User Manual
SMC Dialog Plus
™
Controller
Bulletin 150
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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.
Table of Contents
Chapter 1 Product Overview 1-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Starting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Selectable Kickstart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Current Limit Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Energy Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Phase Rebalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Protection and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Stall Protection and Jam Detection . . . . . . . . . . . . . . . . . . . . . 1-8
Open Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Line Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Excessive Starts/Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Status Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Soft Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Pump Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Preset Slow Speed Option . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SMB‰ Smart Motor Braking Option . . . . . . . . . . . . . . . . . . 1-14
Accu-Stop‰ Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Slow Speed with Braking Option . . . . . . . . . . . . . . . . . . . . . 1-15
Chapter 2 Installation
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Ventilated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Non-ventilated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
toc–iv
Table of Contents
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Power Factor Correction Capacitors . . . . . . . . . . . . . . . . . . . . . . 2-9
Fast Acting Current-limiting Fuses . . . . . . . . . . . . . . . . . . . . . . 2-10
Protective Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Two-speed Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Multi-motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Connecting the Human Interface Module to the Controller . . . 2-13
Control Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Converter Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . 2-18
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Accessory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Chapter 3 Wiring
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
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
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
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
toc–viii
Table of Contents
Figure 2.10 Current Transformer Connection
to Converter Module . . . . . . . . . . . . . . . . . . . . . . 2-18
Figure 3.1 Wiring Terminal Locations (24 to 54 Amp) . . . . . . . 3-1
Figure 3.2 Wiring Terminal Locations (97 and 135 Amp) . . . . 3-1
Figure 3.3 Wiring Terminal Locations (180 to 360 Amp) . . . . . 3-2
Figure 3.4 Wiring Terminal Locations (500 Amp). . . . . . . . . . . 3-2
Figure 3.5 Wiring Terminal Locations (650 to 1000 Amp) . . . . 3-3
FIgure 3.6 97A and 135A Fan Terminations . . . . . . . . . . . . . . 3-5
Figure 3.7 180A to 500A Fan Terminations . . . . . . . . . . . . . . . 3-5
Figure 3.8 650A to 1000A Fan Terminations . . . . . . . . . . . . . . 3-5
Figure 3.9 SMC Dialog Plus Controller Control Terminals . . . . 3-6
Figure 3.10 Grounding Provision . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3.11 Typical Wiring Diagram for Standard Controller . . . 3-7
Figure 3.12 Typical Wiring Diagram for Two-Wire Control or
Programmable Control Interfacing . . . . . . . . . . . . . 3-8
Figure 3.13 Typical Wiring Diagram for
Dual Ramp Applications . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3.14 Typical Wiring Diagram for Start-Stop
Control via the SCANport . . . . . . . . . . . . . . . . . . . 3-10
Figure 3.15 Typical Wiring Diagram for
Retrofit Applications. . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3.16 Typical Wiring Diagram for
Isolation Applications . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3.17 Typical Wiring Diagram for
Bypass Applications . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3.18 Typical Wiring Diagram for Bypass
with Isolation Applications . . . . . . . . . . . . . . . . . . 3-14
Figure 3.19 Typical Wiring Diagram for
Shunt Trip Applications . . . . . . . . . . . . . . . . . . . . 3-15
Figure 3.20 Typical Wiring Diagram for Single
Speed Reversing Applications . . . . . . . . . . . . . . . 3-16
Figure 3.21 Typical Wiring Diagram for
Two-speed Applications . . . . . . . . . . . . . . . . . . . 3-17
Figure 3.22 Typical Wiring Diagram for
Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 3-18
Figure 4.1 Menu Structure Hierarchy . . . . . . . . . . . . . . . . . . . 4-2
Figure 4.2 Memory Block Diagram . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 7-1 Typical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 7-6
Figure 7.2 Typical Retrofit Wiring Diagram . . . . . . . . . . . . . . . 7-7
Figure 7.3 Typical Wiring Diagram for Applications
Requiring an Isolation Contactor . . . . . . . . . . . . . . 7-8
Figure 7.4 Typical Wiring Diagram for Applications
Requiring a Bypass Contactor . . . . . . . . . . . . . . . . 7-9
Figure 7.5 Typical Wiring Diagram for Two-wire Control
or Programmable Controller Interfacing . . . . . . . . 7-10
Figure 7.6 Typical Wiring Diagram for
Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 7-11
Figure 7.7 Soft Stop Option Sequence of Operation . . . . . . . 7-12
Figure 7.8 Pump Control Option Sequence of Operation . . . . 7-13
Table of Contents
toc–ix
Figure 7.9 SMB Smart Motor Braking Sequence
of Operation 7-14
Figure 7.10 Typical Wiring Diagram for the
Preset Slow Speed Option . . . . . . . . . . . . . . . . . . 7-15
Figure 7.11 Typical Retrofit Wiring Diagram . . . . . . . . . . . . . . 7-16
Figure 7.12 Typical Wiring Diagram for Applications
Requiring an Isolation Contactor . . . . . . . . . . . . . 7-17
Figure 7.13 Typical Wiring Diagram for Applications
Requiring a Bypass Contactor . . . . . . . . . . . . . . . 7-18
Figure 7.14 Typical Wiring Diagram for
Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 7-19
Figure 7.15 Preset Slow Speed Option
Sequence of Operation . . . . . . . . . . . . . . . . . . . . 7-20
Figure 7.16 Accu-Stop Option Sequence of Operation . . . . . . 7-21
Figure 7.17 Typical Wiring Diagram for the
Slow Speed with Braking Option . . . . . . . . . . . . . 7-22
Figure 7.18 Typical Retrofit Wiring Diagram for the
Slow Speed with Braking Option . . . . . . . . . . . . . 7-23
Figure 7.19 Typical Wiring Diagram for the Slow Speed
with Braking Option with an Isolation Contactor . . 7-24
Figure 7.20 Typical Wiring Diagram for the Slow Speed
with Braking Option with a Bypass Contactor . . . . 7-25
Figure 7.21 Slow Speed with Braking Option Sequence
of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Figure 9.1 Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Figure 10.1 Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . 10-2
Figure 10.2 Removal of Control Module (24–135A) . . . . . . . . 10-7
Figure 10.3 Removal of Control Module (180–360A) . . . . . . . 10-9
Figure 10.4 Removal of Protective Cover (500–1000A) . . . . 10-12
Figure 10.5 Removal of Control Module (500–1000A) . . . . . 10-10
Figure 10.6 MOV Fuse Replacement . . . . . . . . . . . . . . . . . . 10-13
Figure 10.7 Pin Locations for Power Module
Resistance Check . . . . . . . . . . . . . . . . . . . . . . . 10-22
Figure 10.8 Pin Locations for Power Pole Resistance
Check (180–1000A) . . . . . . . . . . . . . . . . . . . . . 10-24
Figure 10.9 Gate and Thermistor Lead Identification
(180–1000A) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Tables
Table 2.A Maximum Heat Dissipation. . . . . . . . . . . . . . . . . . . 2-2
Table 2.B Minimum Ventilation Openings . . . . . . . . . . . . . . . 2-3
Table 2.C Recommended Fuses . . . . . . . . . . . . . . . . . . . . . 2-10
Table 2.D Converter Module Selection Guide . . . . . . . . . . . . 2-16
Table 3.A Lug Wire Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Table 3.B Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Table 3.C Lug Wire Capacity and Tightening Torque . . . . . . . 3-4
Table 3.D Heatsink Fan Control Power . . . . . . . . . . . . . . . . . . 3-4
Table 3.E Control Wiring and Tightening Torque . . . . . . . . . . 3-4
Table 4.A Parameter Linear List . . . . . . . . . . . . . . . . . . . . . . 4-4
Table 5.A Motor Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
toc–x
Table of Contents
Table 8.A Logic Control Data . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Table 8.B SMC Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Table 8.C Fault Code Cross-reference . . . . . . . . . . . . . . . . . . 9-2
Table 10.A SMC Fault Display Explanation . . . . . . . . . . . . . . 10-3
Table 10.B Motor Will Not Start — No Output Voltage
to the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Table 10.C Motor Rotates
(but does not accelerate to full speed) . . . . . . . . . 10-4
Table 10.D Motor Stops While Running . . . . . . . . . . . . . . . . . 10-4
Table 10.E Miscellaneous Situations . . . . . . . . . . . . . . . . . . . 10-5
Table B.1 Parameter Text/Display Unit Cross Reference. . . . . B-5
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.
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)
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)
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
T
orque #2
100%
Percent
Voltage
Time (seconds)
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.
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.
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.
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)
Approximate Trip Time (seconds)
Approximate Trip Time (seconds)
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%
0
1
10
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
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
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
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.
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%.
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.
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.
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.
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)
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)
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.
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.
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
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
2
(10 in2)
65 cm
2
(10 in2)
110 CFM
97 and 135A
233 cm
2
(36 in2)
233 cm
2
(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
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
A
Width
B
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
A
E
G F B
D
C
Ground Screw
(10-32)
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