Rockwell Automation SMC Flex Soft Starters User Manual

This manual links to KnowledgeBase Article SMC Flex Soft Starter Parameters, which contains the parameters; download the spreadsheets now to ensure offline access.

SMC Flex Soft Starters

Bulletin 150-F

User Manual

Original Instructions

SMC Flex Soft Starters User Manual

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

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

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

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

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

2	Rockwell Automation Publication 150-UM008I-EN-P - October 2020

Table of Contents

	Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 7
	About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 7
	Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	View Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
	Chapter 1
Product Overview	Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
	Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
	Starting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
	Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
	Linear Speed Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
	Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	Selectable Kickstart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	Pump Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	Dual Ramp Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	Full-voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	Preset Slow Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	Stopping Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14
	Coast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14
	Soft Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
	Linear Speed Deceleration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
	Pump Stop(a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
	Braking Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
	Smart Motor Braking (SMB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
	Slow Speed with Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
	Accu-Stop(a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
	Protection and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	Undervoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
	Overvoltage(a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
	Unbalance(a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
	Stall Protection and Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
	Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
	Ground Fault Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
	Ground Fault Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
	Thermistor/PTC Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
	Excessive Starts/Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
	Overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25
	Open Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25
	Line Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25
	Metering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25
	I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	26
	Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	26
	Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	27

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Table of Contents

	Status Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	27
	Chapter 2
Installation	Receive the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
	Unpack the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
	Inspect the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
	Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
	Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
	General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	30
	Degree of Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
	Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
	Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
	Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32
	Power Factor Correction Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	33
	Protective Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	34
	Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	34
	Two-speed Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	34
	Multi-motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
	Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
	Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
	Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
	Additional Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
	New EMC Compliance – Conducted Emissions . . . . . . . . . . . . . . . . .	36
	Chapter 3
Wiring	Wiring Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	37
	Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	39
	Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	39
	Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	40
	Delta Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	40
	Power Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	40
	Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41
	Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41
	Controllers rated 5…480 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	42
	Controllers rated 625…1250 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	42
	Control Wire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	45
	Fan Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	46
	Fan Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	46
	Control Terminal Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
	Standard Controller Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . .	48
	Soft Stop, Pump Control, and SMB Smart Motor Braking . . . . . . . . . . .	59
	Preset Slow Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	63
	Slow Speed with Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	65
	Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	66
	Special Application Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	72
	Protective Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	72
	Multi-motor Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	73
	SMC Flex Controller as a Bypass to an AC Drive . . . . . . . . . . . . . . . .	73
	SMC Flex Controller with a Bulletin 1410 Motor Winding Heater . 74

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Table of Contents

	Dual-voltage Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 75
	Low-voltage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 76
	High-voltage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	77
	Chapter 4
Programming	Keypad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	79
	Programming Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	79
	Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
	Parameter Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
	Random Access Memory (RAM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
	Read-only Memory (ROM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
	Parameter Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
	Soft Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	86
	Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	86
	Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	86
	Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
	Linear Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
	Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
	Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
	Motor Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
	Chapter 5
Metering	Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
	View Metering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
	Chapter 6
Optional HIM Operation	Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
	Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
	Chapter 7
Communication	Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
	Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
	Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
	Keypad Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	96
	Connect the Human Interface Module to the Controller . . . . . . . . .	97
	Control Enable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	98
	HIM and COMM Card Control Enable . . . . . . . . . . . . . . . . . . . . . . . . .	98
	Loss of Communication and Network Faults. . . . . . . . . . . . . . . . . . . . . . .	99
	SMC Flex Controller-specific Information . . . . . . . . . . . . . . . . . . . . . . . . .	99
	Default Input/Output Configuration . . . . . . . . . . . . . . . . . . . . . . . . .	100
	Variable Input/Output Configuration . . . . . . . . . . . . . . . . . . . . . . . .	100
	Bit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
	Reference/Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	102
	Parameter Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	102
	Scale Factors for PLC Communication . . . . . . . . . . . . . . . . . . . . . . . .	102
	Display Text Unit Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	103
	Configuring DataLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	103
	Criteria for Using DataLink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	103

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Table of Contents

	Updating Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	104
	Chapter 8
Diagnostic Capabilities	Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
	Protection Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
	Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
	Clear Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
	Fault Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	108
	Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	108
	Fault and Alarm Auxiliary Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109
	Fault Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109
	Chapter 9
Troubleshooting	Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 111
	Power Module Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115
	Shorted SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115
	Appendix A
Renewal Parts	Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	117
	Appendix B
Renewal Parts Cross Reference	Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	119
	Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	123

6	Rockwell Automation Publication 150-UM008I-EN-P - October 2020

Preface

About This Publication

Terminology

View Parameters

This user manual provides you with the information that is required to program and operate your SMC™ Flex soft starter.

The SMC Flex controller is modular so that it can help simplify installation and commissioning. A built-in LCD display, keypad, and flexible communications provide optimized configuration, advanced performance, diagnostics, and protection. Three-phase control, electronic overload, and integrated bypass along with removable control module, power modules, and fan assembly are combined in a cost-effective package for your demanding applications.

The user manual assumes that the installer is a qualified person with previous experience and basic understanding of electrical terminology, configuration procedures, required equipment, and safety precautions.

For safety of maintenance personnel and others who might be exposed to electrical hazards associated with maintenance activities, follow all local safety-related work practices (such as NFPA 70E, Part II in the United States). Maintenance personnel must be trained in the safety practices, procedures, and requirements that pertain to their respective job assignments.

Throughout this publication, we also refer to the SMC Flex soft starter as the SMC Flex controller. These terms are interchangeable.

Parameter definitions are listed in Excel® spreadsheets in KnowledgeBase. The spreadsheets let you filter and sort parameters, and add your own setting values and notes. Table 1 summarizes the information that is in the spreadsheet.

Knowledgebase Answer ID 1125564, SMC Flex Soft Starter Parameters, contains the parameters. Download the spreadsheet from this public article.

You may be asked to log in to your Rockwell Automation web account or create an account if you do not have one. You do not need a support contract to access the article.

Table 1 - SMC Flex Parameter Categories

	Parameter Group	Description
	Full Parameter List	Full list of all SMC Flex Controller Parameters
	Logic Mask Requirements	Lists the Logic Mask Codes and Binary equivalents
	Parameter Special Behavior	Describes codes that can appear under specific conditions and parameter
		configurations

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Preface

Summary of Changes

This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect all changes. Translated versions are not always available for each revision.

	Topic	Page
	Reformatted pages	Throughout
	Added information about conducted emissions compliance for EMC directive	35
	Added parameter list for control module	parameter
		spreadsheet
	Added enumerated binary bit pattern for the Logic Mask parameter	99

Removed Parameter List appendix. This information is contained in the spreadsheet that is attached to this document.

Removed specifications and accessory appendices. This information is contained in the technical data, publication 150-TD009.

8	Rockwell Automation Publication 150-UM008I-EN-P - October 2020

Chapter 1

Product Overview

Description

Operation

The SMC™ Flex controller is modular so that it can help simplify installation and commissioning. A built-in LCD display, keypad, and flexible communications provide optimized configuration, advanced performance, diagnostics, and protection. SMC Flex controllers combine three-phase control, electronic overload, and integrated bypass along with removable control module, power modules, and fan assembly in a cost-effective package for your demanding applications.

•Modular for simplified installation and maintenance

•Built-in LCD and keypad or personal computer software setup

•Integrated bypass

•Nine start/stop modes and three slow-speed modes

•Full metering and diagnostics

Modes of operation include the following:

•	Soft start	•	Full-voltage Start
•	Current Limit Start	•	Dual Ramp Start
•	Selectable Kickstart	•	Pump Start
•	Coast-to-rest	•	Preset Slow Speed
•	Soft stop	•	Pump Stop
• Smart Motor Braking (SMB™)		•	Accu-Stop™
• Slow Speed with Braking		•	Linear Speed Acceleration
			(Tachometer required)

IMPORTANT The three controller options are Standard Control, Pump Control, and Brake Control. Some modes of operation are only available on certain controllers, such as Smart Motor Braking on Brake Control. Consider the available modes of operation for a controller when configuring a catalog number to order. You can upgrade an existing controller to another control option by replacing the control module. Consult your local Rockwell Automation sales office or Allen-Bradley distributor.

The SMC Flex controller can operate standard squirrel-cage induction motors rated 1…1250 A or Star-delta (wye-delta) type motors rated 1.8…1600 A up to 690V AC, 50/60 Hz. Depending upon the controller type ordered, the control power input can range from 100…240V AC or 24V AC/DC. Verify voltage on the product before you apply power.

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Starting Modes

The SMC Flex Smart Motor Controller provides the following starting modes of operation as standard:

	Starting Modes
Soft Start		Pump Control Mode
Linear Speed Acceleration		Dual Ramp Start
Current Limit Start		Full-voltage Start
Selectable Kickstart		Preset Slow Speed

Soft Start

Soft Start limits the current throughout the soft start, and covers the largest number of general applications. The motor is given an initial torque setting. From the initial torque level, the output voltage to the motor is steplessly increased (ramped) during the acceleration ramp time. Initial torque setting and acceleration ramp time are user adjustable.

A motor’s torque curve is not a linear function and depends on both applied voltage and current. If the soft starter ramped voltage that is applied to the motor is sufficient for it to develop enough torque to overcome the inertia of the load, the motor could quickly accelerate to full speed in less than the configured ramp time when using the Soft Start mode.

Figure 1 - Soft Start Timing Diagram

100%
<![if ! IE]> <![endif]>% Voltage
Initial	Ramp Time
Torque
	Start	Run
		Time (seconds)

Linear Speed Acceleration

With this type of starting mode, the motor acceleration is at a constant rate. The controller accelerates the motor in a linear fashion from the off (0 speed) condition to full speed condition in the time configured in the user-defined ramp time (0…30 seconds). Kickstart is available with this option.

A tachometer input (0…5V DC) is required to perform this start mode.

Linear Speed Acceleration presents the least amount of stress on mechanical components. An initial torque value is configured to define a motor starting value.

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Chapter 1 Product Overview

Figure 2 - Linear Speed Acceleration Timing Diagram

100%
Linear Acceleration		Linear Deceleration
<![if ! IE]> <![endif]>% Speed
Ramp Time		Stop Time
Start	Run	Stop

Time (seconds)

Current Limit Start

Current Limit Start provides a current limit-controlled start by maintaining a constant current to the motor. Use this method when it is necessary to limit the maximum starting current. You can adjust the starting current and current limit starting ramp time.

Figure 3 - Current Limit Start Timing Diagram

600%

Current Limit

<![if ! IE]>

<![endif]>% Full Load Current

50%

Start

Time (seconds)

Selectable Kickstart

The kickstart feature provides a boost at startup to break away loads that can require a pulse of current/torque to get started. It is intended to provide a current/voltage pulse for a short time. Kickstart is available in Soft Start, Current Limit, Linear Speed Acceleration, and Pump Control modes.

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Figure 4 - Selectable Kickstart Timing Diagram

100%	Kickstart
	Level
			Coast-to-Rest
<![if ! IE]> <![endif]>% Voltage			Soft stop
	Kickstart
Initial	Time
Torque
	Start	Run	Soft stop
		Time (seconds)

Pump Control Mode

Use Pump Control Mode to reduce surges in a fluid piping system and the resulting fluid hammer or check valve slam that is caused by starting or stopping a centrifugal pump at full voltage and full speed. This mode increases pump life by reducing pump cavitations. To provide these benefits, the microprocessor of the SMC Flex controller generates a motor start curve that follows the starting characteristics of a centrifugal pump and monitors operation during start to deliver reliable pump starts.

Figure 5 - Pump Control Mode Timing Diagram

100%

<![if ! IE]>

<![endif]>Motor Speed

Pump Start				Run				Pump Stop
Ramp Time			Time (seconds)					Stop Time

Dual Ramp Start

Dual Ramp Start is useful on applications with variable loads, starting torque, and start time requirements. Dual Ramp Start gives you the ability to select between two separate start profiles via any programmable auxiliary input. Each start profile can use any of the available starting modes.

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Figure 6 - Dual Ramp Start Timing Diagram

		Current Limit 2
		Current Limit 1
	100%	Ramp Time 2
<![if ! IE]> <![endif]>% Voltage	Initial
	Torque 2
		Ramp Time 1
	Initial
	Torque 1
		Start 1	Run 1
		Start 2	Run 2

Time (seconds)

Full-voltage Start

Full-voltage Start is used in applications that require across-the-line starting. The SMC Flex controller performs like a solid-state across-the-line contactor. Full inrush current and locked-rotor torque are realized. You can program the SMC Flex controller to provide a full-voltage start in which the output voltage to the motor reaches full voltage in 250 ms.

Figure 7 - Full-voltage Start Timing Diagram

100%

<![if ! IE]>

<![endif]>% Voltage

Time (seconds)

Preset Slow Speed

Use Preset Slow Speed on applications that require slow speed moves for positioning material. You can set the Preset Slow Speed at either 7% (low) or 15% (high) in the forward direction. You can program reverse speed and 10% (low) or 20% (high) of the base speed setting. No reversing contacts are required. To help achieve more-accurate stops, braking is also a part of this function. You can program two independent preset slow speed parameters for both speed and direction.

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Stopping Modes

Figure 8 - Preset Slow Speed Timing Diagram

100%
<![if ! IE]> <![endif]>Motor Speed
Forward
15% - High
7% - Low
10% - Low	Start	Run
20% - High
Reverse	Time (seconds)

The SMC Flex Smart Motor Controller provides the following Stopping Modes of operation as standard:

	Stopping Modes
Coast		Linear Speed Deceleration
Soft stop		Pump Stop

Coast

Configure the stop mode to Coast sets the controller to perform a motor coast- to-stop maneuver.

Figure 9 - Coast-to-stop Timing Diagram

100%		Coast-to-Rest
<![if ! IE]> <![endif]>Voltage
		Stop Time
<![if ! IE]> <![endif]>%

Run						Soft stop

Time (seconds)

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Soft Stop(a)

The soft stop mode can be used in applications that require an extended stop time. You can adjust the voltage ramp down time from 0...120 seconds. The load stops when the programmed stop time has elapsed or the voltage ramp drops to a point where the load torque is greater than the motor torque.

Figure 10 - Soft Stop Timing Diagram

100%

<![if ! IE]>

<![endif]>% Voltage

Stop Time

Run				Soft stop

Time (seconds)

Linear Speed Deceleration(a)

Configuring the motor stop mode to Linear Speed Deceleration mode commands the motor to stop from full speed to zero speed following a linear ramp based on the user-configured stop time. This stopping mode requires a tachometer input (0…5V DC).

You do not need to set up Linear Stop even if you have programmed a linear start. The Linear Stop cannot brake the motor/load and reduce the stopping time.

Figure 11 - Linear Speed Deceleration Timing Diagram

100%
Linear Acceleration		Linear Deceleration
<![if ! IE]> <![endif]>% Speed
Ramp Time		Stop Time
Start	Run	Stop
	Time (seconds)

(a) Not intended to be used as an emergency stop. Consult the applicable standards for emergency stop requirements.

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Pump Stop(a)

Just as starting a centrifugal pump at full voltage causes fluid hammer and check valve slam, stopping a centrifugal pump that is running at full speed can also produce the same results. The Pump Stop mode of the SMC Flex generates a motor stop curve, which follows the stop characteristics of a centrifugal pump. The motor stop curve results in the gradual decrease in motor speed.

IMPORTANT Pump stopping can cause motor heating, depending on the mechanical dynamics of the pumping system. Select the lowest stopping time setting that satisfactorily stops the pump.

Figure 12 - Pump Stop Timing Diagram

100%

<![if ! IE]>

<![endif]>Motor Speed

Pump Start				Run				Pump Stop
Ramp Time			Time (seconds)					Stop Time

Braking Control Modes(a)	The SMC Flex Smart Motor Controller provides the following braking control
	modes of operation as standard:
		Braking Control Modes
	SMB—Smart Motor Braking	Accu-Stop	Slow Speed with Braking

Smart Motor Braking (SMB)(a)

SMB provides motor braking for applications that require the motor to stop faster than a coast-to-rest. Braking control with automatic zero speed shutoff is fully integrated into the design of the SMC Flex controller. This design facilitates a clean, straight-forward installation and eliminates the requirement for additional hardware (for example, braking contactors, resistors, timers, and speed sensors). The micro-processor based braking system applies braking current to a standard squirrel-cage induction motor. The strength of the braking current is programmable from 0…400% of full-load current.

(a) Not intended to be used as an emergency stop. Consult the applicable standards for emergency stop requirements.

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Figure 13 - SMB Timing Diagram

100%			Smart Motor Braking
			Coast-to-Rest
<![if ! IE]> <![endif]>Motor Speed
		Stop Time
Start	Run	Brake	Automatic Zero-
	Time (seconds)		speed Shutoff

Slow Speed with Braking(a)

Slow Speed with Braking is used on applications that require slow speed (in the forward or reverse direction) for positioning or alignment and also require braking control to stop. Preset Slow Speed provides either 7% of base speed (low) or 15% of base speed (high) settings in the forward direction. Braking current is adjustable from 0…400%.

Figure 14 - Slow Speed with Braking Timing Diagram

100%
			Braking
<![if ! IE]> <![endif]>Motor Speed			Coast-to-Rest
7 or 15%
Slow	Start	Run	Stop
Speed

Time (seconds)

Accu-Stop(a)

Use Accu-Stop in applications that require controlled position stopping. During stopping, braking torque is applied to the motor until it reaches the configured preset slow speed value (7% or 15%) and holds the motor at this speed until a stop command is given. Braking torque is then applied until the motor reaches zero speed. Braking current is programmable from 0…400% of full-load current.

(a) Not intended to be used as an emergency stop. Consult the applicable standards for emergency stop requirements.

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Figure 15 - Accu-Stop Timing Diagram

	100%
	<![if ! IE]> <![endif]>Speed			Braking
					Slow Speed
	<![if ! IE]> <![endif]>Motor
					Coast-to-Rest
	7% or 15%			7% or 15%
	Slow	Start	Run	Brake	Slow Speed
					Braking
	Speed

Time (seconds)

Protection and Diagnostics This section describes the protection and diagnostic features that the SMC Flex controller provides.

Overload

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

Parameter No.	Parameter	Range
44	Overload Class	Off, 10, 15, 20, 30
47	Overload Reset	Manual – Auto
46	Motor FLC	1.0…2200 A
45	Service Factor	0.01…1.99

The trip rating is 117% of the programmed FLC. Figure 16 and Figure 17 provide the overload trip curves for the available trip classes.

Underload(a)

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

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

(a) Underload protection is disabled during slow speed and braking operations.

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Figure 16 - Overload Trip Curves

Class 10

Class 15

Class 20

Class 30

1000.0

100.0

<![if ! IE]>

<![endif]>[s]Time

Trip 10.0 Approx.

1.0

0.1

100000

1000

							<![if ! IE]> <![endif]>Trip Time[s]	100
							<![if ! IE]> <![endif]>Approx.	10
								1
1	2	3	4	5	6	7 8 910		1		2	3	4	5	6	7 8 910

<![if ! IE]>

<![endif]>Approx. Trip Time [s]

100000

1000

100

10

1

100000

1000

							<![if ! IE]> <![endif]>Trip Time[s]	100
							<![if ! IE]> <![endif]>Approx.	10
								1
1	2	3	4	5	6	7 8 910		1		2	3	4	5	6	7 8 910

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

Graph Line

Description

Approximate trip time for 3-phase balanced condition from COLD start

Approximate trip time for 3-phase balanced condition from HOT start

Figure 17 - Restart Trip Curves after Auto Reset

100000

1000

Seconds	100					Graph Line		Trip Class	Auto Reset Time [s]
								10	90
								15	135
	10							20	180
	1							30	270
	0
	100%		1000%

Percent Full Load Current Setting

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Undervoltage(a)

You can halt motor operation if a sudden drop in voltage is detected by utilizing the undervoltage protection of the SMC Flex controller.

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

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

Overvoltage(a)

You can halt motor operation if a sudden increase in voltage is detected by utilizing the overvoltage protection of the SMC Flex controller.

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

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

Unbalance(a)

The SMC Flex controller can detect an unbalance in line voltages. You can halt motor operation if the unbalance is greater than the desired range.

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

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

(a) Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.

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Stall Protection and Jam Detection

Motors can experience locked-rotor currents and develop high torque levels if a stall or a jam occurs. These conditions can result in breakdown of the winding insulation or mechanical damage to the connected load. The

SMC Flex controller provides both stall protection and jam detection for enhanced motor and system protection. A jam level (as a percent of motor FLC) is configurable for both an alarm and motor shutdown (fault). In addition, both stall and jam conditions let you set a delay time before initiating an alarm (jam only) or motor shutdown (fault).

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

Figure 18 - Stall Protection

600%

<![if ! IE]>

<![endif]>% FLC

					Stall
	Programmed Start Time

Time [s]

Jam detection lets you determine the jam level (up to 1000% of the motor’s FLC rating) and the delay time (up to 99.0 seconds) for application flexibility.

Figure 19 - Jam Detection(a) (b)

User-defined Trip Level

<![if ! IE]>

<![endif]>% FLC

100%

Running					Jam

Time [s]

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

(a)Jam detection is disabled during slow speed and braking operation.

(b)Unit self-protects in a jam condition.

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Ground Fault

ATTENTION: The ground fault sensing feature of the SMC Flex controller is intended for monitoring purposes only. It is not intended as a ground fault circuit interrupter for personnel protection as defined in Article 100 of the National Electrical Code (NEC) and has not been evaluated to UL 1053.

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

The ground fault detection capabilities of the SMC Flex controller require the use of an external sensor. The external sensor lets you enable Ground Fault Trip, Ground Fault Alarm, or both.

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

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

•Manufacturer: Flex-Core

•Description: 600V Rated Current Transformer

•Catalog Number: 126-252

•CT Ratio:2500:5

Figure 20 - Core Balance Current Transformer

Branch Protection (1)
						L1/1		T1/2
			(1)								Motor (1)
3-Phase Input Power			(2)			L2/3		T2/4
						L3/5		T3/6
			Black			SMC Flex Controller
			White
			Shield

11	12	13	14				15	16	17	18	19	20	21	22

Shield

SMC Flex Control Terminals

23

24

25

26

27

28

29

30

31

32

33

34

		Black
(1) Customer supplied.		White
(2) Cat. No. 825-CBCT or Flex-Core Cat. No. 126-252

When you connect the ground fault sensors, the secondary of the CT should be shorted until you complete the connection to the SMC Flex control module.

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Ground Fault Trip

The SMC Flex controller trips with a ground fault (GF) indication if:

•No other fault currently exists

•Ground fault protection is enabled

•GF Inhibit Time (Parameter 75) has expired

•GF Current is equal to or greater than the GF Trip Level (Parameter 73) for a time period greater than the GF Trip Delay (Parameter 74)

Table 2 - Ground Fault Trip Parameters

	Parameter No.	Parameter Name	Description	Adjustment
				Range
	73	Gnd Flt Level	Defines the ground fault current at which the SMC	1.0…5.0 A or
			Flex controller trips	5.0…25 A
	74	Gnd Flt Delay	Defines the time period a ground fault condition	0.1…250 s
			must be present before a trip occurs
	75	Gnd Flt Inh Time	Inhibits a ground fault trip from occurring during	0…250 s
			the motor starting sequence

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

Ground Fault Alarm

The SMC Flex controller indicates a Ground Fault Alarm if:

•No warning currently exists

•Ground fault alarm is enabled

•GF Inhibit Time (Parameter 75) has expired

•GF Current is equal to or greater than the Gnd Flt A Lvl (Parameter 77)

Table 3 - Ground Fault Alarm Parameters

	Parameter No.	Parameter Name	Description	Adjustment Range
	77	Gnd Flt A Lvl	Defines the ground fault current at which the SMC	1.0…5.0 A or
			Flex controller indicates a warning	5.0…25 A
	78	Gnd Flt A Dly	Defines the time period a ground fault alarm	0…250 s
			condition must be present before a trip occurs

Thermistor/PTC Protection

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

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Table 4 defines the SMC Flex PTC thermistor input and response ratings:

Table 4 - PTC Input Ratings

Description	Value
Response resistance	3400 Ω ± 150 Ω
Reset resistance	1600 Ω ± 100 Ω
Short-circuit Trip Resistance	25 Ω ± 10 Ω
Maximum Voltage at PTC Terminals (RPTC = 4 kW)	<7.5V
Maximum Voltage at PTC Terminals (RPTC = open)	30V
Maximum Number of Sensors	6
Maximum Cold Resistance of PTC Sensor Chain	1500 Ω
Response Time	800 ms

Figure 21 illustrates the required PTC sensor characteristics that are specified in IEC-34-11-2.

Figure 21 - PTC Sensor Characteristics per IEC-34-11-2

4000
1330
550
250
100
20
10	TNF -20K	TNF +20K
-20 °C 0 °C
	TNF -5K	TNF +5K

TNF

PTC Trip

The SMC Flex controller trips with a PTC indication if:

•No other fault currently exists

•PTC protection is enabled

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

Excessive Starts/Hour

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

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Overtemperature

The SMC Flex controller uses the value in Parameter 119 to monitor the temperature of the SCRs and Bypass by using internal thermistors. When the maximum rated temperature of the power poles is reached, the unit shuts down and restart is inhibited.

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

Open Gate

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

Line Faults

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

•Line Fault (with phase indication)

-Line voltage loss

-Missing load connection

-Shorted SCR

Running protection includes:

•Line Fault (no phase indication)

-Line voltage loss

-Missing load connection

You can toggle Phase Reversal protection either On or Off. Phase Reversal protection is functional only at pre-start.

Metering

Power monitoring parameters include:

•Three-phase current (Parameters 4, 5, and 6)

•Three-phase voltage (Parameters 1, 2, and 3)

•Power in kW (Parameter 7)

•Power usage in kWH (Parameter 8)

•Power factor (Parameter 11)

•Motor thermal capacity usage (Parameter 12)

•Elapsed time (Parameter 9)

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Voltage measurement is not available during the braking operation of the Smart Motor Braking, Accu-Stop, and Slow Speed with Braking control options.

The elapsed time and kWH values are automatically saved to memory on power down.

Motor thermal capacity usage is determined by the built-in electronic thermal overload. An overload fault occurs when this value reaches 100%.

I/O

The SMC Flex controller can accept up to two inputs and four outputs that are controlled over a network. The two inputs are controlled at terminal 16 (Option Input #1, Parameter 132), and terminal 15 (Option Input #2, Parameter 29). For these two inputs, see Table 26 for the parameter settings and Table 39 and Table 40 for the bit identification.

You can program the Stop Input to meet the desired stop functionality by using these two terminals as inputs.

The four outputs are Aux #1 (Parameter 107), Aux #2 (Parameter 110), Aux #3 (Parameter 108), and Aux #4 (Parameter 109). All auxiliary contacts are programmable to the function found in Table 26. If the outputs are programmed to Network or Network NC, they can be controlled over a Network. See Table 40, which defines the Logic Command Word (Control).

Communication

A serial interface port (DPI) is provided as standard, which lets you connect the SMC Flex controller connection to the Bulletin 20-HIM LCD interface modules.

Figure 22 - DPI Location

DPI

You can connect two peripheral devices to the DPI. The maximum output current through the DPI is 280 mA.

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Programming

Status Indication

Chapter 1 Product Overview

Setup is easy with the built-in keypad and three-line, 16 character backlit LCD. Parameters are organized in a three-level menu structure that uses a text format for straightforward programming.

Figure 23 - Built-in Keypad and LCD

Port 5 — DPI

Communications

Port 2

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

•Four programmable hard contact outputs are provided as standard. All auxiliary contacts are programmable for the following states:

•Normal (selectable N.O./N.C.)

•Up-to-Speed (selectable N.O./N.C.)

•Alarm (selectable N.O./N.C.)

•Fault (selectable N.O./N.C.)

•Network Control (selectable N.O./N.C.)

•External Bypass (N.O. only)

Figure 24 - Control Terminals

	Option Input #2	Option Input #1

		Start	Stop
			Aux #1
PTC	TACH	Ground Aux #2 Aux #3 Aux #4
		Fault

Network inputs can be obtained via proper programming of Option Input #1 (Parameter 132) and Option Input #2 (Parameter 24).

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Chapter 1 Product Overview

Notes:

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Chapter 2

Installation

Receive the Controller

Unpack the Controller

Inspect the Controller

Storage

Lifting

This chapter explains how to receive, unpack, and set up the SMC™ Flex controller.

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

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

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

Keep the controller in its shipping container prior to installation. If the equipment is not to be used for an extended period, you must store it according to the following instructions in order to maintain warranty coverage.

•Store in a clean, dry location.

•Maintain an ambient temperature range of –20… +75 °C (–4…+167 °F).

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

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

•Do not store equipment in a construction area.

For controllers rated 625…1250 A, the device should only be lifted from designated lifting points. The lifting points are designed to accept a 1/2…13 threaded hoist ring capable of lifting 2500 pounds. Figure 26 shows the lifting points.

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Chapter 2

Installation

Figure 25 - Lifting Caution Label

Figure 26 - Lifting Points

Lifting Points

General Precautions

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

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

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

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

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