable

To enable motor control from a connected human interface module,

follow the procedure below with the connected human inte rface

module’s programming keys.

Note: Series A and Series B human interface modules require

different procedures. Be sure to use the correct table.

2-14

Installation

Human Interface Module (cont.)

Series A Human Interface Modules

Description Action Display

——

1. Press any key to access the Choose Mode function.

2. Scroll with the Up/Down keys until the Program option appears.

3. Press the Enter key to access the Program option.

4. Scroll with the Up/Down keys to the Linear List option.

5. Press the Enter key to access the Linear List programming group.

STOPPED

0.0 AMPS

CHOOSE MODE _ _ _ _ _

CHOOSE MODE PROGRAM

PROGRAM _ _ _ _ _

PROGRAM LINEAR LIST

VOLTS PHASE A-B 0 VOLTS 1

6. Scroll with the Up/Down keys to parameter number 85 – Logic

LOGIC MASK 085

Mask.

7. Press the Select key to move the cursor to the second line to modify the parameter.

①

8. Press the Up key until the value 4 appears.

9. Press the Enter key to accept the new setting.

Zero and 4 are the only valid settings.

①

LOGIC MASK 085

LOGIC MASK 485

Note: If a hum an interface module is disconnected from the SMC

Dialog Plus controller while the Logic Mask is set to 4, a “Comm Fault” will occur.

Series B Human Interface Modules

Description Action Display

Installation

2-15

——

1. Press any key to access

the Choose Mode function.

2. Scroll with the Up/Down

keys until the Control Logic option is presented.

3. Press the Enter key to

access Control Logic options.

4. Press the Select key to

access the settings available.

5. Use the Up/Down keys

to obtain the Enable option.

6. Press the Enter key to

accept.

STOPPED

0.0 AMPS

CHOOSE MODE _ _ _ _ _

CHOOSE MODE CONTROL STATUS

CONTROL LOGIC DISABLE

CONTROL LOGIC ENABLE

Note: If a hum an interface module is disconnected from the SMC

Dialog Plus controller while Control Logic is enabled, a “Comm Fault” will occur.

2-16

Installation

Communication Modules

251626

SMC Dialog Plus Controller

The Bulletin 1203 communicati on module al lows the user to connect the SMC Dialog Plus controller to v arious networks and communication protocols . The figure below sho ws how the cont roller and the communication module connec t.

Figure 2.8 SMC Dialog Plus Controller with Communication Module

Latching

Mechanism

Pull back moving part (connector body) to disconnect

cable from the SCANport connection.

V+

V-

Communication Module

Bulletin 1202

Cable

Converter Modules

The Bulletin 825 con verter module provides three-phase current feedback to the SMC Dialog Plus controller for metering and overload protection during phase rebalance and bypass operation.

Select the converter module based on the motor full load current (FLC) rating. Table 2.A details the information for proper selection.

Table 2.A Converter Module Selection Guide

Motor FLC Range Cat. No.

1–12.5A 825-MCM20

9–100A 825-MCM180

64–360A 825-MCM630

Installation

Figure 2.9 shows the connection between the controller and the module.

Figure 2.9 Converter Module Connection Interface

T1 T2 T3

L2 L3

Converter

➀

Module

Cable (provided as standard with the converter module)

➁

150-NFS

Fanning Strip

21 22 23 24 25 26 27 28 29 30

2-17

①

The converter module rating must be programmed in the calibration group for proper current measurement scaling.

②

Cable length is three meters. Only the cable provided with the converter module is compatible with the SMC Dialog Plus controller. Use of any other cable may result in faulty controller operation.

2-18

Installation

Converter Modules (cont.)

For applications in which the motor’s full load current rating is greater than 360A, three additional current transformers with 5A secondaries are requ ir ed. The figure below illustrates the connection of the current transformers to the converter module.

Figure 2.10 Current Transformer Connection to Converter Module

➀➁

Current Transformer

T1 T3

Converter Module

➂

Electromagnetic Compatibility (EMC)

The current transformer (CT) ration must be programmed in the calibration group for proper current

①

measurement scaling. See page 5-2 for instructions on programming this parameter.

②

Another current transformer connects L2 and T2, and another connects L3 and T3.

③

The converter module, Cat No. 825-MCM20, must be used in these applications.

ATTENTION: This product has been designed for Class A equipment. Use of the product in domestic

envir onments may cause radio interference, in which case, the installer may need to employ additional mitigation methods.

The followi ng guidelines are provided for EMC install ation compliance.

Enclosure

Install the product in a grounde d metal enclosure.

Grounding

Connect a grounding conductor to the screw or terminal provided as standard on each controller. Refer to Figure 2.1 through Figure 2.5 for grounding provision location.

Installation

2-19

Wiring

Wire in an industrial control application can be divided into three groups: power, control, and signal. The following recom mendations for physical separa tion between these groups is pro vided to reduce the coupling eff ect.

• Different wire gr o ups should cross at 90° inside an enclosur e.

• Minimum spacing be tween different wire groups in the same tray should be six inches (16 cm).

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

• Different wire gr o ups should be run in separate conduits.

• Minimum spacing between conduits co nta ining differe n t wire groups should be three inches (8 cm).

Accessory Requirements

When connection of the Bulletin 825 converter module or Bulletin 1202 communication c able is required, a f err ite core suppressor (FairRite PN 2643802702 or equal) should be used in conjuncti on. Mount the suppressor as close to the controller as practical, wrapping the cable twice through the suppr ess or.

2-20

Installation

Wiring

Chapter 3

Terminal Locations

The SMC Dialog Plus controller wiring terminal locations are shown in Figure 3.1 through Figure 3.4. Make wiring connections as indicated in the typical connection diagrams. Connect the line to terminals L1/1, L2/3, and L3/5. Connect the load to terminals T1/2, T2/4, and T3/6. For controllers rated 24–135A, a grounding screw is provided to ground the heatsink per applicable codes. For controllers rated 180A–1000A, a grounding lug is provided on the mounting plate.

Figure 3.1 Wiring Terminal Locations (24 to 54 Amp)

1121132312

14241525162617271828192920

Input Power

Connections

Control

Circuit

Connections

ESC. SEL .

Output Power

Figure 3.2 Wiring Terminal Locations (97 and 135 Amp)

Input Power

Connections

Control

Circuit

Connections

Output Power

Connections

Fan

Power

Connections

3-2

Wiring

Terminal Locations (cont.)

Input Power

Connections

Control

Circuit

Connections

Output Power

Connections

Figure 3.3 Wiring Terminal Locations (180 to 360 Amp)

Control Wiring Access Door

Fan Power

Connections

TB3

12 3 4 5

Figure 3.4 Wiring Terminal Locations (500 Amp)

Input Power

Connections

Fan Power

Connections

Control Circuit

Connections

Output Power

Connections

Wiring

Figure 3.5 Wiring Terminal Locations (650 to 1000 Amp)

Input and

Output Power

Connections

Control Circuit

Connections

Fan Power

Connections

Power Wiring

3-3

24–54A

The power modules for controllers rated 24A–54A have internal mechanical-type lugs to accept line and load cables. Table 3.A and Table 3.B provide the lug wire capacity and tightening torque requirements.

Table 3.A Lug Wire Capacity

Metric AWG

2.5–25 mm

#14–#4

Table 3.B Tightening Torque

Tightening Torque

Wire Size

To rq ue

2.5–6 mm

(14–10 AWG)

2.80 N-m (25 Lb-in)

10 mm (8 AWG)

3.4 N-m

(30 Lb-in)

16–25 mm

(6–4 AWG)

3.95 N-m (35 Lb-in)

97–1000A

Power lugs are available as optional kits. Each kit contains three lugs. The number of terminal lug kits required is listed in the table below. Table 3.C also provides the lug wire capacity and the tightening torque requirements.

3-4

Wiring

Terminal Locations (cont.)

Control Power

Table 3.C Lug Wire Capacity and Tightening Torque

SMC

Rating

97–

135A

180– 360A

500A 199-LG1

650– 720A

850–

1000A

Lug Kit

Cat. No.

199-LF1

199-LG1

199-LJ1

Conductor

Range

16–120 mm (#6–4/0 AWG)

25–240 mm

(#4–500 AWG)

50–240 mm

(1/0–500 AWG)

50–240 mm

[(2) 1/0–500 AWG]

Max. No.

Lugs/Pole

Line

Load

Side

Tightening Torque

Wire –

Lug

31 N-m

(275 lb-in)

31 N-m

(275 lb-in)

42 N-m

(375 lb-in)

42 N-m

(375 lb-in)

42 N-m

(375 lb-in)

Lug –

Busbar

31 N-m

(275 lb-in)

31 N-m

(275 lb-in)

45 N-m

(400 lb-in)

45 N-m

(400 lb-in)

45 N-m

(400 lb-in)

Control Voltage

Depending upon the catalog number ord ere d, the SMC Dialog Plus controller will accept a contr ol power input of:

• 100

• 24V AC, (–15/+10%), 1 phase, 50/60 Hz

240V AC, (–15/+10%), 1 pha se, 50/60 Hz

–

• 24V DC, (–20/+10%), 1 phase

Refer to the product nameplate. Connect control power to the controller at terminals 11 and 12. The

control po wer requirement for the control module is 40 VA. For controllers rat ed 97A

1000A, control power is also required for the

–

heatsink fans as defined in Table 3.D. Depending on the specific application, additional control circuit transformer VA capacity may be required.

Table 3.D Heatsink Fan Control Power

SMC Rating Heatsink Fan VA

97–360A 45

500A 145

650–1000A 320

Control Wiring

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

Table 3.E Control Wiring and Tightening Torque

Wire Size Torque

0.75–2.5 mm

(#18–#14)

.8 N-m (7 lb-in.)

Wiring

3-5

Fan Power

Controllers rated 97A–1000A have heats ink fan(s). Refer to Table 3.D for the control power VA requirements of the heatsink fans.

Fan Terminations

See Figure 3.2 to Figure 3.4 for fan power connection locations.

ATTENTION: The fan jumpers have been factory installed for 110/120 VAC input. Refer to Figure 3.6

Figure 3.6 97A and 135A Fan Terminations

through Figure 3.8 for 220/240 VAC fan wiring. Note that 220/240 VAC fan wiring is not available for the 650A–1000A controllers . After wiring f or the 97A and 135A controllers is complete, replace cont rol terminal strip cover.

Factory Set

110/120 VAC

1 2

Jumpers

Supply

Optional

220/240 VAC

1 2

Jumper

Supply

Figure 3.7 180A to 500A Fan Terminations

Factory Set

110/120 VAC

Supply

Jumpers Jumper

1 2 3 4 5

Figure 3.8 650A to 1000A Fan Terminations

Factory Set

110/120 VAC

Supply

Note: 220/240 VAC is not available.

Optional

220/240 VAC

Supply

1 2 3 4 5

3-6

Wiring

Control Terminal Designations

As shown in Figure 3.9, the SMC Dialog Plus controller contains 20 control terminals on the front of the controller.

Figure 3.9 SMC Dialog Plus Controller Control Terminals

Ter min al

Number

11 Control Power Input 21 Not Used

12 Control Power Common 22 Not Used

13 Controller Enable Input

14 Logic Ground 24 Not Used

15 Dual Ramp/Option Input

16 Start Input

17 Stop Input

18 Auxiliary Relay Common 28 Converter Module Fanning Strip Connection

19 N.O. Auxiliary Contact #1 (Normal/Up-to-speed) 29 N.O./N.C. Auxiliary Contact #3 (Normal/Fault)

20 N.C. Auxiliary Contact #2 (Normal/Up-to-speed) 30 N.O./N.C. Auxiliary Contact #3 (Normal/Fault)

Description

①

Ter min al

Number

23 Not Used

25 Converter Module Fanning Strip Connection

26 Converter Module Fanning Strip Connection

27 Converter Module Fanning Strip Connection

Description

② ② ② ②

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.

① ②

When control power is absent from terminals 11 and 12, this contact will be normally open. Upon application of control power, the contact will take the state, normally open or normally closed, as programmed.

Grounding Provision

Provision for connecting a field installed grounding conductor is provided on each controller . It is shown in Figure 3.10 and is located on the heatsink. This symbol is the ground connection identific ation symbol as defined by IEC Publication 417, Symbol 5019.

If the pr o tec tive c onductor is not connected to the heatsink, the plating and/or pain t must be cleaned from the four mounting holes or four star washers (t ooth lock washers) must be used.

Figure 3.10 Grounding Provision

Wiring

Stop

➀

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Start

➀

Internal Auxiliary Contacts

SMC Dialog Plus

Control Terminals

3-Phase

Input Power

Branch

Protection

➀

Fast-acting SCR Fuses (optional)

➀

SMC Dialog Plus

Controller

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

➀

➁

3-7

Standard Controller Wiring Diagrams

Figure 3.11 through Figure 3.22 show typical wiring for the SMC Dialog Plus controller.

Figure 3.11 Typical Wiring Diagram for Standard Controller

Customer supplied.

① ②

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

3-8

Two-wire Device

➀

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Internal Auxiliary Contacts

3-Phase

Input Power

Branch

Protection

➀

Fast-acting SCR Fuses (optional)

➀

SMC Dialog Plus

Controller

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

➀

➁

SMC Dialog Plus

Control Terminals

Wiring

Standard Controller Wiring Diagrams (cont.)

Figure 3.12 Typical Wiring Diagram for Two-Wire Control or Programmable

Control Interfacing

Customer supplied.

① ②

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

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

PLC’s output contacts and the SMC Dialog Plus controller’s control terminals. For a wiring diagram related to programmable controller interfacing via the SMC Dialog Plus controller’s SCANport, refer to Figure 3.14.

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

Stop

➀

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Start

➀

Ramp 1 ➀Ramp 2

Internal

Auxiliary Contacts

3-Phase

Input Power

Branch

Protection

➀

Fast-acting SCR Fuses (optional)

➀

SMC Dialog Plus

Controller

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

➀

➁

SMC Dialog Plus

Control Terminals

Wiring

3-9

Figure 3.13 Typical Wiring Diagram for Dual Ramp Applications

Customer supplied.

① ②

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

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

3-10

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Internal Auxiliary Contacts

3-Phase

Input Power

Branch

Protection

➀

Fast-acting SCR Fuses (optional)

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

➀

➁

➂

SMC Dialog Plus

Controller

SMC Dialog Plus

Control Terminals

Wiring

Standard Controller Wiring Diagrams (cont.)

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

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

either a Bulletin 1201 human interface module or a Bulletin 1203 communication module connec ted to the SMC Dialog Plus controller’s SCANport.

① ②

③

Customer supplied.

If the Soft Stop, Pump Control, or the SMB Smart Motor Braking option is installed, place additional jumper to terminal 15.

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

Stop

➀

Start

➀

3-Phase

Input Power

Branch

Protection

➀

Fast-acting SCR Fuses

(optional)

➀

➀ ➁

➀

➂

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Internal Auxiliary Contacts

Auxiliary contacts

set for Normal

SMC Dialog Plus

Controller

SMC Dialog Plus

Control Terminals

Existing Motor

Starter

➀

Wiring

3-11

Figure 3.15 Typical Wiring Diagram for Retrofit Applications

Customer supplied.

① ②

Overload protection should be disabled in the SMC Dialog Plus controller.

③

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

3-12

Stop

➀

3-Phase

Input Power

Branch

Protection

➀

Fast-acting

SCR Fuses

(optional)

➀

Isolation

Contactor

(IC)

➀

➁

11 12 13 14

21 22 23

Contacts

Auxiliary contacts

set for Normal

SMC Dialog Plus

Controller

SMC Dialog Plus

Control Terminals

Wiring

Standard Controller Wiring Diagrams (cont.)

Figure 3.16 Typical Wiring Diagram for Isolation Applications

L1/1

T1/2

L2/3

T2/4

L3/5

T3/6

Start

Customer supplied.

① ②

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

15 16 17 18 19 20

Internal

Auxiliary

24 25 26 27 28 29 30

Wiring

Stop

➀

Start

➀

3-Phase

Input Power

Branch

Bypass Contactor (BC)

➀

Protection

➀

Fast-acting SCR Fuses

(optional)

➀

Bulletin 825

Converter

Module

➀ ➁

➀

➂

11 12 13 14 15 16 17 18 19

21 22 23 24 25 26 27 28 29

Contacts

Fanning Strip

➀

Bulletin 825

Converter

Module

Auxiliary

contacts set for

Up-to-speed

SMC

Dialog Plus

Controller

SMC Dialog Plus

Figure 3.17 Typical Wiring Diagram for Bypass Applications

T1/2

L1/1

T2/4

L2/3

T3/6

L3/5

3-13

Control Terminals

Internal

Auxiliary

Customer supplied.

① ②

The Bulletin 825 Converter Module is required when the SMC Dialog Plus controller will be providing motor overload protection during bypass operation.

③

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

3-14

Stop

➀

Start

➀

Bypass Contactor (BC)

➀

➁

3-Phase

Input Power

Branch

Protection

➀

Fast-acting

SCR Fuses

(optional)

➀

Isolation

Contactor

(IC)

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Fanning Strip

➀

Bulletin 825

Converter

Module

Auxiliary contacts

set for Up-to-speed

Auxiliary contact

set for Normal and N.O.

SMC Dialog Plus

Controller

SMC Dialog Plus

Control Terminals

Wiring

Standard Controller Wiring Diagrams (cont.)

Figure 3.18 Typical Wiring Diagram for Bypass with Isolation Applications

Bulletin 825 Converter Module

Customer supplied.

① ②

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

Wiring

Stop

➀

Start

➀

➁

3-Phase

Input Power

Branch

Protection

➀

Fast-acting

SCR Fuses

(optional)

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

Auxiliary contact

set for Fault

and N.O.

SMC Dialog Plus

Controller

SMC Dialog Plus

Control Terminals

Figure 3.19 Typical Wiring Diagram for Shunt Trip Applications

Shunt Trip Circuit Breaker

3-15

12 13 14 15 16 17 18 19 20

➀

22 23 24 25 26 27 28 29 30

Customer supplied.

① ②

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

3-16

Wiring

Standard Controller Wiring Diagrams (cont.)

3-Phase

Input Power

➀

Stop

Branch

Protection

➀

FOR REV

Figure 3.20 Typical Wiring Diagram for Single Speed Reversing Applications

➀

OFF

Reversing Contactors

➀

Bulletin 825

Coverter

➀

Module

(optional)

➀

Fast-acting

SCR Fuses

(optional)

L1/1

L2/3

L3/5

SMC Dialog Plus

Controller

➀

T1/2

T2/4

T3/6

➀

➁

11 12 13 14 15 16 17 18 19 20

SMC Dialog Plus

Control Terminals

21 22 23 24 25 26 27 28 29 30

Customer supplied.

① ②

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

Internal Auxiliary Contacts

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

(2) Phase Reversal protection

must

be disabled in reversing applications.

Wiring

3-Phase

Input Power

Branch

Protection

➀

Two-speed Motor Starter

➀

Fast-acting

SCR Fuses

(optional)

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

➁

Stop

➀

High

Low

LOL

➀

HOL

➀

1 sec.

➂

➀

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Internal

Auxiliary

Contacts

SMC Dialog Plus

Controller

SMC Dialog Plus

Control Terminals

Figure 3.21 Typical Wiring Diagram for Two-speed Applications

3-17

① ②

③

Customer supplied.

Two-speed, consequent pole installations.

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

3-18

3-Phase

Input Power

Branch

Protection

➀

Fast-acting

SCR Fuses

(optional)

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

➁

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Internal Auxiliary Contacts

SMC Dialog Plus

Controller

SMC Dialog Plus

Control Terminals

Wiring

Standard Controller Wiring Diagrams (cont.)

Figure 3.22 Typical Wiring Diagram for Hand-Off-Auto (SCANport) Control

Customer supplied.

① ②

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

Programming

Chapter 4

Overview

Keypad Description

This chapter provides a basic understanding of the programming keypad built into the SMC Dialog Plus controller. This chapter also describes programming the cont roller by modifying the parameters.

The keys found on the front of the SMC Dialog Plus contr oller are described below.

Escape

ESC

Select

SEL

Up/Down

Arrows

Pressing the Escape key causes the programming system to move up one level in the menu structure.

The Select key has two functions:

• Pressing the Select key alternately causes the top or bottom line of the display to become active (indicated by flashing first character).

• In parameter modification with series A FRN 3.00 or greater and series B human interface modules, Select moves the cursor from the least significant digit to the most significant.

These keys are used to increment and decrement a parameter value or to scroll through the different modes, groups, and parameters.

Programming Menu

Enter

When pressed, a mode or group will be selected, or a parameter value will be entered into memory. After a parameter value has been entered into memory, the top line of display will automatically become active, allowing the user to scroll to the next parameter.

Parameters are organize d in a four-level menu struc t ur e for straightforw ard programming. Figure 4.1 details the programming menu structure and the four-level hierarchy.

4-2

Programming

Programming Menu (cont.)

Control

➁

Status

Display

read only

Figure 4.1 Menu Structure Hierarchy

Power-up and

Status Display

Choose Mode

Program

read/write

Password

See page 4-5

OPERATION LEVEL

read only

See page 4-5

MODE LEVELMODE LEVEL

➂➃➂➃

➀

Control Logic

Fault Queue

Linear

List

Metering

See

Chapter 6

Basic Setup Advanced Setup

➁

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

① ②

Steps back one level.

③

Control Status and Search are only available when using a Series B Bulletin 1201 human interface module.

④

Password protected.

⑤

English is currently the only available language.

Faults

Calibrate

See

Chapter 5

Language

⑤

GROUP LEVEL

Programming

Figure 4.1 (Cont.) Menu Structure Hierarchy

4-3

Linear

List

Metering

See

Chapter 6

Basic Setup Advanced Setup

Faults

➀

Calibrate

See

Chapter 5

Language

➁

GROUP LEVEL

➀

Volts Phase A–B Volts Phase B–C Volts Phase C–A Current Phase A Current Phase B Current Phase C Wattmeter Kilowatt Hours Elapsed Time Power Factor Mtr. Therm. Usage

SMC Option Starting Mode Ramp Time #1 Initial Torque #1 Curr. Limit Level Kickstart Time Stall Delay Energy Saver Aux Contacts 1&2 Aux Contact #3 Contact 3 Config (Option Setting) Parameter Mgmt

④

SMC Option Starting Mode Dual Ramp Ramp Time #1 Initial Torque #1 Ramp Time #2 Initial Torque #2 Curr. Limit Level Kickstart Time Stall Delay Energy Saver Aux Contacts 1&2 Aux Contact #3 Contact 3 Config (Option Setting)

Clear Fault Fault Buffer #1 Fault Buffer #2 Fault Buffer #3 Fault Buffer #4 Fault Buffer #5

Overload Class Overload Reset Motor HP Rating Motor kW Rating Line Voltage Motor FLC Service Factor Motor Code Letter LRC Ration Converter Rating CT Ratio Calibration Enter Calib. Amps Current Phase A Parameter Mgmt.

④

Undervolt Level Undervolt Delay Overvolt Level Overvolt Delay Jam Level Jam Delay Unbalance Level Unbalance Delay Rebalance Underload Level Underload Delay Phase Reversal Starts per Hour Restart Attempts Restart Delay ETM Reset Parameter Mgmt

④

③

PARAMETER LEVEL

Steps back one level.

① ②

English is currently the only available language.

③

For further information on parameters, see Appendix B.

④

For further information on parameter management, see pages 4-6 and 4-7.

4-4

Programming

Programming Menu (cont.)

Table 4.A Parameter Linear List

Parameter No. Description Parameter No. Description

1 Volts Phase A–B 45 Slow Speed Dir.

2 Volts Phase B–C 46 Slow Accel Cur.

3 Volts Phase C–A 47 Slow Running Cur.

4 Current Phase A 48 Braking Current

5 Current Phase B 49 Factory Use

6 Current Phase C 50 Factory Use

7 Wattmeter 51 Stopping Current

8 Kilowatt Hours 52 Undervolt Level

9 Elapsed Time 53 Undervolt Delay

10 Power Factor 54 Overvolt Level

11 Mtr. Therm Usage 55 Overvolt Delay

12 Factory Use 56 Jam Level

13 Factory Use 57 Jam Delay

14 SMC Option 58 Unbalance Level

15 ETM Reset 59 Rebalance

16 Factory Use 60 Underload Level

17 Parameter Mgmt. 61 Underload Delay

18 Clear Fault 62 Phase Reversal

19 Fault Buffer #1 63 Starts per Hour

20 Fault Buffer #2 64 Restart Attempts

21 Fault Buffer #3 65 Restart Delay

22 Fault Buffer #4 66 Factory Use

23 Fault Buffer #5 67 Factory Use

24 Factory Use 68 Factory Use

25 Factory Use 69 Line Voltage

26 Factory Use 70 Motor FLC

27 Factory Use 71 Factory Use

28 Starting Mode 72 Mtr. Code Letter

29 Dual Ramp 73 Factory Use

30 Ramp Time #1 74 Converter Rating

31 Initial Torque #1 75 CT Ratio

32 Ramp Time #2 76 Calibration

33 Initial Torque #2 77 Enter Calib. Amps

34 Curr. Limit Level 78 Language Select

35 Kickstart Time 79 Motor HP Rating

36 Overload Class 80 Motor kW Rating

37 Stall Delay 81 LRC Ratio

38 Energy Saver 82 Factory Use

39 Aux Contacts #1&2 83 Factory Use

40 Aux Contact #3 84 Service Factor

41 Contact 3 Config 85 Logic Mask

42 Stop Time 86 Unbalance Delay

43 Factory Use 87 S/W Version

44 Slow Speed Sel. 88 Overload Reset

Programming

4-5

Password

The SMC Dialog Plus control ler allows the user to limit access to the programming system through password protection. This feature is a disabled with a facto ry-se t parameter with a default setting of 0. T o modify the password or login after a password is programmed, complete the procedure below.

Description Action Display

——

1. Press any key to go from the status display to the Choose Mode menu.

2. Scroll with the Up/ Down keys until the Password option appears.

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

STOPPED

0.0 AMPS

CHOOSE MODE DISPLAY

CHOOSE MODE PASSW ORD

PASSW ORD |MODIFY

Options:

Logout

4. Press the Enter key.

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

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

After you have completed the programming process, re-enter the Password mode to log out. This

①

will eliminate unauthorized access to the programming system.

①

ENTER PASSWORD _ _ _ _ _

ENTER PASSWORD #####

CHOOSE MODE PASSW ORD

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

Allen-Bradle y sales office. You can also call 1-800-765- SMCS (765-7627) for assistance.

The Search mode allows the user to view only those parameters that have settings other than the factory defa ult values. This mode is ava ilable only when using Bulletin 1201 human interface module.

4-6

Programming

Parameter Management

Before you begin progr amming, it’s important to understand how the controller memory is:

• structured withi n the SMC Dialog Plus cont roller

• used on power-up and during normal operation Refer to Figure 4.2 and the explanations below.

Figure 4.2 Memory Block Diagram

EEPROM RAM ROM

Random Access Memory (RAM)

This is the work area of the controller after it is powered up. When you modify parameters in the Program mode, the new va lues are stored in RAM. When power is applied to the controller, para meter values stored in the EEPROM are copied to RAM. RAM is volatile

and the values store d in this area are lost when the controller is powered down.

Read-only Memory (ROM)

The SMC Dialog Plus controller comes with factory default parameter va lues. These settings are stored in nonvolatile ROM and are displayed the first time you enter the Program mode.

Electrically Erasable Programmable Read-only Memory (EEPROM)

The SMC Dialog Plus controller provides a nonvolatile area for storing user-modified parameter values in the EEPROM.

Using Parameter Management

Description Action Display

Saving to EEPROM

To ensure that the newl y modified parameters are not lost if control power is removed from the controller, store the values into EEPROM.

Recalling from EEPROM

Parameters stored in EEPROM can be manually brought to RAM by directing the controller to recall the values stored in its EEPROM.

Recalling Defaults

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

Programming

4-7

PARAMETER MGMT STORE IN EE

PARAMETER MGMT RECLL FRM EE

PARAMETER MGMT DEFAULT INT

4-8

Programming

Parameter Modification

All parameters are modif ied using the same method. The basic steps to performing parameter modification are described bel ow.

Note: Parameter values modif ied while the motor is operating are

not valid until the next start sequence begins.

Description Action Display

——

1. Press any key to go from the status display to the Choose Mode menu.

2. Scroll with the Up/Down keys until the Program option appears.

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

4. Scroll with the Up/Down keys until the option you want to use (Basic Setup, Advanced Setup, etc.) appears. For this example, Basic Setup will be used.

STOPPED

0.0 AMPS

CHOOSE MODE DISPLAY

CHOOSE MODE PROGRAM

PROGRAM METERING

PROGRAM BASIC SETUP

5. Press Enter to select the Basic Setup group.

6. Scroll to the next parameter by using the Up key.

7. To modify the parameter, press the Select button to move the cursor to the second line.

8. 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 Up key. Continue the process until all desired settings are entered.

11. Press the Enter key to save the new settings to EEPROM.

SMC OPTION STANDARD

STARTING MODE SOFT START

Options:

Soft Start,

Current Limit

STARTING MODE SOFT START

STARTING MODE CURRENT LIMIT

RAMP TIME # 1 10 SEC

PARAMETER MGMT STORE IN EE

If the Choose Mode menu does not provide the Program option, then you must enter your password.

① ②

The first parameter displayed advises the user if any control option (i.e., Pump Control) is resident. This parameter is factory set and cannot be modified by the user.

③

The display will indicate that the second line is now active by flashing the first character. If the LCD display does not provide a flashing cursor, then the controller is in the Display mode.

④

You will now notice that the cursor has returned to flashing the first character of the first line.

Programming

4-9

Soft Start

Current Limit Start

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

Para meter Option

Starting Mode

This must be programmed for Soft Start.

Ramp Time #1

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 #1

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

If the controller senses that the motor has reached full speed before completing the voltage ramp,

①

it will automatically switch to providing full voltage to the motor.

①

Soft Start

0 to 30 seconds

0 to 90% locked rotor torque

0.0 to 2.0 seconds

, Current Limit

To apply a fixed reduced output volta ge to the motor, the foll owing parameters are provided for user adjustment:

Paramete r Option

Starting Mode

This must be programmed for Current Limit.

Ramp Time #1

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

If the controller senses that the motor has reached full speed before completing the current limit

①

start, it will automatically switch to providing full voltage to the motor.

①

Soft Start,

0 to 30 seconds

50 to 600% full load current

0.0 to 2.0 seconds

Current Limi

4-10

Programming

Dual Ramp Start

The SMC Dialog Plus controller provides the user with the ability to select between two Soft Start settings. The parameters below are ava ilable in the Advanced Setup progr ammin g mode to obtain Dual Ramp contr o l:

Parameter Option

Advanced Setup

The user must select the Advanced Setup programming mode to obtain access to the Dual Ramp parameters.

Starting Mode

This must be programmed for Soft Start.

Dual Ramp

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

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 #1 are selected. When this input is high, ramp time/initial torque #2 are selected.

Ramp Time #1

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

Initial Torque #1

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

Ramp Time #2

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

Initial Torque #2

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

①

1. Ramp Time #1/Initial Torque #1 and

2. Ramp Time #2/Initial Torque #2.

—

No, Yes

0 to 30 seconds

0 to 90% locked rotor torque

0 to 30 seconds

0 to 90% locked rotor torque

Full Voltage Start

The Dual Ramp feature is available only with the standard controller.

①

The SMC Dialog Plus controller may be programmed to provide a full volta ge start (output voltage to the motor rea ches full voltage within 1/4 second) with the following programming:

Parameter Option

Starting Mod

This

Ramp Time #1

This voltage start.

Initial Torque #1

This start.

Kickstart Time

This voltage start.

must

be programmed for Soft Start.

must

be programmed for 0 seconds for a full

must

be programmed for 90% for a full voltage

must

be programmed for 0.0 seconds for a full

—

Programming

4-11

Basic Setup

The Basic Setup programming group provides a limited parameter set, allowing quick start-up with minimal adjustmen t. If the user is planning to implement some of the advanced features (i.e., Dual Ramp, Phase Rebalance, etc.), then the Advanced Setup programming group should be selec ted. It provides all the Basic Setup parameter set plus the advanced set.

Parameter Option

SMC Option

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

Starting Mode

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

Ramp Time #1

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

Initial Torque #1

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

Current Limit Level

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

Kickstart Time

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

Stall Delay

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

Energy Saver

The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded.

Aux Contacts 1&2

Form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19 and 20. Aux Contacts 1&2 allows the user to configure the operation of the contacts.

Aux Contact 3

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

Contact 3 Config

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

Parameter Mgmt

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

Standard

Soft Start, Current Limit

0 to 30 seconds

①

②

③

0 to 90% of locked rotor torque

50 to 600% full load current

0.0 to 2.0 seconds

0.0 to 10.0 seconds

Off, On

Normal, Up-to-speed

Normal, Fault

N.O., N.C.

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

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

① ②

Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter.

③

The new programmed parameter values will not be stored to the EEPROM without the user’s direction in Parameter Management: Store In EE.

4-12

Programming

Advanced Setup

While the Basic Setup group allows the user to get started with a minimum number of parameters to modify, the Advanced Setup group allo ws f ull access t o the SMC Dialo g Plus cont roller ’s powerful parameter set. Following is a listing of the additiona l setup parameters pro vided.

Note: Al l of the Ba sic Setup paramet er s are available in the

Advanced Setup gr oup. The par amet ers shown below are in addition to the parameters in Basic Setup.

Parameter Option

Dual Ramp

Ramp Time #2

Initial Torque #2

Undervoltage Level

Undervoltage Delay

Overvoltage Leve

Overvoltage Delay

Jam Level

Jam Delay

Unbalance Level

Unbalance Delay

Rebalance

Underload Level

Underload Delay

①

Allows the user the option to choose between two Soft Start profiles.

Determines the soft start time for the second ramp of the Dual Ramp feature.

Provides the initial torque setting for the second ramp of the Dual Ramp feature.

Determines the trip level as a percentage of line voltage.

②

Provides a delay period prior to a trip occurrence.

l Determines the trip level as a percentage of line voltage.

②

Provides a delay period prior to a trip occurrence.

③

Determines the trip level as a percentage of the motor’s full load current.

Provides a delay period prior to a trip occurrence.

Allows the user to set the voltage unbalance trip level.

②

Provides a delay period prior to a trip occurrence.

④

Allows the user access to enable the Rebalance feature. See page 1-5 for a description.

②

Determines the trip level as a percentage of the motor’s full load current.

Provides a delay period prior to a trip occurrence.

Off, On

0 to 30 seconds

0 to 90% locked rotor torque

0 to 99% (0 is the Off setting)

0 to 99 seconds

0 to 199% (0 is the Off setting)

0 to 99 seconds

0 to 999% (0 is the Off setting)

0.0 to 10.0 seconds

0 to 25% (0 is the Off setting)

0 to 99 seconds

Off, On

0 to 99% (0 is the Off setting)

0 to 99 seconds

The Dual Ramp feature is available only with the standard controller.

① ②

The delay time must be set to a value greater than zero when Undervoltage, Overvoltage, and Unbalance are enabled.

③

For Jam and Underload detection to function, the Motor FLC must be programmed in the Calibration group. See Chapter 5 for instructions.

④

To enable Rebalance, the Converter Rating parameter in the Calibrate programming group must be set for 20, 180, or 630.

Programming

Parameter Option

Phase Reversal

This parameter allows the user to enable phase reversal protection.

Starts Per Hour

Allows the user to limit the number of starts during a one hour period.

Restart Attempts

Determines the number of attempts the controller will make to automatically restart the motor after a fault.

Restart Delay

Provides a delay period prior to a restart attempt.

ETM Reset

Allows the user to reset the accumulated value of the elapsed time meter.

Parameter Management

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

The Auto Restart feature is not available.

① ②

The new programmed parameter values will not be stored to the EEPROM without the user’s direction in parameter management: Store In EE

①

②

Off, On

0–99 (0 is the Off setting)

0 to 5

0 to 60 seconds

Off, On

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

4-13

Example Settings

Undervoltage

①

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

Overvoltage

①

Wit h Line Voltage programmed for 240V and the Overvol tage level programmed for 115%, the trip value is 276V.

②

Jam

Wit h Motor FLC programmed for 150 Amps and the Jam level programmed for 400%, the trip value is 600 Amps.

Underload

②

Wit h Motor FLC programmed for 90 Amps and the Underl oad level programmed for 60%, the trip value is 54 Amps.

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

① ②

The largest value of the three phase currents is utilized.

4-14

Programming

Calibration

Chapter 5

Overview

Motor Data Entry

The Calibrate programming group a llo ws t he use r to set pa rameters t o calibrate the contr oller to the connected motor. It is important to correctly input the data to achieve the best performance from your controller.

ATTENTION: For over load protection, it is critical that the data be entered as it appears on the motor

nameplate.

In the Program mode, enter the correct values into the Calibrate group:

Parameter Option Display

Overload Class

The factory default setting disables overload protection. To enable it, enter the desired trip class in this parameter. See pages 1-5 and 1-7 for further details and trip curves.

Overload Reset

Allows the user to select either a manual or auto reset after an overload fault.

Motor HP Rating

Enter the value from the motor’s nameplate.

Motor kW Rating

Enter the value from the motor’s nameplate.

①②

Off, 10, 15, 20, 30

Manual, Auto

0.0–6,553.5 HP

0.0–6,553.5 kW

OVERLOAD CLASS _____

OVERLOAD RE SET MANUAL

MOTOR HP RATING #### HP

MOTOR KW RATING #### KW

Line Voltage

Enter the system voltage in this parameter. This ensure optimum motor performance and correct operation of undervoltage and overvoltage protection.

Motor FLC

Enter the value from the motor’s nameplate.

Service Factor

Enter the value from the motor’s nameplate.

Refer to the SMC Dialog Plus controller nameplate for maximum ratings. Exceeding these could

①

result in damage to the controller.

②

The controller’s programming system will not allow both HP and kW to be programmed.

①

must

be done to

①

1–9,999V

1.0–999.9A

0.01–1.99

LINE VOLTAGE #### VOLTS

MOTOR FLC ###.# AMPS

SERVICE FACTOR #.##

5-2

Calibration

Motor Data Entry (cont.)

Parameter Option Display

Motor Code Letter

①

Enter the value from the motor’s nameplate. If the motor nameplate does not provide this, consult the motor manufacturer. See Table 5.A for code letter definitions.

LRC Ratio

①

IEC motors do not provide a motor code letter. Consult the motor manufacturer for the motor’s locked rotor current/full load current ratio.

Converter Rating

If a Bulletin 825 converter module will provide current feedback to the controller, enter the converter’s rating to ensure proper current measurement scaling.

CT Ratio

For controllers using external current transformers with the 20A converter module for current feedback, current transformers with 5A secondaries are required. Enter the current transformer ratio in this parameter.

A–V

0.0–19.9

None, 20, 180, 630

5 through 1200:5

MOTOR CODE LETTER #

LRC RATIO ##.#

CONVERTER RATING ###

CT RATIO #### : 5

The controller’s programming system will not allow both Motor Code Letter and LRC Ratio to be

①

programmed.

Table 5.A Motor Codes

Letter

Designation

kVA/HP

①

A 0–3.15 L 9.0–10.0

B 3.15–3.55 M 10.0–11.2

C 3.55–4.0 N 11.2–12.5

D 4.0–4.5 P 12.5–14.0

E 4.5–5.0 R 14.0–16.0

F 5.0–5.6 S 16.0–18.0

G 5.6–6.3 T 18.0–20.0

H 6.3–7.1 U 20.0–22.4

J 7.1–8.0 V 22.4 and up

K 8.0–9.0

Locked kVA per horsepower range includes the lower figure up to, but not including,

①

the higher figure. For example, 3.14 is designated by letter A and 3.15 by letter B.

Letter

Designation

kVA/HP

①

Calibration

5-3

Calibration Procedure

For current measurement accuracy, use the procedure below to calibrate the SMC Dialog Plus controller to the connected motor. A clamp-on ammeter , which pro vid es a true rms measure ment and has a published accuracy of ±1% (Fluke model 33 or equal), is required to perform this procedure.

Notes: (1) If you plan to use the Bulletin 825 converter module for

current feedback to the SMC Dialog Plus controller, this calibration proc edure is not necessary.

(2) An unbalanced three-phase system may affect the

accuracy of the calibration.

(3) It is recommended that Parameter #36, Overload Class,

is programmed to OFF during the calibration procedure.

Calibration requi res the motor to be operated at full speed. Additionally, the motor must be connected to its load in order that the motor draw as near to its full load current (FLC) rating as possible. This is necessary so that maximum accuracy is achieved for current measurements at overload trip levels.

Description Action Display

1. Check all power and control wiring connections to the controller and motor. Apply a start command to the controller and check for motor rotation to full speed.

2. Using the clamp-on ammeter, measure the three-phase motor currents. Place the ammeter around the phase with the largest current draw.

①

—

AT SPEED ###.# AMPS

3. In the Calibrate group, scroll to the Calibration parameter.

4. Monitor the clamp-on ammeter and verify that the motor current is stable. Press the Select key. Toggle the Up/Down keys to the Activate setting. Press the Enter key to accept. Monitor the ammeter display for the next 2 seconds and record the average value. During this time period, the SMC Dialog Plus controller samples motor response data.

5. Access the next parameter using the Up key.

6. Press the Select key. Enter the clamp-on meter value monitored in step 4. Press the Enter key to

The SMC Dialog Plus

accept.

controller is now calibrated

The currents should measure a minimum of 70% of the motor’s full load current rating in order to

①

achieve the best results in accuracy.

CALIBRATION OFF

CALIBRATION ACTIVATE

ENTER CALIB. AMPS

0.0 AMPS

ENTER CALIB. AMPS ###.# AMPS

5-4

Calibration

Calibration Procedure (cont.)

Description Action Display

7. You can scroll to the next parameter to view the current measurement in phase A.

8. Scroll to the next parameter to save the Calibrate group settings.

9. Press the Select key. Scroll with the Up/Down keys to Store In EE selection. Press the Enter key to save the settings to EEPROM.

ATTENTION: After calibration is completed, program the desired ov erload class and sa v e the setting

to the controller’s EEPROM.

ATTENTION: This method of current measurement is not applicable to multi-motor install ations or resisti ve

heating loads. Ut ilization of the Bulletin 825 con ve rter module is required for these applications if current measurement is required.

CURRENT PHASE A ###.# AMPS

PARAMETER MGMT READY

PARAMETER MGMT STORE IN EE

Metering

Chapter 6

Overview

Viewing Metering Data

While the SMC Dialog Plus controller operates your motor, it also monitors several different parameters, pr oviding a full function metering① package.

To access the metering information, follow the procedure below.

Description Action Display

——

1. Press any button to access the Choose Mode menu.

2. Scroll with the Up/Down keys until the Display option is shown.

3. Press the Enter key to select the Display option.

4. Scroll with the Up/Down keys until the Metering option is displayed.

AT SPEED ###.# AMPS

CHOOSE MODE _ _ _ _ _

CHOOSE MODE DISPLAY

CHOOSE GROUP _ _ _ _ _

CHOOSE GROUP METERING

5. Press the Enter key to access the Metering group.

Refer to page 1-10 for details on the metering functions.

①

6-2

Metering

Viewing Metering Data (cont.)

Description Action Display

6. Scroll through the Metering parameters with the Up/Down keys to access the desired information.

VOLTS PHASE A–B ### VOLTS

VOLTS PHASE B–C ### VOLTS

VOLTS PHASE C–A ### VOLTS

CURRENT PHASE A ###.# AMPS

CURRENT PHASE B ###.# AMPS

CURRENT PHASE C ###.# AMPS

WATTMETER ##### kW

KILO-WATT HOURS ##### kWH

ELAPSED TIME ##### HOURS

POWER FACTOR .##

MTR. THERM USAGE ## %

Options

Chapter 7

Overview

Human Interface Module

The SMC Dialog Plus controller offers a variety of unique control options that pro vide enhanced motor starting and stopping capabilities . ( See page s 1-12 through 1-15 for brief descriptions of each option.)

Note: Only one option can reside in a controller.

The control buttons available with the Bulletin 1201 human interface modules are compatible with the SMC Dialog Plus contr oller’s control options. The follow ing table details the functionality of each button with re gards to each option.

Notes: (1) Control logic must be enabled prior to initiating control

commands to the SMC Dialog Plus controller. Refer to pages 2-14 and 2-15 for instructions.

(2) The control terminals must be wired a ccording to Figure

3.14 on page 3-10.

Option Action Operation

Soft Stop The green start button, when pressed,

will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop.

JOG

Pump Control The green start button, when pressed,

JOG

The jog button, when pressed, will initiate a soft stop maneuver.

will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop.

The jog button, when pressed, will initiate a pump stop maneuver.

7-2

Options

Option Action Operation

Preset Slow Speed The green start button, when pressed,

will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop.

JOG

Smart Motor Braking The green start button, when pressed,

JOG

Accu-Stop The green start button, when pressed,

JOG

Slow Speed with

Braking

The jog button, when pressed, will initiate slow speed motor operation from a “stopped” status.

will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop.

The jog button, when pressed, will initiate a brake stop.

will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop.

With a “stopped” status, the jog button, when pressed, will initiate slow speed motor operation. From an “at speed” condition, the jog button, when pressed, will initiate braking to slow speed operation. The controller will maintain slow speed operation as long as the jog button is pressed.

The green start button, when pressed, will commence motor acceleration to full speed.

The red stop button, when pressed, will provide a coast stop.

With a “stopped” status, the jog button,

JOG

when pressed, will initiate slow speed motor operation. From an “at speed” condition, the jog button, when pressed, will initiate a brake stop.

ATTENTION: The Bulletin 1201 human interface module’ s stop push b utt on i s not inte nded to be us ed a s

an emergency stop. Refer to applicable standards for emergency sto p requirements.

Options

7-3

Programming Parameters

The followi ng table provides the option-specific parameters that are provided with each con trol option. These parameters are in addition to those already discussed in the Basic Setup, Advanced Setup, Metering, and Calibration groups. Diagrams supporting the options described below are shown later in this chapter.

Option Parameter Range

Soft Stop

Pump Control

Preset Slow

Speed

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.

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 Dialog Plus controller for the type of starting that best fits the application.

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.

Slow Running Current

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

Soft Stop

0–60 seconds

Pump Control

0–120 seconds

Pump Start, Soft Start, Current Limit Start

Preset Slow

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

Forward, Reverse

0–450% of full load current

7-4

Options

Programming Parameters (cont.)

SMB Smart

Motor Braking

Accu-Stop

Slow Speed

with Braking

SMC Option

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

Braking Current

①

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

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 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

①

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

Stopping Current

①

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

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 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

①

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

SMB Braking

0–400% of full load current

Accu-Stop

Low: 7% High: 15%

0–450% of full load current

0–400% of full load current

Slow Speed Brake

Low: 7% High: 15%

0–450% of full load current

0–400% of full load current

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

①

the motor.

Options

➀

Control Power

➂

Option Stop

➀ ➁

Start

➀

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Internal Auxiliary Contacts

SMC Dialog Plus

Control Terminals

7-5

Control Wiring for SCANport Control

Soft Stop, Pump Control, and SMB Smart Motor Braking Options

Refer to Figure 3.14 on page 3-10 for the applicable wiring diagram to achieve start-stop control via the SCANport.

Figure 7.1 through Figure 7.6 show the different wiring for the Soft Stop, Pump Control, and SMB Smart Motor Braking options.

Figure 7.1 Typical Wiring Diagram

Stop

① ②

③

Note: Refer to Chapter 3 for typical power circuits.

Customer supplied.

Soft Stop, Pump Stop, or Brake.

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

7-6

Stop

➀

➀ ➁

➀

Control Power

➂

Option Stop

➀ ➃

Start

➀

11 12

21 22

Contacts

Auxiliary contacts set

for Normal

SMC Dialog Plus

Control Terminals

Options

Figure 7.2 Typical Retrofit Wiring Diagram

13 14 15 16 17 18 19 20

Internal

Auxiliary

23 24 25 26 27 28 29 30

Customer supplied.

① ②

Overload protection should be disabled in the SMC Dialog Plus controller.

③

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

④

Soft Stop, Pump Stop, or Brake.

Note: Refer to Chapter 3 for typical power circuits.

Options

Stop

➀

Control Power

➁

Option Stop

➀ ➂

Start

➀

11 12

21 22

Contacts

Auxiliary contacts set

for Normal

SMC Dialog Plus

Control Terminals

7-7

Figure 7.3 Typical Wiring Diagram for Applications Requiring an Isolation

Contactor

13 14 15 16 17 18 19 20

Internal

Auxiliary

23 24 25 26 27 28 29 30

Customer supplied.

① ②

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

③

Soft Stop, Pump Stop, or Brake.

Note: Refer to Chapter 3 for typical power circuits.

7-8

Stop

➀

Control Power

➁

Option Stop

➀ ➂

Start

➀

11 12

21 22

Contacts

Converter

Module

for Up-to-speed

Fanning Strip

➀

SMC Dialog Plus

Control Terminals

Options

Figure 7.4 Typical Wiring Diagram for Applications Requiring a Bypass

Contactor

13 14 15 16 17 18 19 20

Auxiliary contacts set

Bulletin 825

Internal

Auxiliary

Customer supplied.

① ②

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

③

Soft Stop, Pump Stop, or Brake.

Note: Refer to Chapter 3 for typical power circuits.

23 24 25 26 27 28 29 30

Options

Control Power

➁

Two-wire device

➀

11 12

21 22

Contacts

SMC Dialog Plus

Control Terminals

7-9

Figure 7.5 Typical Wiring Diagram for Two-wire Control or Programmable

Controller Interfacing

13 14 15 16 17 18 19 20

23 24 25 26 27 28 29 30

Customer supplied.

① ②

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

Notes: (1) Refer to Chapter 3 for typical power circuits.

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

Internal

Auxiliary

7-10

xoo

oox

3-Phase

Input Power

Branch

Protection

➀

Fast-acting

SCR Fuses

(optional)

➀

SMC Dialog Plus

Controller

Control Power

100-240 VAC

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

Contacts

SMC Dialog Plus

Control Terminals

Options

Soft Stop, Pump Control, and SMB Smart Motor Braking Options (cont.)

Figure 7.6 Typical Wiring Diagram for Hand-Off-Auto (SCANport) Control

12 13 14 15 16 17 18 19 20

22 23 24 25 26 27 28 29 30

Customer supplied.

① ②

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

Internal

Auxiliary

Options

Motor Speed

Push Buttons

Start

Stop

Soft Stop

Auxiliary Contacts

Normal

Up-to-speed

Start Run

Open

Closed

100%

Coast-to-rest

Soft Stop Operation

Coast-to-rest Operation

Soft Stop

Time (seconds)

7-11

Soft Stop Option

Figure 7.7 Soft Stop Option Sequence of Operation

ATTENTION: The user is responsible for

determining which stopping m ode is best suited to the application and will meet applicable standards for operator safety on a particula r machine .

7-12

Motor Speed

Push Buttons

Start

Stop

Soft Stop

Auxiliary Contacts

Normal

Up-to-speed

Start Run

Open

Closed

100%

Coast-to-rest

Pump Stop Operation

Coast-to-rest Operation

Soft Stop

Time (seconds)

Options

Pump Control Option

Figure 7.8 Pump Control Option Sequence of Operation

Pump Stop

ATTENTION: The user is responsible for

determining which stopping m ode is best suited to the application and will meet applicable standards for operator safety on a particula r machine .

Options

Motor Speed

Push Buttons

Start

Stop

Soft Stop

Auxiliary Contacts

Normal

Up-to-speed

Start Run

Open

Closed

100%

Shut-off

Smart Motor Braking

Brake

Time (seconds)

Smart Motor Braking Operation

7-13

SMB Smart Motor Braking Option

Brake

Figure 7.9 SMB Smart Motor Braking Sequence of Operation

Coast-to-rest

Automatic Zero Speed

Coast-to-rest Operation

ATTENTION: The user is responsible for determining which stopping m ode is best suited to the application and will meet applicable standards for operator safety on a particula r machine .

7-14

➀

Control Power

➁

Option Command

➀ ➂

Start

➀

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Auxiliary Contacts

SMC Dialog Plus

Control Terminals

Options

Preset Slow Speed and Accu-Stop Options

Figure 7.10 through Figure 7. 14 shows the differe nt wiring for the Preset Slow Spee d and Accu-Stop options.

Figure 7.10 Typical Wiring Diagram for the Preset Slow Speed Option

Stop

① ②

③

Note: Refer to Chapter 3 for typical power circuits.

Internal

Customer supplied.

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

Slow Speed or Accu-Stop.

Figure 7.11 Typical Retrofit Wiring Diagram

Stop

➀

➀ ➁

➀

Control Power

➂

Option Command

➀ ➃

Start

➀

11 12

21 22

Contacts

Auxiliary contacts set

for Normal

SMC Dialog Plus

Control Terminals

13 14 15 16 17 18 19 20

Options

7-15

Internal

Auxiliary

23 24 25 26 27 28 29 30

Customer supplied.

① ②

Overload protection should be disabled in the SMC Dialog Plus controller.

③

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

④

Slow Speed or Accu-Stop.

Note: Refer to Chapter 3 for typical power circuits.

7-16

Stop

➀

Control Power

➁

Option Command

➀ ➂

Start

➀

11 12

21 22

Contacts

Auxiliary contacts set

for Normal

SMC Dialog Plus

Control Terminals

Options

Figure 7.12 Typical Wiring Diagram for Applications Requiring an Isolation

Contactor

13 14 15 16 17 18 19 20

23 24 25 26 27 28 29 30

Customer supplied.

① ②

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

④

Slow Speed or Accu-Stop.

Note: Refer to Chapter 3 for typical power circuits.

Internal

Auxiliary

Rockwell Automation 150 USE M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual