Rockwell Automation SMC Dialog Plus User Manual

Download

Page 1

User Manual

SMC Dialog Plus

™

Controller

Bulletin 150

112112

152516

172718

Page 2

Please Read!

This manual is intended to guide qualified personnel in the installation and operation of this product.

Because of the variety of use s for this eq uipment and because of the differen ces between this soli d-sta te equipment and electr omechanic al equipment, the user of and those responsible for applying this equipment must satisfy themselves as to the acceptability of each application and use of the equipment. In no event will Allen-Bradl ey Company, Inc. be responsible or liable for indirect or consequential damages resulting from the use or applica tion of this equipment.

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

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

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

Important User Information

The information in this manual is organized in numbered chapters. Read each chapter in sequence and perform procedure s when you are instructed to do so. Do not proc eed to the next chapter until you ha ve completed all procedures.

Throughout this manual attention statements make you aware of safety considerations:

Attentions help you:

• Identify a hazard

• Avoid the hazard

• Recognize the consequences Important: Identif ies information that is especially importa nt for

successful applicat ion and underst anding of thi s product.

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.)

ATTENTION: Identifies inf ormation about pract ices

or circumst an ce s tha t can lead to p erso n al inj ur y or death, property damage, or economic loss .

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.

Page 3

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

Page 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

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

Chapter 4 Programming

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

Page 5

Table of Contents

toc–v

Example Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Jam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Chapter 5 Calibration

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

Motor Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Chapter 6 Metering

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

Viewing Metering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Chapter 7 Options

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

Chapter 8 Serial Communications

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

Page 6

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

Page 7

Table of Contents

toc–vii

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

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

Page 8

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

Page 9

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

Page 10

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

Page 11

Chapter 1

Product Overview

Description

The SMC Dialog Plus controller of fers a full range of starting modes as standard:

• Soft Start with Selectable Kickstart

• Current Limit Start with Selectable Kickstart

•Dual Ramp Start

• Full Voltage Start Other features that of fer further user benefit inc lude:

• Expanded protecti ve features

•Metering

• Communication capability Innovative starting and stopping options provide enhanced

performance:

• Soft Stop

• Pump Control

• Preset Slow Speed

• SMB™ Smart Motor Braking

• Accu-Stop™

• Slow Speed with Braking These modes, features, and options are further described in this

chapter.

Operation

The SMC Dialog Plus controller can ope rate three-phase squirrel cage motors rated 1–1000A; 200–480V AC or 200–600V AC; 50/60 Hz. Depending upon the catalog number ordere d, the controller will accept a control power input of either 100–240V AC or 24V A C/DC. If the control power input option is 100–240V AC, the controller’s microprocessor will self-adjust to the input control volta ge.

Page 12

1-2

Product Overview

Starting Modes

Soft Start

This mode has the most general application. The motor is given an initial torque setting, which is user-adjustable from 0 to 90% of locked rotor t orq ue. Fro m the init ial tor que l e v el, t he output v olt age to the motor is steplessly increased during the acceleration ramp time. The acceleration r amp time is use r- adjus table from 0 to 30 sec onds. If the SMC Dialog Plus controller senses that th e motor has reached the up-to-speed condition during the voltage ramp operation, the output voltag e autom atica l ly switch es to full voltag e.

Figure 1.1 Soft Start

Start Run

Percent Voltage

Initial

Tor que

100%

Time (seconds)

Page 13

Product Overview

1-3

Selectable Kickstart

①

This feature provide s a boost at startup to break away loads that require a pulse of high torque to get started. This is intended to provide a pulse of current that is 550% of full load current. Selectable kickstart is user-adjustable from 0.0 to 2.0 seconds.

Figure 1.2 Selectable Kickstart

Current Limit Start

②

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 load 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 con dition dur ing the cur rent limi t st arting mode, the output volt age aut omatically switches to full voltage.

Figure 1.3 Current Limit Start

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.

Start Run

Kickstart

Initial

Tor que

100%

Percent

Voltage

Time (seconds)

Start

600%

50%

Percent

Full Load

Current

Time (seconds)

Page 14

1-4

Product Overview

Starting Modes (cont.)

Dual Ramp Start

①

This starting mode is useful on applications that have varying loads (and therefore va rying 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 v olta ge to the motor will reach full voltage within 1/4 second.

Figure 1.5 Full Voltage Start

①

Dual Ramp Start is available only with the standard controller.

Percent

Voltage

Initial

Torque #1

100%

Start #1 Run #1

Ramp #2

Ramp #1

Start #2

Time (seconds)

Run #2

Initial

orque #2

100%

Percent Voltage

Time (seconds)

Page 15

Product Overview

1-5

Energy Saver

The Energy Saver feature is typically used in applic ations where the motor is lightly loaded or unloaded for extended periods of time. With the Energy Saver feature enabled, the SM C D i alog Pl us controller continuously monitors motor load with its internal feedback circuitry. Because SCRs control the output voltage, motor power losses may be reduced 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 ta ke s precedence in operation.

Phase Rebalance

With the Phase Rebalance feature enabled, the SMC Dialog Plus controller continuously monitors the incoming three-phase line voltage and automatically adjusts the output voltage to balance the three phase currents dra w n by the motor.

Notes: (1) Phase Rebalance requires that the Bulletin 825 con verter

module is utilized. (2) Phase Rebalance is not active durin g bypass operation. (3) When Phase Rebalance and Energy Saver are both

enabled, Phase Rebalanc e takes precedence in operation.

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. Thermal memory provides added protection and is maintained even when control po wer is removed . The built-in overload algorithm controls the value stored in Parameter 11, Motor Thermal Usage; an Overload Fault will occur when this value reaches 100%. The programming parameters below provide application flexibility and easy setup.

Parameter Range

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

Motor FLC

1.0

–

999.9 Amps

Service Factor

0.01

–

1.99

ATTENTION: During slow speed and/or braking

operations, current waveforms exhibit non-sinusoidal characteristics. These non-sinusoidal characteristics inhibit the controller’ s current measurement capa bility . To compensate for additional motor heating that may result, the controller uses motor thermal modeling, which increments motor thermal usage. This compensation takes pl ace when these options are in use: Preset Slow Spe ed, Sm art Mot o r Bra kin g, A cc u- Sto p , and Slow Speed with Braking.

Page 16

1-6

Product Overview

Protection and Diagnostics (cont.)

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

“Off,” disables overload protection. An overload trip

class and the motor’s full load current rating must be

programmed to enable ov erload protection. (2) The current sensing capability of the SMC Dialog Plus

controller is disabled during bypass operation. Using a

Bulletin 825 converter module in these applications is

recommended to provide curre nt feedback. Otherwise, a

separate overload relay is required. (3) Motors with full load current ratings of 5 Amps and

below may require 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 control scheme. This

applies to the following firmware release s: 1.07

(standard), 1A07L (Soft Sto p) and 1B05L (Pump

Control) or earlier.

Figure 1.6 and Figure 1.7 provide the overload trip curves for the availab le trip classes.

Page 17

Product Overview

1-7

Figure 1.6 Overload Trip Curves

Figure 1.7 Restart Trip Curves after Auto Reset

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

Class 10 Class 15 Class 20 Class 30

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

Approximate Trip Time (seconds)

1.0

10.0

100.0

1000.0

10000.0

1 10 2 3 9 8 7 6 5 4

0.1

1.0

10.0

100.0

1000.0

1 10 2 3 9 8 7 6 5 4

1.0

10.0

100.0

1000.0

10000.0

1 10 2 3 9 8 7 6 5 4

1.0

10.0

100.0

1000.0

10000.0

1 10 2 3 9 8 7 6 5 4

1000%100%

100

1000

100000

Percent Full Load Current Setting

Seconds

Class 10 Class 15

Class 20 Class 30

Auto Reset Times:

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

Page 18

1-8

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 motor 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 allows the user to determine the jam leve l (up to 999% of the motor’ s FLC rating) and the delay time (up to 10.0 seconds) for application flexibility.

Figure 1.8 Stall Protection

Figure 1.9 Jam Detection

①

Jam detection is disabled during slow speed and braking operation.

Stall

600%

Percent

Full

Load

Current

Time (seconds)

Programmed Start Time

100%

Running Jam

Percent

Full

Load

Current

Time (seconds)

User Programmed Trip Level

Page 19

Product Overview

1-9

Open Gate

An open gate fault indicates 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 indic ation) –Power loss – Missing load connection – Shorted SCR

Running protection includes:

• Line Fault (no phase indication) –Power loss – Missing load connection – Shorted SCR

Additional programmable parameters are provided for the following protective features:

• Undervoltage

①

can be adjusted from 0 t o 99% of t he pr ogrammed line voltage and has a programmable delay time of 0 to 99 seconds.

• Overvoltage

①

can be adjuste d fro m 0 to 199% of the pr ogrammed line voltage and has a programmable delay time of 0 to 99 seconds.

• Phase reversal

②

protection can be toggled either On or Off.

• Voltage unbalance

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 prote ction 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 pro vides an adjusta ble underload trip setting from 0 to 99% of the programmed motor full load current rating. Tr ip 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.

Page 20

1-10

Product Overview

Protection and Diagnostics (cont.)

Excessive Starts/Hour

The SMC Dialog Plus controller allo ws the user to program the allowed number of starts per hour (up to 99). This helps eliminate motor stress caus ed by repeat ed sta rt ing over a short tim e pe ri od.

Overtemperature

The SMC Dialog Plus controller monitors the temperature of the SCRs by using internal the rmistors. When the po wer poles’ maximum rated temperature is reache d, S CR firing is inhibited.

An overtemperature condition can indicate inadequate ventilation, high ambient temperature, overloading, or excessive cycling. After the SCR temperature is reduced to allowable lev els, the fault can be cleared (see pa ge 9- 1 for inst ru cti o ns) .

Metering

Power monitorin g para meters include:

• Three-phase current

• Three-phase voltage

•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 disabled during bypass operation. A Bulletin 825 converter module is required to maintain the three-phase current, kW, kWH, and motor thermal capacity me asu rem en ts .

(2) Current measurement is not avail able during the slow

speed and/or braking operati ons of the Preset Slow Speed, SMB Smart Motor Braking, Accu-Stop and Slow Speed with Braking control options.

(3) Voltage measurement is not available during the braking

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

(4) The po wer fa ctor paramet er is provi ded as a displacement

power factor value. Power factor measurement is disabled during bypass operation.

(5) The elapsed time and kWH values are automatically

saved to memory every 12 hours.

(6) Motor therm al capac ity usage is determined by the built-

in electronic thermal o verload protection system. An overload fault occurs when this value reaches 100%.

Page 21

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 communicati on modules.

Figure 1.10 SCANport Location

Programming

Setup is easy with the built- in keypad and two -li ne , sixteen ch ar act er 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

Status Indication

Three programmable hard contact outputs are provided as standard. The first two contacts are Form C and programmable for N ormal/Upto-speed. The third conta ct is progr ammable as Normal/Fault.

SCANport

ATTENTION: Only one peripheral devic e can be

connected to the SCANport. The maximum output current through the SCANport is 100 ma.

Page 22

1-12

Product Overview

Control Options

The SMC Dialog Plus controller offe rs the control options described below.

Important: The options listed in this section are mutually exclusi ve

and must be specified when order ing. An existing controller may be upgraded to another control option by replacing the control module. Consult your n earest/local Allen-Bradley sales office.

Soft Stop Option

This option can be used in applications that require an extended coastto-rest. The volta ge ramp down time is user-adjustable from 0 to 60 seconds and is adjusted independently 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

Start Run Soft Stop

Coast-to-rest

Soft Stop

Kickstart

Initial

Torqu e

100%

Perce nt Voltage

Time (seconds)

ATTENTION: Soft Stop is not inten ded to be used as

an emergency stop. Refer to the appli cable standards for emergency stop requirements.

Page 23

Product Overview

1-13

Pump Control Option

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

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

Figure 1.13 Pump Control Option

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 (low) and 20% of base speed (high) settings.

Pump Start Run Pump Stop

Motor Speed

100%

Time (seconds)

ATTENTION: Pump stopping is not intended to be

used as an emergen cy stop . Re fer to the ap plicable standard for emergency stop requirements.

ATTENTION: Pump stopping may cause motor

heating depending on the mechanical dynamics of the pumping system. Theref ore, se lect the lo west stopping time setting that will satisfactorily stop the pump.

Page 24

1-14

Product Overview

Figure 1.14 Preset Slow Speed Option

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 incorporates a micropro cess or-based system that app lie s brak in g cur ren t to a standard squirrel cage induction motor without any additional equipment. This option offers a user-adjustable bra king 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

Forward

15% – High

7% – Low

10% – Low

20% – High

Reverse

Run

Start Time (seconds)

ATTENTION: Slow speed runni ng is not intended for

continuous operation due to reduced motor cooling.

Start

Motor

Speed

100%

Run

Automatic Zero Speed

Shut-off

Brake

Smart Motor Braking

Coast-to-rest

Time (seconds)

Page 25

Product Overview

1-15

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

provide 100% braking current to the motor.

Accu-Stop™ Option

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

Figure 1.16 Accu-Stop Option

ATTENTION: SMB Smart Motor Braking is not

intended to be used as an emergency stop. Refer to applicable standards for emer gency stop requirements.

Start

Run

Motor Speed

100%

Slow

Speed

Accu-Stop

Braking

Slow

Speed

Slow Speed

Braking/Coast

7% or 15%

Time (seconds)

Page 26

1-16

Product Overview

Slow Speed with Braking Option

The Slow Speed with Braking option pr ovide s a jog spe ed for process set-up and braking-to-stop at the end of the cycle.

Figure 1.17 Slow Speed with Braking Option

Motor Speed

100%

Start

Run Slow

Speed

Braking

7% or 15%

Stop

Coast-to-rest

Time (seconds)

ATTENTION: Accu-Stop and Slow Speed with

Braking are not intended to be used as an emergency stop. Refer t o applicable standards for emergenc y stop requirements.

Page 27

Chapter 2

Installation

Receiving

It is the responsibility of the user to thorough ly inspect the equipm ent before accepting the shipment from the freight company. Check the item(s) received against the purchase order. If any items are damaged, it is the responsibil ity of the user not to accept deli very until the freight agent has noted the damage on the freight bill. Should any concealed damage be found during unpacking, it is again the responsibility of the user to notify the freight agent. The shipping container must be left intact and the fre ight agent should be requeste d to make a visual inspection of the equipment.

Unpacking

Remove all packing material, wedges, or braces from within and around the controller. Remove all packing material from the heat sink.

Inspecting

After unpacking, check the item(s’) nameplate catalog number against the purchase order.

Storing

The controller should remain in its shipping container prior to installation. If the equipment is not to be used for a period of time, it must be stored according to the following instructions in order to maintain warranty coverage.

• Store in a clean, dry loc at ion.

• 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 expos ed to a corro sive atmosphere.

• Do not store equipment in a construction area.

Page 28

2-2

Installation

General Precautions

In addition to the precautions listed throughout this manual, the following statements, which are general to the system, must be read and understood.

Heat Dissipation

The following table provides the maximum heat dissipation at rated current for the controllers. For currents lower than rated value, heat dissipation will be reduced.

Table 2.A Maximum Heat Dissipation

Enclosures

The open-style de sig n of t he SMC Dialog Plus contr oll er requir es t hat it be installed in an encl o su re. The internal temperature of the

enclosure must be kept within the range of 0°C to 50°C.

ATTENTION: The controller contains ESD

(electrostatic discharge) sensitive parts and assemblies. Static control precaut ions are requir ed when installi ng, 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 or installed

controller can damage components or reduce product life . Wiring or applicat ion erro rs, such as undersizing the motor, incor rect or inadequate AC supply, or excessive ambient temperatures, may result in malfunction of the system.

ATTENTION: Only personnel familiar with the

controller and associated machine ry should plan or implement the installation, start-up, and subsequent maintenance of the syste m. Failure to do this may res ult in personal injury and/or equipment damage.

SMC Rating

24A 35A 54A 97A 135A 180A 240A 360A 500A 650A 720A 850A 1000A

Max. Watts

110 150 200 285 410 660 935 1170 1400 2025 2250 2400 2760

Page 29

Installation

2-3

Ventilated Enclosures

For Type 1 (IP42) enclosur es, the following guidelines are recommended to limit the maximum controller ambient temperature.

Ther e should be a clear ance of at least six inch es (15 cm) above and below the controller. This area allows air to flow through 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 controller with the ventilation inle t placed near the bottom of the enclosure. A filt er is required to prevent conta minants from entering the enclosure.

Use the table below to determ ine the minimum ventilation openings and fan/blower requirements.

Table 2.B Minimum Ventilation Openings

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 p arentheses).

Non-ventilated Enclosures

For Type 12 (IP54) or non-ventilated enclosures, it is recommended that a bypass contactor be used. Th is will allow the SMC Dialo g P lus controller to br ing the m otor up-to- spee d. After the contr oller is up to full voltage, it is bypassed. Note that the Energy Saver, Phase Rebalance, some metering functions, and some protectiv e features of the controller may no longer be availabl e. See Figure 3.17 on page 313 for this configuration.

SMC Rating Top Cutout

①③

Bottom Cutout

①③

Fan Size

①

24–54A

65 cm

(10 in2)

65 cm

(10 in2)

110 CFM

97 and 135A

233 cm

(36 in2)

233 cm

(36 in2)

110 CFM

180A

13 × 51 (5 × 20)

②

100 CFM

240A

13 × 51 (5 × 20)

②

250 CFM

360A

13 × 51 (5 × 20)

②

(2) 250 CFM

500A

13 × 41 (5 × 16)

②

275 CFM

650A

②

13 × 76 (5 × 30)

(3) 240 CFM

720A

②

13 × 76 (5 × 30)

(3) 240 CFM

850A

②

13 × 76 (5 × 30)

(3) 240 CFM

1000A

②

13 × 76 (5 × 30)

(3) 240 CFM

Page 30

2-4

Installation

Mounting

The controller is convection cooled. Additionally, 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 mu s t be mo unt ed with heatsink fins in a vertical plane and have 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

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

Unit

Width

HeightCDepth

DE FGHJ

Approx.

Ship. Wt.

24A

Controller

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.

35A

Controller

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.

54A

Controller

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.

Ø .22 in. (5.56 mm)

4 Mtg. Holes

Ø .28 in. (7.14 mm)

4 Mtg. Holes

G F B

Ground Screw

(10-32)

Page 31

Installation

2-5

Figure 2.2 Dimensions: 97 and 135 Amp Controllers

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

Unit

WidthBHeightCDepth

DE F GH

Approx.

Ship. Wt.

97A

Controller

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.

135A

Controller

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.

D H

.281 in. (Ø 7.14 mm) 4 Mtg. Holes

Fan

Ter min als

Ground

Screw (M6)

Power Terminal M10 Bolt 6 Places

Page 32

2-6

Installation

Mounting (cont.)

Figure 2.3 Dimensions: 180 through 360 Amp Controllers

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

Unit

WidthBHeightCDepth

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

Approx.

Ship.

Wt.

180A Cont.

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

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.

240– 360A Cont.

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

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 65 lbs.

Terminal Detail

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

.413 (10.5) Dia.

.984

(25)

.531

(13.5)

1.161 (29.5)

2.250 (57)

1.02

(25.9)

180, 240, and 360 Amp

Dbl. Lug Mtg.

.281 (7.1)

Rad.

2 Key Holes

.281 (7.1)

Dia.

6 Mtg. Holes

Ground Nut

(1/4-20)

Page 33

Installation

2-7

Figure 2.4 Dimensions: 500 Amp Controller

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

Unit

HeightBWidthCDepth

DEFGHJKLMNPQ

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.

.312 in. (7.9 mm)

6 Mtg. Holes

.531 in. (13.5 mm)

for 1/2 Bolts Typ.

Ground Nut

(1/4-20)

Q Q

Page 34

2-8

Installation

Mounting (cont.)

Figure 2.5 Dimensions: 650-1000 Amp Controllers

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

Unit

WidthBHeightCDepth

DEFGHJ K L MNPQR

650 and

720A

Controller

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

850 and

1000A

Controller

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

.5 Dia. (Ø 12.7)

6 – Holes

.56 Dia. (Ø 14.2)

2 – Lifting Holes

.105 Steel

Sheet (2.67)

4.0

(101.6)

2.0

(50.8)

.688

(17.5)

.515

(13.1)

Dia. Typ.

1.312 (33.3)

650–720 Amp

.688

(17.5)

.67

(17)

.64

(16.3)

Typ.

.64

(16.3)

850–1000 Amp

5.0

(127)

2.5

(63.5)

Typical Line and Load Bus

.75 Dia. (Ø 19.1) 2 – Holes

Grounding Lug

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

1.312 (33.3)

.64

(16.3)

R R

Page 35

Installation

2-9

Power Factor Correction Capacitors

The controller can be install ed on a system with power factor correction (P FC ) cap aci to rs . The capa ci tor s 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 discha rged, a capacitor essentia lly ha s zero im pe dan ce . 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 fe ct. Also, mount the coils on insulated supports away from metal parts so they will not act as induction heaters. If an isolation contactor is used, put capacitors in front of contactor.

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

Figure 2.6 Typical Wiring Diagram for Power Factor Correction Capacitors

Power Factor

Correction Capacitors

SMC Dialog

Plus

Motor

Branch Circuit

Protection

➀

Customer supplied

➁

Not required

L1/1 T1/2

L2/3 T2/4

L3/5 T3/6

➀

➀➀➀

➀

➁

Page 36

2-10

Installation

Fast Acting Current-limiting Fuses

Short-circuit pr otec tion guide lines a re pr ov ided in App endix A of th is 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 coordinated to protect the controller SCRs in the ev ent of a ground fault or short-c ircui 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

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.

SMC

Rating

Fuse Manufacturer Cat. No.

①

Bussman Shawmut Edison (Brush) Ferraz Littlefuse

24A

SPP-4F60

170M 3610-63

A70P70 XL70F080 A070F060 L70S60

35A

SPP-4F100

170M 3612-100

A70P100 XL70F125 A070F100 L70S100

54A

SPP-4F150

170M 3614-160

A70P200 XL70F200 A070F150 L70S150

97A

SPP-4F300

170M 3617-315

A70P300 XL70F300 A070F300 L70S300

135A

SPP-4F300

170M 3617-315

A70P300 XL70F300 A070F300 L70S300

180A

SPP-4F400

170M 3619-400

A70P400 XL70F400 A070F400 L70S400

240A

SPP-6F400

170M 5608-400

A70P500 XL70F500 A070F400 L70S400

360A

SPP-6F600

170M 5612-630

A70P800 XL70F600 A070F800 L70S600

500A

SPP-6F800

170M 6613-900

A70P1000 XL70F500

②

A070F800 L70S800

650A

SPP-6F800

170M 6613-900

A70P1000 XL70F500

②

A070F800 L70S500

720A

SPP-5F600

②

170M 5612-630

②

A70P1200 XL70F600

②

A070F800 L70S500

850A

SPP-7F1200

170M 6615-1100

A70P1000

②

— A070F1200 L70S800

1000A

SPP-6F800

②

170M 6613-900

②

A70P1000

②

— A070F1200 L70S800

ATTENTION: The fast acting current- limiting fuses

specified in Table 2.C may not provide branch circuit protection. Branch circuit protection in accordance with applicable electric al codes may require additio nal fusing (or a circuit breaker) e ven though fast acting current-limiting fuses are used.

ATTENTION: Applications requiring extended acceleration times or high duty cycles may experience nuisance tripping of the coordi nated fa st acting c urrentlimiting fuses. This ty pe 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 fa ti g ue.

Page 37

Installation

2-11

Protective Modules

Protective modules containing metal oxide v aristors (MOVs) and capacitors can be ins talle d on co ntrolle rs ra ted 24A to 360A to protec t the power component s fr om electr ical transie nts and/or high electr ical noise. The protective modules clip voltage transients generated on the lines to prevent such surges from damaging the SCRs. The capacitors in the protective modules are used to shunt noise energy away from the controller electronics. Surg e prote ction is provided as standard for controller s rated 500–1000A.

Motor Overload Protection

Thermal motor overload protection is provi ded as standard (though it must be programmed) with the SMC Dialog Plus controller. If the overload trip class is less than the acceleration time of the motor, nuisance tripping may occur.

Three special applicat ions require consideration: bypass , two-speed motors, and multi-motor prote ction.

Bypass

In a bypass configuration, the SMC Dialog Plus controller loses current sensing capability. It is recommended that a Bulletin 825 converter module be used to provide current feedb ack 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 electromechanical overload relay for bypa ss con figurations.

Two-speed Motors

The SMC Dialog Plus controller has ov erloa d protecti on av a ilabl e for single speed motors. Whe n the SMC Dialog P lus controll er i s appl ie d to a two-speed moto r, the Overload Cl ass parameter must be programmed to OFF and separate overload relays must be provided for each speed.

Multi-motor Protection

If the SMC Dialog Plus controll er is c ontrol ling mor e than one motor, individual overload protection is required for each motor.

ATTENTION: When installing or inspecting the

protective module, make sure that the controller has been disconnected from the power source. The protectiv e modul e should be ins pecte d periodi cally for damage or discoloration. Replace if necessa ry.

ATTENTION: Overload protecti on should be

properly coordinated with the motor.

Page 38

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 panel and a cont rol panel. The display panel duplicates the 2-line, 16-character backlit LCD display and programming keypad found on front of the SMC Dialog Plus controller. Refer to Chapter 4 for a descripti on of the programming keys; refer to Append ix D for a listing of human interface module catalog numb ers that are compatible with the controller.

The control panel provides the operator interface to the contr oller.

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

Start

The green start but ton, when presse d, will begi n moto r operation.

Stop

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

Jog

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

JOG

ATTENTION: The Bulletin 1201 human interfac e

module’ s stop push b utt on i s not i ntended to be us ed a s an emergency stop. Refer to the appli cable standards for emergency stop requirements.

Page 39

Installation

2-13

Connecting the Human Interface Module to the Controller

Figure 2.7 sho ws the conne ction of the SMC Dial og Plus contr oller to a human interface module. See Figure 3.14 on page 3-10 for the control wiring diagram that enable s start-stop control from a human interface module.

Figure 2.7 SMC Dialog Plus Controller with Human Interface Module

Control Enable

To enable motor control from a connect ed human interface module, follow the procedure below with the connected human interface module’s programming keys.

Note: Series A and Series B human interface modules require

different procedu re s. Be sure to u se the co rre ct tabl e.

Human Interface Module

SMC Dialog Plus Controller

Pull back moving part (connector body) to disconnect

cable from the SCANport connection.

Bulletin 1202

Cable

Latching

Mechanism

172718

Page 40

2-14

Installation

Human Interface Module (cont.)

Series A Human Interface Modules

①

Zero and 4 are the only valid settings.

Note: If a human interface module is disconnected from the SMC

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

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.

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

STOPPED

0.0 AMPS

CHOOSE MODE _ _ _ _ _

CHOOSE MODE PROGRAM

PROGRAM _ _ _ _ _

PROGRAM LINEAR LIST

VOLTS PHASE A-B 0 VOLTS 1

LOGIC MASK 085

LOGIC MASK 485

Page 41

Installation

2-15

Series B Human Interface Modules

Note: If a human interface module is disconnected from the SMC

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

Description Action Display

——

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

Page 42

2-16

Installation

Communication Modules

The Bulletin 1203 communication module al lows the user to connect the SMC Dialog Plus controller to various networks and communication protocols . The figure belo w sho ws how the contro ller and the communication module connect.

Figure 2.8 SMC Dialog Plus Controller with Communication Module

Converter Modules

The Bulletin 825 converter 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 modul e bas ed on the motor fu l l load cur rent (FLC) rating. Table 2.A details the information for proper selection.

Table 2.A Converter Module Selection Guide

Communication Module

SMC Dialog Plus Controller

Pull back moving part (connector body) to disconnect

cable from the SCANport connection.

Bulletin 1202

Cable

Latching

Mechanism

V+

V-

251626

Motor FLC Range Cat. No.

1–12.5A 825-MCM20

9–100A 825-MCM180

64–360A 825-MCM630

Page 43

Installation

2-17

Figure 2.9 shows the conn ection between the controller and the module.

Figure 2.9 Converter Module Connection Interface

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.

T1 T2 T3

L2 L3

150-NFS

21 22 23 24 25 26 27 28 29 30

Converter Module

➀

Cable (provided as standard with the converter module)

➁

Fanning Strip

Page 44

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 required. The figure below illustrates the connection of the current transformers to the converter module.

Figure 2.10 Current Transformer Connection to Converter Module

①

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

Electromagnetic Compatibility (EMC)

The following guidelines are provided for EMC installat ion compliance.

Enclosure

Install the product in a grounded metal enclosur e.

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.

Current Transformer

➀➁

L1 L3

T1 T3

Converter Module

➂

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

Page 45

Installation

2-19

Wiring

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

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

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

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

• Different wire groups should be run in separate conduits.

• Minimum spacing between conduits conta ining different wire groups should be three inches (8 cm).

Accessory Requirements

When connection of the Bulletin 825 converter module or Bulletin 1202 communication cable is required, a ferrite core suppressor (FairRite PN 2643802702 or equal) should be used in conjunc ti on. Mount the suppressor as close to the controller as practical, wrapping the cable twice through the suppress or.

Page 46

2-20

Installation

Page 47

Chapter 3

Wiring

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)

Figure 3.2 Wiring Terminal Locations (97 and 135 Amp)

Input Power Connections

Control Circuit

Connections

Output Power

Connections

ESC. SEL.

11211323122214241525162617271828192920

Input Power

Connections

Control

Circuit

Connections

Output Power

Connections

Fan

Power

Connections

Page 48

3-2

Wiring

Terminal Locations (cont.)

Figure 3.3 Wiring Terminal Locations (180 to 360 Amp)

Figure 3.4 Wiring Terminal Locations (500 Amp)

Control Wiring Access Door

Input Power

Connections

Control

Circuit

Connections

Output Power

Connections

Fan Power

Connections

TB3

12 3 4 5

Input Power Connections

Control Circuit

Connections

Output Power

Connections

Fan Power

Connections

Page 49

Wiring

3-3

Figure 3.5 Wiring Terminal Locations (650 to 1000 Amp)

Power Wiring

24–54A

The power modules for controllers rated 24A–54A have internal mechanica l- typ e lugs to acc ep t line and loa d ca bles . Table 3.A and Table 3.B provide the lug wire capacity and tightening torque requirements.

Table 3.A Lug Wire Capacity

Table 3.B Tightening Torque

97–1000A

Power lugs are available as optional kits. Each kit con tains 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.

Input and

Output Power

Connections

Control Circuit

Connections

Fan Power

Connections

Metric AWG

2.5–25 mm

#14–#4

Tightening Torque

Wire Size

2.5–6 mm

(14–10 AWG)

10 mm

(8 AWG)

16–25 mm

(6–4 AWG)

To rq ue

2.80 N-m (25 Lb-in)

3.4 N-m

(30 Lb-in)

3.95 N-m (35 Lb-in)

Page 50

3-4

Wiring

Terminal Locations (cont.)

Table 3.C Lug Wire Capacity and Tightening Torque

Control Power

Control Voltage

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

• 100

–

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

• 24V 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 power requirement for the control module is 40 VA. For controllers rated 97A

–

1000A, control power is also required for the heatsink fans as defined in Table 3.D. Depending on the specifi c application, additional control circuit transformer VA capacity may be required.

Table 3.D Heatsink Fan Control Power

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

SMC

Rating

Lug Kit

Cat. No.

Conductor

Range

Max. No.

Lugs/Pole

Tightening Torque

Line Side

Load

Side

Wire –

Lug

Lug –

Busbar

97–

135A

199-LF1

16–120 mm

(#6–4/0 AWG)

31 N-m

(275 lb-in)

31 N-m

(275 lb-in)

180– 360A

199-LF1

16–120 mm

(#6–4/0 AWG)

31 N-m

(275 lb-in)

31 N-m

(275 lb-in)

500A 199-LG1

25–240 mm

(#4–500 AWG)

42 N-m

(375 lb-in)

45 N-m

(400 lb-in)

650– 720A

199-LG1

50–240 mm

(1/0–500 AWG)

42 N-m

(375 lb-in)

45 N-m

(400 lb-in)

850–

1000A

199-LJ1

50–240 mm

[(2) 1/0–500 AWG]

42 N-m

(375 lb-in)

45 N-m

(400 lb-in)

SMC Rating Heatsink Fan VA

97–360A 45

500A 145

650–1000A 320

Wire Size Torque

0.75–2.5 mm

(#18–#14)

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

Page 51

Wiring

3-5

Fan Power

Controllers rated 97A–1000A hav e heats ink f an(s). Refe r 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.

Figure 3.6 97A and 135A Fan Terminations

Figure 3.7 180A to 500A Fan Terminations

Figure 3.8 650A to 1000A Fan Terminations

ATTENTION: The fan jumpers have been factory

installed for 110/120 VAC input. Refer to Figure 3.6 through Figure 3.8 for 220/240 VAC fan wiring. Note that 220/240 VAC fan wiring is not ava ilable for the 650A–1000A controllers. Af ter wiring for the 97A and 135A controllers is complete, replace control te rminal strip cover.

Factory Set

110/120 VAC

Optional

220/240 VAC

Jumpers

Supply

Jumper

Supply

1 2 3 4

Factory Set

110/120 VAC

Optional

220/240 VAC

Supply

Jumpers Jumper

1 2 3 4 5

Factory Set

110/120 VAC

Supply

1 2 3 4 5

Note: 220/240 VAC is not available.

Page 52

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

①

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.

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 groundi ng 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 identification symbol as defined by IEC Publication 417, Symbol 5019.

If the protective conductor is not connected to the heatsink, the plating and/or paint must be cleane d from the four mounting holes or four star washers (tooth loc k washers) must be used.

Figure 3.10 Grounding Provision

Ter mi na l

Number

Description

Ter mi na l

Number

Description

11 Control Power Input 21 Not Used

12 Control Power Common 22 Not Used

13 Controller Enable Input

①

23 Not Used

14 Logic Ground 24 Not Used

15 Dual Ramp/Option Input

①

25 Converter Module Fanning Strip Connection

②

16 Start Input

①

26 Converter Module Fanning Strip Connection

②

17 Stop Input

①

27 Converter Module Fanning Strip Connection

②

18 Auxiliary Relay Common 28 Converter Module Fanning Strip Connection

②

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)

Page 53

Wiring

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

①

Customer supplied.

②

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

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

Page 54

3-8

Wiring

Standard Controller Wiring Diagrams (cont.)

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

Control Interfacing

①

Customer supplied.

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.

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

Page 55

Wiring

3-9

Figure 3.13 Typical Wiring Diagram for Dual Ramp Applications

①

Customer supplied.

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.

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

Page 56

3-10

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 connected to the SMC Dialog Plus controller’s SCANport.

①

Customer supplied.

②

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

③

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

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

Page 57

Wiring

3-11

Figure 3.15 Typical Wiring Diagram for Retrofit Applications

①

Customer supplied.

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.

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

Page 58

3-12

Wiring

Standard Controller Wiring Diagrams (cont.)

Figure 3.16 Typical Wiring Diagram for Isolation Applications

①

Customer supplied.

②

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

Isolation

Contactor

(IC)

➀

➁

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

Page 59

Wiring

3-13

Figure 3.17 Typical Wiring Diagram for Bypass Applications

①

Customer supplied.

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.

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

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

Fanning Strip

➀

Bulletin 825

Converter

Module

Auxiliary

contacts set for

Up-to-speed

SMC

Dialog Plus

Controller

SMC Dialog Plus

Control Terminals

Page 60

3-14

Wiring

Standard Controller Wiring Diagrams (cont.)

Figure 3.18 Typical Wiring Diagram for Bypass with Isolation Applications

①

Customer supplied.

②

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

Stop

➀

Start

➀

Bypass Contactor (BC)

➀

➁

3-Phase

Input Power

Branch

Protection

➀

Fast-acting

SCR Fuses

(optional)

➀

Bulletin 825 Converter Module

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

Page 61

Wiring

3-15

Figure 3.19 Typical Wiring Diagram for Shunt Trip Applications

①

Customer supplied.

②

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

Stop

➀

Start

➀

➁

3-Phase

Shunt Trip Circuit Breaker

Input Power

Branch

Protection

➀

Fast-acting

SCR Fuses

(optional)

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

➀

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Auxiliary contact

set for Fault

and N.O.

SMC Dialog Plus

Controller

SMC Dialog Plus

Control Terminals

Page 62

3-16

Wiring

Standard Controller Wiring Diagrams (cont.)

Figure 3.20 Typical Wiring Diagram for Single Speed Reversing Applications

①

Customer supplied.

②

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

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

(2) Phase Reversal protection

must

be disabled in reversing applications.

Stop

➀

OFF

➀

FOR REV

➁

3-Phase

Input Power

Branch

Protection

➀

Reversing Contactors

➀

Fast-acting SCR Fuses

(optional)

➀

Bulletin 825

Coverter

Module

(optional)

➀

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

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

Page 63

Wiring

3-17

Figure 3.21 Typical Wiring Diagram for Two-speed Applications

①

Customer supplied.

②

Two-speed, consequent pole installations.

③

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

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

Page 64

3-18

Wiring

Standard Controller Wiring Diagrams (cont.)

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

①

Customer supplied.

②

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

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

Page 65

Chapter 4

Programming

Overview

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.

Keypad Description

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

Programming Menu

Parameters are organized in a four-level menu structure for straightforward programming. Figure 4.1 details the programming menu structure and the four-level hierarchy.

Escape

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

Select

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.

Up/Down Arrows

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

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.

ESC

SEL

Page 66

4-2

Programming

Programming Menu (cont.)

Figure 4.1 Menu Structure Hierarchy

①

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

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.

Power-up and Status Display

Choose Mode

Control

Status

Control Logic

Fault Queue

Linear

List

Basic Setup Advanced Setup

Faults

Language

Display

read only

Metering

See

Chapter 6

Calibrate

See

Chapter 5

Program

read/write

Password

See page 4-5

read only

See page 4-5

OPERATION LEVEL

MODE LEVELMODE LEVEL

GROUP LEVEL

➀

➂➃➂➃

➁

⑤

Page 67

Programming

4-3

Figure 4.1 (Cont.) Menu Structure Hierarchy

①

Steps back one level.

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.

Linear

List

Basic Setup Advanced Setup

Faults

Language

Metering

See

Chapter 6

Calibrate

See

Chapter 5

GROUP LEVEL

➁

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

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.

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) 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

PARAMETER LEVEL

③

④

Page 68

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

Page 69

Programming

4-5

Password

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

①

After you have completed the programming process, re-enter the Password mode to log out. This will eliminate unauthorized access to the programming system.

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

Allen-Bradley 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 default values. This mode is available only when using Bulletin 1201 human interface module.

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.

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.

①

STOPPED

0.0 AMPS

CHOOSE MODE DISPLAY

CHOOSE MODE PASSW ORD

PASSW ORD |MODIFY

Options:

Logout

ENTER PASSWORD _ _ _ _ _

ENTER PASSWORD #####

CHOOSE MODE PASSW ORD

Page 70

4-6

Programming

Parameter Management

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

• structured within 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

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 values are stored in RAM. When power is applied to the controller, paramete r values stored in the EE PROM are copi ed to RA M . RAM is volatile

and the values stored 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 value s. These settings are stored in nonvolatile R OM 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.

EEPROM RAM ROM

Page 71

Programming

4-7

Using Parameter Management

Description Action Display

Saving to EEPROM

To ensure that the newly modified parameters are not lost if control power is removed from the controller, store the values into EE PROM.

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.

PARAMETER MGMT STORE IN EE

PARAMETER MGMT RECLL FRM EE

PARAMETER MGMT DEFAULT INT

Page 72

4-8

Programming

Parameter Modification

All parameters are modified using the same method. The basic steps to performing parameter modification are described below.

Note: Parameter values modified while the motor is operating are

not valid until the next start sequence begins.

①

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

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.

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 th is example, Basic Setup will be used.

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.

STOPPED

0.0 AMPS

CHOOSE MODE DISPLAY

CHOOSE MODE PROGRAM

PROGRAM METERING

PROGRAM BASIC SETUP

SMC OPTION STANDARD

STARTING MODE SOFT START

Options:

Soft St art,

Current Limit

STARTING MODE SOFT START

STARTING MODE CURRENT LIMIT

RAMP TIME # 1 10 SEC

PARAMETER MGMT STORE IN EE

Page 73

Programming

4-9

Soft Start

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

①

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

Current Limit Start

To apply a fixed reduced output voltage to the motor, the following parameters are provided for user adjustment:

①

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

Para meter Option

Starting Mode

This must be programmed for Soft Start.

Soft Start

, Current Limit

Ramp Time #1

①

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

0 to 30 seconds

Initial Torque #1

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

0 to 90% locked rotor torque

Kickstart Time

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

0.0 to 2.0 seconds

Parameter Option

Starting Mode

This must be programmed for Current Limit.

Soft Start,

Current Limi

Ramp Time #1

①

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

0 to 30 seconds

Current Limit Level

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

50 to 600% full load current

Kickstart Time

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

0.0 to 2.0 seconds

Page 74

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 available in the Advanced Setup programmin g mode to obtain Dual Ramp control:

①

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

Full Voltage Start

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

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

①

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

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

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

When this feature is turned on, the ramp time/initial torque combination is determined by a hard contact input to terminal 15. When this input signal is low, ramp time/initial torque #1 are selected. When this input is high, ramp time/initial torque #2 are selected.

No, Yes

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.

0 to 30 seconds

Initial Torque #1

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

0 to 90% locked rotor torque

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.

0 to 30 seconds

Initial Torque #2

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

0 to 90% locked rotor torque

Parameter Option

Starting Mod

This

must

be programmed for Soft Start.

—

Ramp Time #1

This

must

be programmed for 0 seconds for a full

voltage start.

—

Initial Torque #1

This

must

be programmed for 90% for a full voltage

start.

—

Kickstart Time

This

must

be programmed for 0.0 seconds for a full

voltage start.

—

Page 75

Programming

4-11

Basic Setup

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

①

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

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.

Parameter Option

SMC Option

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

Standard

Starting Mode

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

Soft Start, Current Limit

Ramp Time #1

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

0 to 30 seconds

Initial Torque #1

①

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

0 to 90% of locked rotor torque

Current Limit Level

②

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

50 to 600% full load current

Kickstart Time

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

0.0 to 2.0 seconds

Stall Delay

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

0.0 to 10.0 seconds

Energy Saver

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

Off, On

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.

Normal, Up-to-speed

Aux Contact 3

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

Normal, Fault

Contact 3 Config

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

N.O., N.C.

Parameter Mgmt

③

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

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

Page 76

4-12

Programming

Advanced Setup

While the Basic Setup group allo ws the user to get started with a minimum number of parameters to modify, the Advanced Setup group allows f ull acc ess t o the SMC Dialo g Plus contro ller’s powerful parameter set. Foll owing is a listing of the additional setup parameters provided.

Note: All of the Basic Se tup pa ram et er s are available in the

Advanced Setup group. The par amet ers shown below are in addition to the parameters in Basi c Setup.

①

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

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 enabl e Rebal ance, the Convert er Rating parame ter in the Calibra te programming gr oup must be set for 20, 180, or 630.

Parameter Option

Dual Ramp

①

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

Off, On

Ramp Time #2

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

0 to 30 seconds

Initial Torque #2

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

0 to 90% locked rotor torque

Undervoltage Level

Determines the trip level as a percentage of line voltage.

0 to 99% (0 is the Off setting)

Undervoltage Delay

②

Provides a delay period prior to a trip occurrence.

0 to 99 seconds

Overvoltage Leve

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

0 to 199% (0 is the Off setting)

Overvoltage Delay

②

Provides a delay period prior to a trip occurrence.

0 to 99 seconds

Jam Level

③

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

0 to 999% (0 is the Off setting)

Jam Delay

Provides a delay period prior to a trip occurrence.

0.0 to 10.0 seconds

Unbalance Level

Allows the user to set the voltage unbalance trip level.

0 to 25% (0 is the Off setting)

Unbalance Delay

②

Provides a delay period prior to a trip occurrence.

0 to 99 seconds

Rebalance

④

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

Off, On

Underload Level

②

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

0 to 99% (0 is the Off setting)

Underload Delay

Provides a delay period prior to a trip occurrence.

0 to 99 seconds

Page 77

Programming

4-13

①

The Auto Restart feature is not available.

②

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

Example Settings

Undervoltage

①

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

Overvoltage

①

With Line Voltage programmed for 240V and the Overvoltage le vel programmed for 115%, the trip va lue is 276V.

Jam

②

With Motor FLC programmed for 150 Amps and the Jam level programmed for 400%, the trip va lue is 600 Amps.

Underload

②

With Motor FLC programmed for 90 Amps and the Underload level programmed for 60%, the trip va lue is 54 Amps.

①

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

②

The largest value of the three phase currents is utilized.

Parameter Option

Phase Reversal

This parameter allows the user to enable phase revers al protection.

Off, On

Starts Per Hour

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

0–99 (0 is the Off setting)

Restart Attempts

①

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

0 to 5

Restart Delay

①

Provides a delay period prior to a restart attempt.

0 to 60 seconds

ETM Reset

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

Off, On

Parameter Management

②

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

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

Page 78

4-14

Programming

Page 79

Chapter 5

Calibration

Overview

The Calibrate pr ogramming gr oup all o ws t he user to set par ameters t o calibrate the controller to the connected motor . It is important to correctly input the data to achieve the best performance from your controller.

Motor Data Entry

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

①

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

②

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

ATTENTION: For over load protection, it is critical

that the data be entered as it appears on the motor nameplate.

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.

Off, 10, 15, 20, 30

Overload Reset

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

Manual, Auto

Motor HP Rating

①②

Enter the value from the motor’s nameplate.

0.0–6,553.5 HP

Motor kW Rating

①②

Enter the value from the motor’s nameplate.

0.0–6,553.5 kW

Line Voltage

①

Enter the system voltage in this parameter. This

must

be done to ensure optimum motor performance and correct operation of undervoltage and overvoltage protection.

1–9,999V

Motor FLC

①

Enter the value from the motor’s nameplate.

1.0–999.9A

Service Factor

Enter the value from the motor’s nameplate.

0.01–1.99

OVERLOAD CLASS _____

OVERLO AD RESE T MANUAL

MOTOR HP RATING #### HP

MOTOR KW RATING #### KW

LINE VOLTAGE #### VOLTS

MOTOR FLC ###.# AMPS

SERVICE FACTOR #.##

Page 80

5-2

Calibration

Motor Data Entry (cont.)

①

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

Table 5.A Motor Codes

①

Locked kVA per horsepower range includes the lower figure up to, but not including, the higher figure. For example, 3.14 is designated by letter A and 3.15 by letter B.

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.

A–V

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.

0.0–19.9

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.

None, 20, 180, 630

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.

5 through 1200:5

MOTOR CODE LETTER #

LRC RATIO ##.#

CONVERTER RATING ###

CT RATIO #### : 5

Letter

Designation

kVA/HP

①

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

Page 81

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 provid es a tr ue rms measurement a nd 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 converte r module for

current feedback to the SMC Dialog Plus contro ller, this calibration procedure is not necessary.

(2) An unbalanced three-phase system may affe ct the

accuracy of the calibr at ion.

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

is programmed to OFF during the calibration proce dure.

Calibration requires 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 necessar y so that max i mum accu ra cy is achi eved for curre nt measuremen t s at overload tr ip levels.

①

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

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

—

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 accept.

The SMC Dialog Plus

controller is now calibrated

AT SPEED ###.# AMPS

CALIBRATION OFF

CALIBRATION ACTIVATE

ENTER CALIB. AMPS

0.0 AMPS

ENTER CALIB. AMPS ###.# AMPS

Page 82

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 ove rload class and sa ve the se tting to the controller’s EEPROM.

ATTENTION: This method of current measurement

is not applicable to multi-motor install ations or resistiv e heating loads. Ut ilization of the Bulletin 825 con ve rter module is required for these applicat ions if current measurement is required.

CURRENT PHASE A ###.# AMPS

PARAMETER MGMT READY

PARAMETER MGMT STORE IN EE

Page 83

Chapter 6

Metering

Overview

While the SMC Dialog Plus controller operate s your motor, it also monitors several different parameters, providing a full function metering

①

package.

Viewing Metering Data

To access the metering informati on, f ollow the procedure below.

①

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

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.

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

AT SPEED ###.# AMPS

CHOOSE MODE _ _ _ _ _

CHOOSE MODE DISPLAY

CHOOSE GROUP _ _ _ _ _

CHOOSE GROUP METERING

Page 84

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. THER M USAGE ## %

Page 85

Chapter 7

Options

Overview

The SMC Dialog Plus controller of fers a variety of unique control options that provide 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.

Human Interface Module

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

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

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

(2) The control terminals must be wired according 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.

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

Pump Control The green start button, when pressed,

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.

JOG

Page 86

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.

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

Smart Motor Braking The green start button, when pressed,

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.

Accu-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.

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.

Slow Speed with

Braking

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

JOG

ATTENTION: The Bulletin 1201 human interfac e

module’ s stop push b utt on i s not i ntended to be us ed a s an emergency stop. Refer to applic able standards for emergency stop requir ements.

Page 87

Options

7-3

Programming Parameters

The following tabl e provides the option-specific parameters that are provided with each control option. These parameters are in addition to those already discussed in the Basic Setup, Advanced Setup, Metering, and Calibrati on grou ps. Diag rams supporting the options described below are shown later in this chapter.

Option Parameter Range

Soft Stop

SMC Option

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

Soft Stop

Soft Stop Time

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

0–60 seconds

Pump Control

SMC Option

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

Pump Control

Pump Stop Time

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

0–120 seconds

Starting Mode

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

Pump Start, Soft Start, Current Limit Start

Preset Slow

Speed

SMC Option

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

Preset Slow

Slow Speed Select

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

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

Slow Speed Direction

This parameter programs the slow speed motor rotational direction.

Forward, Reverse

Slow Accel Current

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

0–450% of full load current

Slow Running Current

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

0–450% of full load current

Page 88

7-4

Options

Programming Parameters (cont.)

①

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

SMB Smart

Motor Braking

SMC Option

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

SMB Braking

Braking Current

①

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

0–400% of full load current

Accu-Stop

SMC Option

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

Accu-Stop

Slow Speed Select

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

Low: 7% High: 15%

Slow Accel Current

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

0–450% of full load current

Slow Running Current

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

0–450% of full load current

Braking Current

①

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

0–400% of full load current

Stopping Current

①

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

0–400% of full load current

Slow Speed

with Braking

SMC Option

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

Slow Speed Brake

Slow Speed Select

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

Low: 7% High: 15%

Slow Accel Current

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

0–450% of full load current

Slow Running Current

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

0–450% of full load current

Braking Current

①

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

0–400% of full load current

Page 89

Options

7-5

Control Wiring for SCANport Control

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

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

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

①

Customer supplied.

②

Soft Stop, Pump Stop, or Brake.

③

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

Note: Refer to Chapter 3 for typical power circuits.

Stop

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

Page 90

7-6

Options

Figure 7.2 Typical Retrofit Wiring Diagram

①

Customer supplied.

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.

Stop

➀

➀ ➁

➀

Control Power

➂

Option Stop

➀ ➃

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

Auxiliary contacts set

for Normal

SMC Dialog Plus

Control Terminals

Page 91

Options

7-7

Figure 7.3 Typical Wiring Diagram for Applications Requiring an Isolation

Contactor

①

Customer supplied.

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.

Stop

➀

Control Power

➁

Option Stop

➀ ➂

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

Auxiliary contacts set

for Normal

SMC Dialog Plus

Control Terminals

Page 92

7-8

Options

Figure 7.4 Typical Wiring Diagram for Applications Requiring a Bypass

Contactor

①

Customer supplied.

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.

Stop

➀

Control Power

➁

Option Stop

➀ ➂

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

Bulletin 825

Converter

Module

Auxiliary contacts set

for Up-to-speed

Fanning Strip

➀

SMC Dialog Plus

Control Terminals

Page 93

Options

7-9

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

Controller Interfacing

①

Customer supplied.

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.

Control Power

➁

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

SMC Dialog Plus

Control Terminals

Page 94

7-10

Options

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

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

①

Customer supplied.

②

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

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

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

Page 95

Options

7-11

Soft Stop Option

Figure 7.7 Soft Stop Option Sequence of Operation

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)

ATTENTION: The user is responsible for

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

Page 96

7-12

Options

Pump Control Option

Figure 7.8 Pump Control Option Sequence of Operation

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)

Pump Stop

ATTENTION: The user is responsible for

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

Page 97

Options

7-13

SMB Smart Motor Braking Option

Figure 7.9 SMB Smart Motor Braking Sequence of Operation

Motor Speed

Push Buttons

Start

Stop

Soft Stop

Auxiliary Contacts

Normal

Up-to-speed

Start Run

Open

Closed

100%

Coast-to-rest

Automatic Zero Speed

Shut-off

Smart Motor Braking

Brake

Time (seconds)

Coast-to-rest Operation

Smart Motor Braking Operation

Brake

ATTENTION: The user is responsible for

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

Page 98

7-14

Options

Preset Slow Speed and Accu-Stop Options

Figure 7.10 through Figure 7.14 shows the different wiri ng for the Preset Slow Speed and Accu-Stop options.

Figure 7.10 Typical Wiring Diagram for the Preset Slow Speed Option

①

Customer supplied.

②

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

③

Slow Speed or Accu-Stop.

Note: Refer to Chapter 3 for typical power circuits.

Stop

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

Internal Auxiliary Contacts

SMC Dialog Plus

Control Terminals

Page 99

Options

7-15

Figure 7.11 Typical Retrofit Wiring Diagram

①

Customer supplied.

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.

Stop

➀

➀ ➁

➀

Control Power

➂

Option Command

➀ ➃

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

Auxiliary contacts set

for Normal

SMC Dialog Plus

Control Terminals

Page 100

7-16

Options

Figure 7.12 Typical Wiring Diagram for Applications Requiring an Isolation

Contactor

①

Customer supplied.

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.

Stop

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

Internal Auxiliary Contacts

Auxiliary contacts set

for Normal

SMC Dialog Plus Control Terminals