Rockwell Automation SMC Flex Soft Starters User Manual

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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

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

Braking Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Smart Motor Braking (SMB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Slow Speed with Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Accu-Stop

Protection and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Undervoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Overvoltage Unbalance

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

(a)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

(a)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

(a)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

(a)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 3

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

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

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

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 5

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

Ter mi no logy

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.

View Parameters

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

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 7

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.

Top ic Page

Reformatted pages Throughout Added information about conducted emissions compliance for EMC directive 35

Added parameter list for control module

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

parameter

spreadsheet

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

Product Overview

Chapter 1

Description

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)

Operation

IMPORTANT

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.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 9

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.

Chapter 1 Product Overview

Time (seconds)

Ramp Time

Start

Run

% Voltage

Initial Tor que

100%

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

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

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

value.

Chapter 1 Product Overview

% Speed

Ramp Time

100%

Time (seconds)

Start Run

Stop

Stop Time

Linear Acceleration Linear Deceleration

% Full Load Current

50%

600%

Current Limit

Time (seconds)

Start

Figure 2 - Linear Speed Acceleration Timing Diagram

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

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.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 11

Chapter 1 Product Overview

% Voltage

Initial Tor que

100%

Kickstart Time

Time (seconds)

Start

Run

Kickstart Level

Soft stop

Coast-to-Rest

100%

Time (seconds)

Run

Motor Speed

Pump Start Ramp Time

Pump Stop Stop Time

Figure 4 - Selectable Kickstart Timing Diagram

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

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.

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

Chapter 1 Product Overview

% Voltage

Time (seconds)

Current Limit 2

Current Limit 1

100%

Initial Torque 2

Initial Torque 1

Ramp Time 2

Ramp Time 1

Start 1

Run 1

Start 2

Run 2

100%

Time (seconds)

% Voltage

Figure 6 - Dual Ramp Start Timing Diagram

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

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.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 13

Chapter 1 Product Overview

Motor Speed

100%

15% - High

Time (seconds)

Start

Run

Forward

Reverse

7% - Low

20% - High

10% - Low

% Voltage

100%

Time (seconds)

Stop Time

Run Soft stop

Coast-to-Rest

Figure 8 - Preset Slow Speed Timing Diagram

Stopping Modes

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 coastto-stop maneuver.

Figure 9 - Coast-to-stop Timing Diagram

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

Chapter 1 Product Overview

% Voltage

100%

Time (seconds)

Stop Time

Run

Soft stop

% Speed

Ramp Time

100%

Time (seconds)

Start Run

Stop

Stop Time

Linear Acceleration Linear Deceleration

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

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

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

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 15

Chapter 1 Product Overview

100%

Time (seconds)

Run

Motor Speed

Pump Start Ramp Time

Pump Stop Stop Time

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

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.

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

Figure 13 - SMB Timing Diagram

Motor Speed

Automatic Zerospeed Shutoff

100%

Time (seconds)

Start

Run Brake

Smart Motor Braking

Coast-to-Rest

Stop Time

Motor Speed

100%

Time (seconds)

Slow Speed

Run

7 or 15%

Braking

Coast-to-Rest

StopStart

Chapter 1 Product Overview

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

Accu-Stop

(a)

Use Accu-Stop in applications that require controlled position stopping.

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

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 17

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.

Chapter 1 Product Overview

Motor Speed

100%

Time (seconds)

Slow Speed

Run

7% or 15%

Braking

Coast-to-Rest

BrakeStart

Slow Speed

Slow Speed Braking

7% or 15%

Figure 15 - Accu-Stop Timing Diagram

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 the overload trip curves for the available trip classes.

and Figure 17 provide

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.

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

Figure 16 - Overload Trip Curves

100

1000

100000

4 5 6 7 832 9

100

1000

100000

4 5 6 7 832 9

100

1000

100000

4 5 6 7 832 9

0.1

1.0

10.0

100.0

1000.0

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

Approx. Trip Time [s]

Multiples of FLC

Class 10 Class 15 Class 20 Class 30

Multiples of FLC Multiples of FLC Multiples of FLC

Approx. Trip Time [s]

Graph Line Trip Class Auto Reset Time [s]

10 90

15 135 20 180 30 270

Seconds

Percent Full Load Current Setting

Chapter 1 Product Overview

Figure 17 - Restart Trip Curves after Auto Reset

100000

1000

100

1000%100% 1000%100%

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 19

Chapter 1 Product Overview

Undervoltage

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

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.

(a)

Unbalance

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)

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

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

Chapter 1 Product Overview

600%

% FLC

Time [s]

Programmed Start Time

Stall

% FLC

Time [s]

Running

Jam

User-defined Trip Level

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

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

100%

(a) (b)

(a) Jam detection is disabled during slow speed and braking operation. (b) Unit self-protects in a jam condition.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 21

Chapter 1 Product Overview

Branch Protection

(1)

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

Motor

(1)

SMC Flex Controller

SMC Flex Control Terminals

3-Phase Input Power

Shield

Black

White

Black White Shield

(1) (2)

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 34

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

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

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.

Chapter 1 Product Overview

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

73 Gnd Flt Level

74 Gnd Flt Delay

75 Gnd Flt Inh Time

IMPORTANT

The ground fault inhibit timer starts after the maximum phase of load

Defines the ground fault current at which the SMC

Flex controller trips

Defines the time period a ground fault condition

must be present before a trip occurs

Inhibits a ground fault trip from occurring during

the motor starting sequence

Adjustment

Range

1.0…5.0 A or

5.0…25 A

0.1…250 s

0…250 s

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

78 Gnd Flt A Dly

Defines the ground fault current at which the SMC Flex controller indicates a warning

Defines the time period a ground fault alarm condition must be present before a trip occurs

1.0…5.0 A or

5.0…25 A

0…250 s

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.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 23

Chapter 1 Product Overview

1330

550

250

100

-20 °C 0 °C

TNF -20K

TNF -5K

TNF

TNF +20K

TNF +5K

4000

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

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.

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

Chapter 1 Product Overview

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)

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 25

Chapter 1 Product Overview

DPI

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

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.

for the parameter settings and Table 39 and

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

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

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

Chapter 1 Product Overview

Port 5 — DPI Communications

Port 2

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

Aux #1

Aux #2 Aux #3

Aux #4

PTC

TACH

Ground Fault

Stop

Start

Option Input #1

Option Input #2

Programming

Status Indication

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

• 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

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

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 27

Chapter 1 Product Overview

Notes:

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

Chapter 2

Installation

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

Receive the Controller

Unpack the Controller

Inspect the Controller

Storage

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.

Lifting

• 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 points.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 29

shows the lifting

Chapter 2 Installation

Lifting Points

Figure 25 - Lifting Caution Label

Figure 26 - 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.

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

Chapter 2 Installation

ATTENTION: Hazardous voltages that can cause shock, burn, or death are

present on L1, L2, L3, T1, T2, T3, T4, T5, and T6. ATTENTION: Power terminal covers can be installed to prevent inadvertent contact with terminals. Disconnect the main power before servicing the motor controller or associated wiring.

Degree of Protection

Heat Dissipation

Enclosures

The SMC Flex soft starters have an IP00 or IP2X protection rating, depending on the size. You must install the device in IP54 (Type 2) switchgear cabinets, taking into account the ambient conditions. Make sure that no dust, liquids, or conductive parts can enter the soft starter. Soft starter operation produces waste heat (heat loss). See Table 5 Smart Motor Controllers Technical Data, publication 150-TD009

or the SMC-3™, SMC Flex, and SMC-50™

Table 5 provides the maximum heat dissipation at rated current for the

controllers. Heat dissipation is reduced for currents that are lower than rated value.

Table 5 - Maximum Heat Dissipation

SMC Rating [A] 5 25 43 60 85 108 135 201 251 317 361 480 625 700 970 1250 Max. Watts 70 70 81 97 129 91 104 180 198 225 245 290 446 590 812 1222

The open-style design of the SMC Flex controller requires that it be installed in an enclosure. The internal temperature of the enclosure must be kept within

the range of 0…50°C.

For Type 12 (IP54) enclosures, the guidelines that are shown in Table 6

are

recommended to limit the maximum controller ambient temperature.

There should be a clearance of at least 15 cm (6 in.) above and below the controller. This area allows air to flow through the heatsink.

Table 6 - Minimum Enclosure Size

Controller Rating [A]

5 610 (24) 406 (16) 254 (10) 25 610 (24) 406 (16) 254 (10) 43 610 (24) 406 (16) 254 (10) 60 610 (24) 406 (16) 254 (10) 85 610 (24) 406 (16) 254 (10)

108 762 (30) 610 (24) 305 (12) 135 762 (30) 610 (24) 305 (12) 201 965 (38) 762 (30) 356 (14) 251 965 (38) 762 (30) 356 (14) 317 1295 (51) 914 (36) 356 (14) 361 1295 (51) 914 (36) 356 (14)

480 1295 (51) 914 (36) 356 (14)

625…780 2286 (90) 762 (30) 508 (20)

970…1250

(2)

B Height A Width C Depth

Non-Combination Controller [mm (in.)]

2286 (90) 762 (30) 508 (20)

IP65 (Type 4/12)

(1)

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 31

Chapter 2 Installation

Table 6 - Minimum Enclosure Size (Continued)

Controller Rating [A]

5 610 (24) 406 (16) 254 (10) 25 610 (24) 406 (16) 254 (10) 43 610 (24) 406 (16) 254 (10) 60 610 (24) 406 (16) 254 (10) 85 610 (24) 406 (16) 254 (10)

108 965 (38) 762 (30) 356 (14) 135 965 (38) 762 (30) 356 (14) 201 965 (38) 762 (30) 356 (14) 251 965 (38) 762 (30) 356 (14) 317 1524 (60) 965 (38) 356 (14) 361 1524 (60) 965 (38) 356 (14)

(3)

480

(4)

480

625…780 2286 (90) 1397 (55) 508 (20)

970…1250

(1) Larger enclosure may be required based on options selected. Consult your local Rockwell Automation Sales office or

Allen-Bradley distributor.

(2) 970 and 1250 A SMC Flex controllers require a door-mounted fan that is capable of delivering 240 cfm. Appropriate inlet and

outlet filtering is required. (3) Use this row for 460V -58 and 575V -59. (4) Use this row for 460V -59 and 575V -60 and -61

(2)

5 610 (24) 406 (16) 254 (10) 25 610 (24) 406 (16) 254 (10) 43 610 (24) 406 (16) 254 (10) 60 610 (24) 406 (16) 254 (10) 85 610 (24) 406 (16) 254 (10)

108 965 (38) 762 (30) 356 (14) 135 965 (38) 762 (30) 356 (14) 201 965 (38) 762 (30) 356 (14) 251 965 (38) 762 (30) 356 (14) 317 1295 (51) 914 (36) 356 (14) 361 1295 (51) 914 (36) 356 (14)

480 1295 (51) 914 (36) 356 (14)

625…780 2286 (90) 1397 (55) 508 (20)

(2)

B Height A Width C Depth

Combination Controllers with Fusible Disconnect

1524 (60) 965 (38) 356 (14)

2286 (90) 889 (35) 508 (20)

2286 (90) 1397 (55) 508 (20)

Combination Controllers with Circuit Breaker

2286 (90) 1397 (55) 508 (20)

IP65 (Type 4/12)

(1)

Mounting

All units 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

must be mounted in a vertical plane and have a minimum of 15 cm (6 in.) free space above and below the controller.

When drilling or installing near the soft starter, make sure that adequate measures are taken to protect the device from dust and debris. SeeFigure 27

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

Figure 27 - SMC Flex Mounting Protection

3-Phase Input Power

Branch Protection (1)

Motor (1)

SMC Flex Controller (2)

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

Power Factor Correction Capacitors (1)

Chapter 2 Installation

Power Factor Correction Capacitors

The controller can be installed on a system with power factor correction capacitors (PFCCs). The capacitors must be located on the line side of the controller. This must be done to prevent damage to the SCRs in the SMC Flex controller.

When it is discharged, a capacitor essentially has zero impedance. For switching, sufficient impedance should be connected in series with the capacitor bank to limit the inrush current. One method for limiting the surge current is to add inductance in the capacitor’s conductors. This can be accomplished by creating turns or coils in the power connections to the capacitors.

• 250V — 15 cm (6 in.) diameter coil, 6 loops

• 480…690V — 15 cm (6 in.) diameter coil, 8 loops

Take care in mounting the coils so that they are not stacked directly on top of each other; stacking causes a canceling effect. Mount the coils on insulated supports away from metal parts so they will not act as induction heaters. If an isolation contactor is used, put capacitors in front of contactor.

For further instructions, consult the PFCC vendor.

Figure 28 - Typical Wiring Diagram for Power Factor Correction Capacitors

Note Number Description

1 Customer supplied.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 33

2 Overload protection is included as a standard feature of the SMC Flex controller.

Chapter 2 Installation

3-Phase Input Power

Branch Protection (1)

Motor (1)

SMC Flex Controller (2)

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

Power Factor Correction Capacitors

(1)

(3) (4)

Figure 29 - Typical Wiring Diagram for Power Factor Correction Capacitors and Contactor

Note Number Description

1 Customer supplied. 2 Overload protection is included as a standard feature of the SMC Flex controller. 3 Energize 1/2 second before start command to the SMC Flex controller.

Alternate: Energize contactor after up-to-speed.

4 Open contactor after stopping method is complete.

Alternate: Open contactor before initiating a stop

Protective Modules

Motor Overload Protection

Protective modules containing metal oxide varistors (MOVs) can be installed on controllers rated 5…1250 A and 200…600V, to protect the power components from electrical transients. The protective modules clip voltage transients generated on the lines to prevent such surges from damaging the SCRs.

ATTENTION: When installing or inspecting the protective module, make sure that the controller has been disconnected from the power source. The protective module should be inspected periodically for damage or discoloration. Replace if necessary.

Thermal motor overload protection is provided as standard with the SMC Flex controller. If the overload trip class is less than the acceleration time of the motor, nuisance tripping may occur.

ATTENTION: Overload protection should be properly coordinated with the motor.

Two applications require special consideration: two-speed motors, and multimotor protection.

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

Two-speed Motors

The SMC Flex controller has overload protection available for single speed motors. When the SMC Flex controller is applied to a two-speed motor, the Overload Class parameter must be programmed to OFF and separate overload relays must be provided for each speed.

Chapter 2 Installation

Multi-motor Protection

If the SMC Flex controller is controlling more than one motor, individual overload protection is required for each motor.

Electromagnetic Compatibility (EMC)

The following guidelines are provided for EMC installation compliance.

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

Enclosure

Install the product in a grounded metal enclosure.

Wiring

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

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

• Minimum spacing between different wire groups in the same tray should be 16 cm (6 in.).

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

• Different wire groups should be run in separate conduits.

• Minimum spacing between conduits containing different wire groups should be 8 cm (3 in.).

• For additional guidelines, please refer to Wiring and Grounding guidelines, publication DRIVES-IN001

Additional Requirements

• If linear acceleration is used, a separate conduit or wire way should be used for the tachometer leads.

• Wire earth ground to control terminal 14.

• Use shielded wire for PTC, Tachometer, and ground fault input.

• Terminate shielded wires to terminal 14.

• Ground fault CT must be inside or within 3 m of metal enclosure.

To meet product susceptibility requirements, ferrite cores need to be added to the communication lines. When using an external HIM (or DPI interface), a core should be added to the HIM cable near the SMC Flex control module. The recommended core is Fair-Rite no. 0431167281 or equivalent. When you are using a DeviceNet™ circuit, two cores need to be added to the DeviceNet cable near the SMC Flex control module. The recommended cores are TDK ZCAT2023 0930H and TDK ZCAT2035 0930 or equivalent. All cores specified are the split type cores and can be added to existing connections.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 35

Chapter 2 Installation

150-SMCAP

SMC Flex Controller

100…240V AC control power ≤ 135 A Rating

Fair-Rite Products 2675102002 (5 turns)

Schaffner FN2090-3-06

Line Load

New EMC Compliance – Conducted Emissions

There are new requirements for conducted emissions per IEC 60947-4-2 ≤20kVA that require additional external components for SMC Flex units with 100…240V AC control power (code “D” in catalog string for control voltage) and rated 135A and below:

• Use Schaffner part number FN2090-3-06 external power line filter for the control power. Connect to SMC Flex controller terminals 11 and 12.

• Use Fair-Rite Products part number 2675102002 external ferrite core with 5 turns for the control power earth ground. Connect to SMC Flex controller terminal 14.

• Use Rockwell Automation Cat. No. 150-SMCAP capacitor module connected to the incoming 3-phase power (terminals L1, L2, L3). Note: This is an SMC-50 controller accessory that you can use with SMC Flex units for this purpose.

Figure 30 - Cat. No. 150-SMCAP Capacitor Module Wiring Configuration

L1 L2 L3

11 12 14

P N PE

P’

N’

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

Chapter 3

(1)

(5)

(4)

(2), (3)

(3)

Wiring

This chapter illustrates basic wiring configurations for the SMC™ Flex controller.

Wiring Terminal Locations

The SMC Flex controller wiring terminal locations are shown in Figure 31 through Figure 33

. Incoming three-phase power connections are made to terminals L1/1, L2/3, and L3/5. Load connections to Line motors are made to T1/ 2, T2/4, and T3/6; load connections to Wye-Delta motors are made to T1/2, T2/4, T3/6, T4/8, T5/10, and T6/12.

Figure 31 - Wiring Terminal Locations—5…85 A Devices

Note Number Information

1 Incoming Line Termination 2 Line Motor Connections

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 37

(1)

Delta Motor Connections

4 Control Terminations 5 Fan Terminations

(1) IP20 protective covers on Delta termination must be removed when connecting in a Delta configuration.

Chapter 3 Wiring

(1)

(5)

(4)

(2), (3)

(3)

Figure 32 - Wiring Terminal Locations—108…480 A Devices

Note Number Information

1 Incoming Line Termination 2 Line Motor Connections 3 Delta Motor Connections 4 Control Terminations 5 Fan Terminations

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

Figure 33 - Wiring Terminal Locations—625…1250 A Devices

(1)

(3)

(2)

Chapter 3 Wiring

Power Structure

Note Number Information

1 Incoming Line Termination 2 Line Motor Connections 3 Terminal Block CP1 - Common Control Power Connections (Fans, Contactors, and Control Modules)

The SMC Flex controller has an integrated mechanical run contactor on each phase of the motor to minimize heat generation during run time. These contacts are pulled in sequentially in the 108…1250 A units. In the 5…85 A units, these contacts are pulled simultaneously. The SMC Flex controller also has a built-in current transformer (CT) on each phase of the motor to provide current readings.

Power Wiring

See the product nameplate or Table 7 for power lug termination information including:

• Lug wire capacity

• Tightening torque requirements

• Lug kit catalog numbers (108…1250 A devices)

ATTENTION: Failure of solid state power switching components can cause overheating due to a single-phase condition in the motor. Voltage could be present on output terminals when the SMC Flex controller has line voltage. To prevent injury or equipment damage, the following is recommended: ATTENTION: Use of an isolation contactor or shunt trip type circuit breaker on the line side of the SMC Flex controller. This device should be capable of interrupting the motor’s locked rotor current. ATTENTION: Connection of this isolation device to an auxiliary contact on the SMC Flex controller. The auxiliary contact should be programmed for the fault condition. See Chapter 4

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 39

for additional information on programming.

Chapter 3 Wiring

SMC Flex Controller

Motor

Isolation Contactor

5/L3

3/L2

1/L1

10/T5

8/T4

12/T6

6/T3

4/T2

2/T1

SMC Flex controller

Motor

Isolation Contactor

5/L3

3/L2

1/L1

10/T5

8/T4

12/T6

6/T3

4/T2

2/T1

Line Connection

The SMC Flex by default is programmed to be connected to a line controlled motor, as shown in Figure 34 rated between 1…1250 A. An optional isolation contactor can be added to the circuit to provide galvanic isolation of the motor and final electro-mechanical removal of power.

Figure 34 - Line-connected Wiring

. These motors typically have 3 leads and must be

Power Lugs

Delta Connection

You can program the SMC Flex controller and connect it to a delta-controlled motor as shown in Figure 35 must be rated between 1.8…1600 A. We recommend that you add an isolation contactor to the circuit to provide galvanic isolation of the motor and final electromechanical removal of power.

Figure 35 - Delta-connected Wiring

Devices that are rated 108…1250 A require power lugs. In some cases, these lugs are sold in kits of three lugs. Table 7 lugs that are required.

. These motors typically have 6 or 12 leads and

and Table 8 list the number and type of

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

Table 7 lists the recommended lugs for the SMC Flex controller when it is

configured as a line connection. Table 8 using the SMC Flex controller with a delta connection. Note that devices rated 625…1250 A require the use of a power distribution block when they are used with a delta connection.

ATTENTION: Terminal covers are available for units rated 108…480 A which can make the product deadfront (IP2X) safe. See the SMC-3™, SMC Flex, and SMC-50™ Smart Motor Controllers Technical Data, publication 150-TD009 the appropriate catalog numbers for ordering.

Table 7 - SMC Flex Controller Line Connection Lug Information—5…1250 A Devices

Chapter 3 Wiring

lists the recommended lugs when

for

Controller

Rating

5…85 A — 18…20 mm

108…135 A 199-LF1 18…20 mm

201…251 A 199-LF1 18…20 mm

317…480 A 199-LG1 18…25 mm

625…780 A 100-DL630 32 mm / 64 mm

970 A 100-DL860 26 mm / 48 mm

1250 A

(1) The 1250 A device requires one (1) each of Cat. No. 100-DL630 and 100-DL860.

(1)

Lug Kit Cat.

No.

100-DL630 32 mm / 64 mm 100-DL860 26 mm / 48 mm

Wire Strip Length Conductor Range

2.5…85 mm 16…120 mm 16…120 mm

25…240 mm

70…240 mm

120…240 mm

70…240 mm

120…240 mm

(#14…3/0 AWG)

(#6…250 MCM)

(#4…500 MCM)

(2/0…500 MCM)

(4/0…500 MCM)

(2/0…500 MCM)

(4/0…500 MCM)

Max. No. Lugs/Pole Tightening Torque

Line Side Load Side Wire — Lug Lug — Busbar

— — 11.3 N•m (100 lb.-in.) —

1 1 31 N•m (275 lb.-in.) 17 N•m (150 lb.-in.) 2 2 31 N•m (275 lb.-in.) 23 N•m (200 lb.-in.) 2 2 42 N•m (375 lb.-in.) 28 N•m (250 lb.-in.) 2 2 45 N•m (400 lb.-in.) 68 N•m (600 lb.-in.) 1 1 45 N•m (400 lb.-in.) 68 N•m (600 lb.-in.) 11 11

45 N•m (400 lb.-in.) 68 N•m (600 lb.-in.)

Table 8 - SMC Flex Controller Delta Connection Lug Information (for Inside-the-Delta Applications)—108…1250 A Devices

Controller Rating Lug Kit Cat. No. Conductor Range

108…135 A 1494R-N15 201…251 A 1494R-N14 317…480 A 150-LG5MC

625…780 A

970…1250 A

(1) For 625…1250 A inside-the-delta connections, terminal blocks are required for line side connections. Required terminal blocks are as follows:

- Allen-Bradley Part# 1492-BG (625…780 A: 2 per phase, 970…1250 A: 4 per phase). Short-circuit Protection = Fuses

- Cooper Bussmann Part# 16504-2 (625…780 A: 1 per phase, 970…1250 A: 2 per phase). Short-circuit Protection = Circuit breaker

(1)

— —

25…240 mm 50…120 mm

95…240 mm

25…240 mm 25…240 mm

(#4…500 MCM)

(1/0…250 MCM)

(3/0…500 MCM)

(#4…500 MCM)

Max. No. Lugs/Pole Tightening Torque

Line Side Load Side Wire — Lug Lug — Busbar

1 2 31 N•m (275 lb.-in.) 23 N•m (200 lb.-in.) 1 33.9 N•m (300 lb.-in.) 28 N•m (250 lb.-in.)

See Table 7 2 42 N•m (375 lb.-in.) — 4 42 N•m (375 lb.-in.) —

42 N•m (375 lb.-in.) 17 N•m (150 lb.-in.)

Control Power

This section explains the control power requirements for the SMC Flex controller.

Control Wiring

See the product nameplate for control terminal wire capacity and tightening torque requirements. Each control terminal can accept a maximum of two wires. See the product nameplate prior to applying control power. Depending on the specific application, additional control circuit transformer VA capacity may be required.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 41

Chapter 3 Wiring

Controllers rated 5…480 A

SMC Flex controllers that are rated 5…480 A accept control power input of 100…240V AC or 24V AC/DC, (+10/–15%) single-phase, 50/60 Hz. A control power source of 125 VA is required. The control power requirement for the control module is 75 VA. The control power requirement for the fans is 20, 40, or 60 VA. The control module and fans are separately wired. The control module requirements are shown in Table 9 as shown in Table 11

Table 9 - Control Module Requirements

120…240V AC Transformer 75 VA

24V AC Transformer 130 VA

24V DC

Inrush Current 5 A Inrush Time 250 ms Transient Watts 60 W Transient Time 500 ms Steady State Watts 24 W Minimum Allen-Bradley Power Supply 1606-XLP50E

. The fans require additional power

Controllers rated 625…1250 A

Controllers that are rated 625…1250 A require common control for proper operation. Control power is connected to the product through terminal block CP1, at terminals 1 and 4. This single connection point feeds the control module, contactors, and fans. Control power must be supplied as 110/120V AC or 230/240V AC, 50/60 Hz only. A control power source of at least 800 VA is required. The control power requirements include the control module (75 VA), bypass contactors (526 VA max), and fan power (150 VA).

Depending on the specific application, additional control circuit transformer VA capacity may be required.

Units with a control power rating of 230/240V AC have an undervoltage relay installed. Units built prior to 2014 may have potentiometers on the undervoltage relay. If potentiometers are present, you must set them according to Figure 36 potentiometers, because the settings are programmed internally to the undervoltage relay and no adjustment is required.

. Units built later than 2014 may not have

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

Chapter 3 Wiring

115%

85%

240

220

208

95%

10 sec

0.1 sec

LED

See nameplate for status

Pick-up % Nominal Voltage

Nominal Voltage

Dropout % Pick-up

Time-delay Dropout

Time-delay Pickup

10 sec

0.1 sec

Figure 36 - 230V Control Undervoltage Relay Settings for 625…1250 A Devices

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 43

Chapter 3 Wiring

Undervoltage Relay See Figure 36

SMC Flex Control Module

Contactor A Contactor B Contactor C

Fan A Fan B Fan C

CP1

Contactor/Fan Input

230V AC

Figure 37 - Internal Wiring and 230V Control Undervoltage Relay Connection Diagram— 625…1250 A Devices

6543

7812

A1 A2 A1 A2 A1 A2

13 21

14 22

FN FL

C C

13 21

14 22

FN FL

23 24 25 26 27 28 29 30 31 32 33 34 11 12 13 14 15 16 17 18 19 20 21 22

13 21

14 22

FN FL

4321

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

Chapter 3 Wiring

C C C

A1 A2 A1 A2 A1 A2

13 21

14 22

13 21

14 22

13 21

14 22

FN FL

4321

23 24 25 26 27 28 29 30 31 32 33 34 11 12 13 14 15 16 17 18 19 20 21 22

SMC Flex Control Module

Contactor A Contactor B Contactor C

Fan A Fan B

Fan C

CP1

Contactor/Fan Input

120V AC

Figure 38 - Internal Wiring and 120V Control Connection Diagram—625…1250 A Devices

Control Wire Specifications

Table 10 lists the control terminal wire capacity, the tightening torque

requirements, and the wire strip length. Each control terminal can accept a maximum of two wires.

Table 10 - Control Wiring and Tightening Torque

Wire Size Torque Wire Strip Length

0.75…2.5 mm

(#18…14 AWG)

0.6 N•m (5 lb.-in.) 5.6…8.6 mm (0.22…0.34 in.)

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 45

Chapter 3 Wiring

1 2 3

Jumpers

Jumper

To Supply

5…480 A Fan Terminations

625…1250 A Control Power/

Fan Terminations

Factory Set, 110/120V AC

CP1: 110/120V AC or

230/240V AC, 50/60 Hz ONLY

Optional, 220/240V AC

Fan Power

Controllers that are rated 5…1250 A have heatsink fan(s). See Table 11 for the heatsink fan control power VA requirements.

Fan Terminations

See Figure 31, Figure 32, and Figure 33 for fan power connection locations.

ATTENTION: The fan jumpers have been factory installed for 110/120V AC input. See Figure 39

Figure 39 - Power Terminations

1 2 3

for 220/240V AC fan wiring (5…480 A devices only).

1 2 3

Table 11 - Heatsink Fan Control Power

Controller Rating Heatsink Fan VA

5…135 A 20

201…251 A 40

317…480 A 60

625…780 A 150 (internally wired)

970…1250 A 150 (internally wired)

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

Chapter 3 Wiring

Control Terminal Designations

Figure 40 shows the 24 control terminals that are on the front of the controller.

Figure 40 - SMC Flex Controller Control Terminals

Table 12 - Control Terminal Designations

Terminal No. Description Terminal No. Description

Control Power Input

Control Power Common

Controller Enable Input

(1) (2)

(3)

23 24 25 Tach Input

14 Control Module Ground 26 Tach Input

(1) (3)

(1) (4)

29 30

Option Input #2

Option Input #1

Start Input

Stop Input

Aux. Contact #1

21 Not Used 33

22 Not Used 34

(1) RC snubbers are required on loads connected to auxiliary. (2) Control power on units rated 625…1250 A is pre-wired internally, from terminal block CP1. (3) Do not connect any additional loads to these terminals. These “parasitic” loads may cause problems with operation,

which may result in false starting and stopping.

(4) External Bypass operates an external contactor and overload relay once the motor reaches full speed. The SMC Flex

overload functionality, diagnostics and metering are disabled when the external bypass is activated. Proper sizing of the contactor and overload is required.

(3)

PTC Input

(3)

PTC Input

Ground Fault Transformer

(3)

Input Ground Fault Transformer

(3)

Input Aux. Contact #2 Aux. Contact #2 Aux. Contact #3 Aux. Contact #3 Aux. Contact #4 Aux. Contact #4

(1) (4)

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 47

Chapter 3 Wiring

Motor (1)

3-phase input power

SMC Flex Control Terminals

Aux 1

(1)

Circuit Protective Device

Stop

Start

(2)

Aux #2 Aux #3 Aux #4PTC Input TACH

Input

Ground Fault

SMC Flex Controller

Standard Controller Wiring Diagrams

Figure 41 through Figure 51 show typical wiring for the SMC Flex controller.

Figure 41 - Typical Wiring Diagram for Standard Controllers

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

Note Number Information

1 Customer supplied

11 12

25 26

15 16

18 19 20

28 29 30 31 32 33

2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

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

Chapter 3 Wiring

11 12

15 16

18 19 20

25 26

28 29 30 31 32 33

L2/3

L3/5

T1/2L1/1

T2/4

T3/6

Motor (1)

3-phase input power

SMC Flex Control Terminals

(1)

(1)(1)

(1)

Circuit Protective Device

Two-wire Device

(2)

Aux #2

Aux #3 Aux #4

PTC Input TACH

Input

Ground Fault

Programmable controller interfacing in this diagram refers to hard-wiring between the PLC output contacts and the SMC Flex controller’s control terminals. The OFF state leakage current for a solidstate device must be less than 6 mA.

Aux #1

SMC Flex Controller

Figure 42 - Typical Wiring Diagram for Two-wire Control with Stopping Control (No DPI Control)

Note Number Information

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 49

Chapter 3 Wiring

Motor (1)

3-phase input power

SMC Flex Control Terminals

Aux #1

(1)

Circuit Protective Device

Stop

Start

(2)

Aux #2 Aux #3 Aux #4PTC Input TACH

Input

Ground Fault

SMC Flex Controller

(1)

Ramp 1 Ramp 2

Figure 43 - Typical Wiring Diagram for Dual Ramp Applications

11 12

L1/1

L2/3

L3/5

15 16

T1/2

T2/4

T3/6

18 19 20

Note Number Information

25 26

28 29 30 31 32 33

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

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

Chapter 3 Wiring

11 12

15 16

18 19 20

25 26

28 29 30 31 32 33

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

Motor (1)

3-phase input power

SMC Flex Control Terminals

Aux #1

(1)

Circuit Protective Device

(2)

Aux #2 Aux #3 Aux #4PTC Input TACH

Input

Ground Fault

SMC Flex Controller

Use Figure 44 when start-stop originates from either a Bulletin 20-HIM LCD interface module or a Bulletin 20-COMM communication module that is connected to the SMC Flex controller.

Logic mask must be properly configured. See page 98

Figure 44 - Typical Wiring Diagram for Start-Stop Control via DPI Communications

Note Number Information

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 51

Chapter 3 Wiring

Motor (1)

3-phase input power

SMC Flex Control Terminals

Aux #1

(1)

Circuit Protective Device

(3)

Aux #2 Aux #3 Aux #4PTC Input TACH

Input

Ground Fault

SMC Flex Controller

Existing Motor Starter

(1)

Existing Motor Starter

(1) (2)

OL (1)

(1)

Stop

Start

(4)

Figure 45 - Typical Wiring Diagram for Retrofit Applications

T1/2L1/1

L2/3

L3/5

T2/4

T3/6

11 12

15 16

18 19 20

25 26

28 29 30 31 32 33

Note Number Information

1 Customer supplied 2 Overload protection should be disabled in the SMC Flex controller. 3 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

4 Aux #4 should be set for normal operation

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

Figure 46 - Typical Wiring Diagram for Isolation Applications (DPI also)

11 12

15 16

18 19 20

25 26

28 29 30 31 32 33

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

Motor (1)

3-phase input power

SMC Flex Control Terminals

Aux #1

(1)

Circuit Protective Device

(2)

Aux #2 Aux #3 Aux #4PTC Input TACH

Input

Ground Fault

SMC Flex Controller

Isolation contactor (1)

(1)

Stop

Start

(3)

Isolation contactor (1)

Chapter 3 Wiring

Note Number Information

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

3 Aux #4 should be set for normal operation

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 53

Chapter 3 Wiring

11 12

15 16

18 19 20

25 26

28 29 30 31 32 33

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

Motor (1)

3-phase input power

SMC Flex Control Terminals

Aux #1

(1)

Circuit Protective Device

(2)

Aux #2 Aux #3 Aux #4PTC Input TACH

Input

Ground Fault

SMC Flex Controller

(1)

Stop

Start

Shunt Trip

(1)

(3)

Figure 47 - Typical Wiring Diagram for Shunt Trip Applications

Note Number Information

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

3 Aux #2 should be set for fault operation

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

Chapter 3 Wiring

Motor (1)

3-phase input power

SMC Flex Control Terminals

Aux #1

(1)

Circuit Protective Device

(2)

Aux #2 Aux #3

Aux #4PTC Input TACH

Input

Ground Fault

SMC Flex Controller

(3)

E-Stop

Reversing Contactors (1)

• Minimum transition time for reversing direction is 1/2 second.

• Phase Reversal protection must be disabled in reversing applications.

(1)

OFF

REV

FOR

(1)

Figure 48 - Typical Wiring Diagram for Single-Speed Reversing Applications

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12

25 26

15 16

18 19 20

28 29 30 31 32 33

Note Number Information

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

3 Maintained push button.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 55

11 12

15 16

18 19 20

21 22

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

25 26

28 29 30 31 32 33 34

Motor (1)

3-phase input power

SMC Flex Control Terminals

Aux #1

(1)

Circuit Protective Device

(3)

Aux #2 Aux #3

Aux #4PTC Input TACH

Input

Ground Fault

SMC Flex Controller

Stop

Two-speed Motor Starter (1)

(2)

1 sec.

(1)

LOL

HOL

(1)

(4)

1 sec.

Low

High

Low

High

(1)

High

Low

(1)

Chapter 3 Wiring

Figure 49 - Typical Wiring Diagram for Two-speed Applications

Note Number Information

1 Customer supplied 2 Two-speed, consequent pole installations. 3 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

4 Overload must be disabled in SMC Flex controller.

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

Figure 50 - Typical Wiring Diagram for SMC-Off-Bypass Control

11 12

15 16

18 19 20

25 26

28 29 30 31 32 33

L1/1

L3/5

L2/3

T3/6

T2/4

T1/2

Motor (1)

3-phase input power

SMC Flex Control Terminals

Aux #1

(1)

Circuit Protective Device

(2)

Aux #2 Aux #3

Aux #4PTC Input TACH

Input

Ground Fault

SMC Flex Controller

SMC

Bypass Contactor (1)

Start

(1)

OFF

Stop

Bypass Contactor

Bypass Overload

Bypass

(1)

Chapter 3 Wiring

Note Number Information

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 57

Chapter 3 Wiring

11 12

15 16

18 19 20

25 26

28 29 30 31 32 33

C (1)

Control power

SMC Flex Control Terminals

Aux #1

(2)

(1)

Aux #2

Aux #3 Aux #4

PTC Input TACH

Input

Ground Fault

Hand

Start

(1)

OFF

Stop

Auto Device (1)

Auto

C (1)

Figure 51 - Typical Wiring Diagram for Hand-Off-Auto Control with Stop Option and Start/Stop Push Buttons

Note Number Information

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

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

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

Chapter 3 Wiring

11 12

15 16

18 19 20

25 26

28 29 30 31 32 33

Control power

SMC Flex Control Terminals

Aux #1

(3)

(1) (2)

Aux #2

Aux #3 Aux #4

PTC Input TACH

Input

Ground Fault

Start

(1)

Stop

Option Stop

Soft Stop, Pump Control, and SMB Smart Motor Braking

Figure 52 through Figure 55 show typical wiring for the Soft Stop, Pump

Control, and SMB Smart Motor Braking options.

Figure 52 - Typical Wiring Diagram

Note Number Information

1 Customer supplied 2 Soft Stop, Pump Stop, or Brake. 3 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 59

Chapter 3 Wiring

Control power

SMC Flex Control Terminals

Aux #1

(3)

(1) (4)

Aux #2

Aux #3 Aux #4

PTC Input TACH

Input

Ground Fault

Start

(1)

Stop

Option Stop

(5)

(1) (2)

Overload

Existing Motor Starter (1)

Figure 53 - Typical Retrofit Wiring Diagram

11 12

25 26

15 16

28 29 30 31 32 33

Note Number Information

1 Customer supplied 2 Overload protection should be disabled in the SMC Flex controller. 3 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4. 4 Soft Stop, Pump Stop, or Brake. 5 Aux #4 should be set to normal operation.

18 19 20

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

Chapter 3 Wiring

Control power

SMC Flex Control Terminals

Aux #1

(2)

(1) (3)

Aux #2

Aux #3 Aux #4

PTC Input TACH

Input

Ground Fault

Start

(1)

Stop

Option Stop

(4)

Isolation Contactor (1)

Figure 54 - Typical Wiring Diagram for Applications That Require an Isolation Contactor

11 12

25 26

15 16

28 29 30 31 32 33

Note Number Information

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4. 3 Soft Stop, Pump Stop, or Brake. 4 Aux #4 should be set to normal operation.

18 19 20

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Chapter 3 Wiring

Control power

110…240V AC

SMC Flex Control Terminals

Aux #1

Aux #2 Aux #3 Aux #4

PTC Input

TACH Input

Ground Fault

Hand

(1)

OFF

X00

Auto

3-phase input power

(1)

Circuit Protective Device

Motor (1)

SMC Flex Controller

X00

00X

Figure 55 - Typical Wiring Diagram for Hand-Off-Auto (DPI) Control (Soft Stop, Braking, and Pump Control Only)

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12

25 26

15 16

28 29 30 31 32 33

Note Number Information

1 Customer supplied

18 19 20

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

Chapter 3 Wiring

Control power

SMC Flex Control Terminals

Aux #1

(3)

(1) (2)

Aux #2

Aux #3 Aux #4

PTC Input TACH

Input

Ground Fault

Start

(1)

Stop

Option

Command

Preset Slow Speed

Figure 56 and Figure 57 show typical wiring examples for Preset Slow Speed.

Figure 56 - Typical Wiring Diagram for Preset Slow Speed

11 12

15 16

18 19 20

Note Number Information

1 Customer supplied 2 Slow Speed. 3 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4.

25 26

28 29 30 31 32 33

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 63

Chapter 3 Wiring

SMC Flex Control Terminals

Aux #1

Aux #2 Aux #3 Aux #4

PTC Input

TACH Input

Ground Fault

Hand

(1)

OFF

(4)

Auto

3-phase input power

(1)

Circuit Protective Device

Motor (1)

SMC Flex Controller

(1) (2)

Start

(1)

Stop

Option

Command

(3)

Figure 57 - Typical Slow Speed Wiring Diagram for Hand-Off-Auto (DPI) Control

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12

25 26

15 16

18 19 20

28 29 30 31 32 33

Note Number Information

1 Customer supplied 2 Slow Speed 3 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4. 4 Aux #4 should be set to normal operation.

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

Chapter 3 Wiring

Control power

SMC Flex Control Terminals

Aux #1

(2)

Aux #2

Aux #3 Aux #4

PTC Input TACH

Input

Ground Fault

Start

(1)

Stop

Brake

(3)

Isolation Contactor (1)

Slow Speed

(1)

Slow Speed with Braking

Figure 58 shows the wiring for the Slow Speed with Braking option.

Figure 58 - Typical Wiring Diagram for Slow Speed with Braking with an Isolation Contactor

11 12

Note Number Information

1 Customer supplied 2 See the controller nameplate to verify the rating of the control power input voltage. For units rated

625…1250 A, terminals 11 and 12 are factory pre-wired from terminal block CP1 - terminals 1 and 4. 3 Aux #4 should be set to normal operation.

25 26

15 16

28 29 30 31 32 33

18 19 20

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 65

Chapter 3 Wiring

100%

Time (seconds)

Soft Stop

Run Soft StopStart

Coast to rest

Start

Soft Stop

Stop

Push Buttons

Auxiliary Contacts

(Stop Option) (1)

Normal

Up-to-speed

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

If Soft Stop is selected

If Coast-to-Rest is Selected

Motor Speed

Sequence of Operation

Figure 59 through Figure 64 show the different operation sequences for the

Soft Stop, Preset Slow Speed, Pump Control, SMB Smart Motor Braking, AccuStop, and Slow Speed with Braking options.

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

Figure 59 - Soft Stop Sequence of Operation

Note Number Information

With the Stop Mode, Parameter 32, configured for Soft Stop and with the Input push button

configured for the Stop Option.

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

(3)

Motor Speed

100%

7% or 15%

Time (seconds)

Start

RunSlow Speed

Coast

Soft Stop

Brake

Coast to rest

Soft Stop

Start

Soft Stop

Stop

Push Buttons

Auxiliary Contacts

(Stop Option)

Normal

Up-to-speed

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Slow Speed

Closed

Open

Coast

If Soft Stop is selected

If Coast-to-Rest is Selected

(2)

(1)

Chapter 3 Wiring

Figure 60 - Preset Slow Speed Sequence of Operation

Note Number Information

1 Coast if Stopping Current, Parameter 43, = 0. 2 Brake if Stopping Current, Parameter 43, > 0. 3 With the Stop Mode, Parameter 32, configured for Soft Stop and with the Input push button

configured for the Stop Option.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 67

Chapter 3 Wiring

(1)

Motor Speed

100%

Time (seconds)

Pump Start

Run Pump Stop

Coast to rest

Start

Pump Stop

Stop

Push Buttons

Auxiliary Contacts

(Stop Option)

Normal

Up-to-speed

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Figure 61 - Pump Control Sequence of Operation

Note Number Information

1 With the Input push button configured for the Stop Option.

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

(1)

Motor Speed

Automatic Zerospeed Shutoff

100%

Time (seconds)

Start

Run Brake

Smart Motor Braking

Coast-to-Rest

Stop Time

Start

Smart Motor Braking

Stop

Push Buttons

Auxiliary Contacts

(Stop Option)

Normal

Up-to-speed

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

If Brake is selected

If Coast-to-Rest is Selected

Figure 62 - Smart Motor Braking (SMB) Sequence of Operation

Chapter 3 Wiring

Note Number Information

With the Stop Mode, Parameter 32, configured for SMB and with the Input push button configured

for the Stop Option.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 69

Chapter 3 Wiring

Motor Speed

100%

Time (seconds)

Slow

Run

Braking

Coast-to-Rest

Brake

Start

Slow Speed

Slow Speed Braking

Start

Stop

Push Buttons

Auxiliary Contacts

Slow Speed

Normal

Up-to-speed

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Coast Input Open Stopping Current = 0 = Coast

Coast From Slow Speed

Figure 63 - Accu-Stop Sequence of Operation

Table 13 - Accu-Stop Parameter Selections

Parameter No. Parameter Name Required Setting

32 Stop Mode Accu-Stop 35 Braking Current User Value 39 Slow Speed Select User Value 43 Stopping Current User Value

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

(3)

Motor Speed

100%

Time (seconds)

Slow Speed

Run

Braking

Coast-to-Rest

StopStart

Coast

Brake

Coast

Brake

If Coast-to-Rest is Selected

Start

Smart Motor Braking

Stop

Push Buttons

Auxiliary Contacts

(Stop Option)

Normal

Up-to-speed

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Slow Speed

(1)

(2)

Chapter 3 Wiring

Figure 64 - Slow Speed with Braking Sequence of Operation

Note Number Information

1 Coast if Stopping Current, Parameter 43, = 0 (coast). 2 Brake if Stopping Current, Parameter 43, > 0. 3 With the Stop Mode, Parameter 32, configured for SMB and with the Input push button configured

for the Stop Option.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 71

Chapter 3 Wiring

MADE IN U.S.A

PROTECTIVE MODULE

MAX. LINE VOLTAGE

Special Application Considerations

This section covers some considerations that you need to address, depending on your application.

Protective Modules

You should install a protective module (see Figure 65) containing MOVs (Metal Oxide Varistors) to protect the SMC Flex power components from electrical transients and/or electrical noise.

You can install protective modules controllers rated from 200…600V to protect the power components from electrical transients. The protective modules clip voltage transients that are generated on the lines to prevent such surges from damaging the SCRs. The use of MOVs is highly recommended, because 480V and 600V MOVs offer maximum protection of 1400V and 1600V, respectively.

Figure 65 - Protective Module

ATTENTION: You can place protective modules on the line, load, or both sides of the SMC Flex controller. However, protective modules must not be placed on the load side of the SMC Flex controller when using inside-the-delta motor connections or with pump, linear speed, or braking control.

ATTENTION: When you install or inspect the protective module, make sure that the controller has been disconnected from the power source. You should inspect the protective module periodically for damage or discoloration. Replace if necessary.

There are two general situations that may occur that could indicate the need for using the protective modules.

1. Transient Spikes — Transient spikes will typically occur on the lines feeding the SMC Flex controller or feeding the load from the SMC Flex controller. Transient spikes are created on the line when devices are attached with current- carrying inductances that are open-circuited. The energy stored in the magnetic field is released when the contacts open the circuit. Examples of these include lightly loaded motors, transformers, solenoids, full voltage starters, and electromechanical brakes. Lightning can also cause spikes.

2. Fast-rising Wavefronts — If the SMC Flex controller is installed on a system that has fast-rising wavefronts present, although not necessarily high peak voltages, protective modules may be needed. Lightning can also cause this type of response. Additionally, if the controller is on the same bus as other SCR devices (such as AC/DC drives, induction heating equipment, or welding equipment), the firing of the SCRs in those devices can cause noise.

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

Chapter 3 Wiring

Overload Relay (1)

SMC Flex Controller Disable the overload function using Parameter 44— Overload Class

Motor 1 (1)

Overload Relay (1)

Motor 2 (1)

3-phase input power

(1)

Circuit Protective Device

Multi-motor Applications

The SMC Flex controller operates with more than one motor connected to it. Motors should be mechanically coupled. To size the controller, add the total nameplate amperes of all of the connected loads. You should turn off the stall and jam features. Separate overloads are still required to meet the National Electric Code (NEC) requirements.

Figure 66 - Multi-Motor Application

L1/1

L2/3

L3/5

Note Number Information

1 Customer Supplied

T1/2

T2/4

T3/6

You cannot use the built-in overload protection in multi-motor applications. Disable the SMC Flex Overload function using Parameter 44—Overload Class.

SMC Flex Controller as a Bypass to an AC Drive

By using the controller as shown in Figure 67, a soft start characteristic can be provided if a variable-frequency AC drive (VFD) is non-operational.

• You can achieve a controlled acceleration with this scheme, but speed control is not available in the bypass mode.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 73

Chapter 3 Wiring

L1/1

L3/5

L2/3

T1/2

T3/6

T2/4

SMC Flex Controller (4)

Motor (1)

3-phase input power

(3)

VFD Branch Protection

VFD

Isolation

Contactor (1)

Isolation

Contactor (1)

(1)

Overload

(2)

L1/1

L3/5

L2/3

T1/2

T3/6

T2/4

SMC Flex Controller

(1)

Motor

Isolation Contactor

Bulletin 1410 Motor Winding Heater

(1)

Overload Relay

Holding Coil

(2)

3-phase input power

Figure 67 - Typical Application Diagram of a Bypass Contactor for an AC Drive

Note Number Information

1 Customer Supplied 2 Mechanical interlock required. 3 Many VFDs are rated 150% FLA. Because the SMC Flex controller can be used for 600% FLA

starting, separate branch circuit protection may be required.

4 Overload protection is included as a standard feature of the SMC Flex controller.

SMC Flex Controller with a Bulletin 1410 Motor Winding Heater

Figure 68 - SMC Flex Controller with Bulletin 1410 Motor Winding Heater

Note Number Information

1 Customer Supplied 2 Overload protection is included as a standard feature of the SMC Flex controller.

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

Chapter 3 Wiring

SMC power pole

Dual-voltage Wiring

This section explains how to wire a 12-lead, dual-voltage Wye-delta motor using an SMC Flex controller that is programmed for Delta starting.

See your motor manufacturer’s wring diagram for detailed instructions on how to wire the motor. The examples in this section show typical motor connections when you use a 12-lead, dual-voltage Wye-delta motor and the SMC Flex controller.

IMPORTANT

Figure 69

perspective of the motor winding connections to the SMC Flex controller power pole. Understanding this wiring helps you to understand how to wire the 12-lead, dual-voltage motor.

Figure 69 - 6-Lead Single-voltage Configuration

The examples in this section show the motor wired for low and high voltage.

shows a typical 6-lead, single-voltage configuration from the

L1 L2 L3

T6 T3

Figure 70 shows the line- and load-side terminal markings of the SMC Flex

controller. The controller has global markings. IEC markings are noted in parentheses, while North American markings are preceded with the letter “T”. The explanations in this section refer only to the North American markings that are on the device.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 75

Chapter 3 Wiring

L1 L3L2

T6 T5T4T1 T3T2

(12) (2) (8)

(4) (10) (6)

IEC marking

North American marking

Delta connections

Motor winding connections

Figure 70 - SMC Flex Controller Terminal Markings

12/T6

T7/T1

3/L21/L1 5/L3

T10/T4

T8/T2

Low-voltage Example

Figure 71 shows three different ways of illustrating the 12-lead connections to

run a delta-connected motor for low-voltage operation. Terminal numbers on each drawing refer to the same connection on the device. For example, Terminal T12 on each drawing is the terminal T12 on the same SMC Flex Controller.

Figure 71 - 12-Lead Delta Connection for Low-voltage Run Mode

T11/T5

T12

T9/T3

T10

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

T8T11

3/L21/L1 5/L3

Delta connections Motor winding connections

Chapter 3 Wiring

High-voltage Example

Figure 72 shows three different ways of illustrating the 12-lead connections to

run a delta-connected motor for high-voltage operation. Terminal numbers on each drawing refer to the same connection on the device. For example, Terminal T12 on each drawing is the terminal T12 on the same SMC Flex Controller.

Figure 72 - 12-Lead Delta Connection for High-voltage Run Mode

T12

T10

T11

T10

T8T11

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 77

Chapter 3 Wiring

Notes:

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

Chapter 4

Lang

Programming

This chapter provides a basic understanding of the built-in programming keypad. This chapter also describes how to program the SMC Flex™ controller by modifying the parameters.

Keypad Description

Programming Menu

Table 14 describes the keys that are on the front of the SMC Flex controller.

Table 14 - SMC Flex Controller Keypad

Menu Button Name Function

Esc

Sel

Escape

Select

Up/Down

Arrows

Enter

Exit a menu, cancel a change to a parameter value, or acknowledge a fault/alarm. Will clear a fault if held for 3 seconds. (Firmware version 6.001 or higher required)

Select a digit, select a bit, or enter edit mode in a parameter screen. Will get to menu to change the language being displayed.

Scroll through options increase/decrease a value, or toggle a bit.

Enter a menu, enter edit mode in a parameter screen, or save a change to a parameter value.

For ease of programming values, after using the Enter key to edit, use the Sel key to jump to the digit that needs to be modified, then use the arrow keys to scroll through the digits.

Parameters are organized in a three-level menu structure for straightforward programming. Figure 73

details the programming menu structure and the

three-level hierarchy.

In order to change parameters, the controller must be in the STOP mode, and the control voltage must be present.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 79

Chapter 4 Programming

Parameter definitions are listed in Excel® spreadsheets in KnowledgeBase.

Table 15

Table 15 - SMC Flex Parameter Categories

Parameter Special Behavior

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.

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

Describes codes that can appear under specific conditions and parameter configurations

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

Figure 73 - Menu Structure Hierarchy

Esc

Monitoring Set Up Motor Protection Communications Utility Linear List

SMC Flex

Reset to Defaults

Change Password User Dspl Line User Dspl Time User Dspl Video Reset User Display

Alarms Faults Device Revision

Enter Password

Power-up and Status Display

Main Menu (1)

(2)

Select language that is displayed

Operation Level

or or or

Choose Mode

(2)

Group Menu

Parameter Menu continued in

Figure 74

Parameter Device Select

Memory Storage

Preferences

Log-in

(3)

Diagnostics

Lang

Sel

Chapter 4 Programming

Esc

Note Information

1 The SMC Flex controller does not support EEPROM, Link, Process, or Start-up modes. 2 Steps back one level. 3 Only displayed if a password other than “0” is entered.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 81

Chapter 4 Programming

Metering Basic Overload Jam Comm Masks Language Linear List

Volts Phase A-B SMC Option Overload Class Jam F Lvl Logic Mask Language All parameters Volts Phase B-C Motor Connection Service Factor Jam F Dly

Parameter Mgt (4) Parameter Mgt (4) Parameter Mgt (4) Volts Phase C-A Line Voltage Motor FLC Jam A Lvl Current Phase A Starting Mode Overload Reset Jam A Dly

DataLinks Motor Data Current Phase B Ramp Time Overload A Lvl

Parameter Mgt (4)

Current Phase C Initial Torque

Parameter Mgt (4)

Data In A1 MotorFLC Watt Meter Cur Limit Lvl

Stall

Data In A2 Motor ID Kilowatt Hours Kickstar t Time

Underload

Data In B1

Parameter Mgt (4) Elapsed Time Kickstart Lvl Stall Dly Data In B2 Meter Reset Stop Input Underload F Lvl

Parameter Mgt (4)

Data In C1 Power Factor Option 1 Input Underload F Dly Data In C2 Mtr Therm Usage Option 2 Input Underload A Lvl

Ground Fault

Data In D1 Motor Speed Stop Mode Underload A Dly Data In D2

Stop Time

Parameter Mgt (4)

Gnd Flt Enable Data Out A1 Braking Current Gnd Flt Lvl Data Out A2 Overload Class

Undervoltage

Gnd Flt Dly Data Out B1 Service Factor Gnd Flt Inh Time Data Out B2 Motor FLC Undervolt F Lvl Gnd Flt A Enable Data Out C1 Overload Reset Undervolt F Dly Gnd Flt A Lvl Data Out C2 Aux1 Config Undervolt A Lvl Gnd Flt A Dly Data Out D1 Aux2 Config Undervolt A Dly

Parameter Mgt (4)

Data Out D2

Aux3 Config

Parameter Mgt (4) Parameter Mgt (4)

Aux4 Config

PTC Backspin Timer

Overvoltage

Parameter Mgt

(4)

PTC Enable

Overvolt F Lvl

Parameter Mgt (4)

Dual Ramp (Option 2 Input = Dual Ramp)

Overvolt F Dly Overvolt A Lvl

Phase Reversal

Overvolt A Dly

Starting Mode 2

Parameter Mgt (4)

Phase Reversal Ramp Time 2

Parameter Mgt (4) Initial Torque 2

Unbalance

Cur Limit Lvl 2

Restart Kickstart Time 2 Unbalance F Lvl

Kickstart Lvl 2 Unbalance F Dly Starts Per Hour Parameter Mgt (4)

Unbalance A Lvl Restart Attempts Unbalance A Dly Restart Dly

Preset SS (Option 2 Input = Preset SS)

Parameter Mgt (4) Para meter Mgt (4)

Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cur

Parameter Mgt (4)

(Option 2 Input = Accu-Stop)

Slow Speed Sel Slow Accel Cur Slow Running Cur Braking Current Stopping Current

Parameter Mgt (4)

Note Information

1 Depending upon the option that is selected, some parameters may not appear in product display.. 2 Steps back one level. 3

For further information about parameters, see KnowledgeBase Article

SMC Flex Soft Starter Parameters

For further information on parameter management, see page 84..

See Table 16 for all SMC Flex parameters that are available by the Linear List.

Esc

(2)

Parameter

(1) (3)

Monitoring

Setup Motor Protection

Communications

Utility

Linear List

(5)

Figure 74 - Parameter Menu Structure

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

Table 16 - Parameter Linear List

0.0 Amps 0 Volt 0 %MTU

Main Menu

Preferences Diagnostics

Chapter 4 Programming

Parameter

No.

Description

Parameter

No.

Description

Parameter

No.

Description

Parameter

No.

1 Volts Phase A-B 35 Braking Current 67 Jam F Lvl 101 Data Out C2 2 Volts Phase B-C 36 Braking Time 68 Jam F Dly 102 Data Out D1 3 Volts Phase C-A 37 Load Type 69 Jam A Lvl 103 Data Out D2 4 Current Phase A 38 High Eff Brake 70 Jam A Dly 104 Motor ID 5 Current Phase B 39 Slow Speed Sel 71 Stall Delay 105 CT Ratio 6 Current Phase C 40 Slow Speed Dir 72 Gnd Flt Enable 106 MV Ratio

7 Watt Meter 41 Slow Accel Cur 73 Gnd Flt Level 107 Aux1 Config 8 Kilowatt Hours 42 Slow Running Cur 74 Gnd Flt Delay 108 Aux3 Config 9 Elapsed Time 43 Stopping Current 75 Gnd Flt Inh time 109 Aux4 Config

10 Meter Reset 44 Overload Class 76 Gnd Flt A Enable 110 Aux2 Config

11 Power Factor 45 Service Factor 77 Gnd Flt A Level 111 Language

12 Mtr Therm Usage 46 Motor FLC 78 Gnd Flt A Delay 112 Timed Start 13 Motor Speed 47 Overload Reset 79 PTC Enable 113 I Shut Off Level 14 SMC Option 48 OL Shunt Time 80 Phase Reversal 114 UTS Level 15 Motor Connection 16 Line Voltage 82 Restart Attempts 116 Backspin Timer

OL Trip Enable/ Disable

81 Start Per Hour 115 Parameter Mgmt

17 Starting Mode 50 Overload A Lvl 83 Restart Delay 117 VShut Off Level 18 Ramp Time 51 Underload F Lvl 84 Line Fault Disable 118 OL Reset Level 19 Initial Torque 52 Underload F Dly 85 Emergency Run 119 Ambient Temp 20 Cur Limit Start 53 Underload A Lvl 86 Current Loss 120 Notch Position 21 Reserved 54 Underload A Dly 87 Logic Mask 121 Notch Maximum 22 Kickstart Time 55 Undervolt F Lvl 88 Data In A1 122 Start Delay 23 Kickstart Level 56 Undervolt F Dly 89 Data In A2 123 By-pass Delay 24 Option Input 2 57 Undervolt A Lvl 90 Data In B1 124 Fault 1 25 Starting Mode 2 58 Undervolt A Dly 91 Data In B2 125 Fault 2 26 Ramp Time 2 59 Overvolt F Lvl 92 Data In C1 126 Fault 3 27 Initial Torque 2 60 Overvolt F Dly 93 Data In C2 127 Fault 4 28 Cur Limit Level 2 61 Overvolt A Lvl 94 Data In D1 128 Fault 5 29 Reserved 62 Overvolt A Dly 95 Data In D2 129 Ramp Time E 30 Kickstart Time 2 63 Unbalance F Lvl 96 Data Out A1 130 Ramp Time 2E 31 Kickstart Level 2 64 Unbalance F Dly 97 Data Out A2 131 Stop Time E 32 Stop Mode 65 Unbalance A Lvl 98 Data Out B1 132 Option Input 1 33 Stop Time 66 Unbalance A Dly 99 Data Out B2 133 Stop Input 34 Pump Pedestal 100 Data Out C1 134 Elapsed Time 2

Description

Password

The SMC Flex controller lets you limit access to the programming system through password protection. This feature is disabled with a factory-set default of 0. To modify the password, complete the in Table 17

. If you lose or forget the password, contact your local Rockwell Automation sales office or Allen-Bradley distributor.

Table 17 - Modify the SMC Flex Controller Password

Description Action Display

——

1. Press the ESC key to go from the status display to the Main menu.

Esc

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Chapter 4 Programming

Main Menu

Preferences

Diagnostics

Main Menu

Preferences

Diagnostics

Preferences: Change Passwor

User Dspy lines

Preferences:

Change Password

User Dspy lines

Prefs: Password

New Code:

Verify: 83

Preferences:

Change Password

User Dspy lines

Esc

Sel

RAM ROM

EEPROM

Table 17 - Modify the SMC Flex Controller Password (Continued)

2. Scroll with the Up/Down keys until the Preferences option is highlighted.

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

4. Scroll with the Up/Down keys until the Change Password option is highlighted.

5. Press the Enter key. —

6. Press the Up/Down keys to enter the desired number. If you are modifying the password, make a note of it as displayed. Use the Sel key to highlight a single digit.

7. Verification of the new password is required. Press the Enter key. —

Parameter Management

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

(1) To complete the programming process, re-enter the Main Menu mode to log out. This prevents unauthorized access to the

(1)

programming system.

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

• structured within the SMC Flex controller

• used on power-up and during normal operation

Figure 75 - Memory Block Diagram

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

Random Access Memory (RAM)

This is the work area of the controller after it is powered up. The SMC Flex controller uses an Auto Store feature when you program parameters. When you modify parameters in the program mode, the new values are stored immediately in RAM and then in EEPROM, once the enter key has been pressed. If control power is lost prior to the enter key being pressed, these values are lost. When the device first powers up, the values from the EEPROM area of memory are copied into RAM.

Read-only Memory (ROM)

The SMC Flex controller comes with factory default parameter values. These settings are stored in non-volatile ROM and are displayed the first time you

Chapter 4 Programming

Esc

FG :P#17

Starting M

ode

Current Lim

FG :P#18

Ramp Ti

10 Secs

enter the Program mode. You can restore defaults at any time by accessing the memory storage menu.

Table 18 - Restore Factory Defaults

Command Description Action Display

Restore

Defaults

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

Memory Storage:

Reset to Defaults

Electrically Erasable Programmable Read-only Memory (EEPROM)

The SMC Flex controller provides a non-volatile area for storing user-modified parameter values in the EEPROM.

Parameter Modification

All parameters are modified using the same method. Table 19 lists the basic steps for modifying parameters.

Parameter values modified while the motor is operating are not valid until the next time that operation occurs. If the password is set, you cannot adjust parameters without logging in. Use the Sel key to highlight a single digit.

Table 19 - Modify Parameters

Description Action

——

1. Press the ESC key to go from the status display to the Main menu.

2. Scroll with the Up/Down keys until the Parameter option is highlighted.

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

4. Scroll with the Up/Down keys until the option you want to use (Monitoring, Motor Protection, etc.) is highlighted. For this example, Set Up will be used.

Main Menu

Parameter

Memory Storage

GP : File

Monitoring

Set Up

GP : File

Set Up

Motor Protection

5. Press Enter to select the Set Up group. —

F P: Group

6. Scroll to Basic Set Up and press Enter.

(2)

G Basic Set Up

Display

0.0 Amps 0 Volt 0 %MTU

—

(1)

7. Scroll to the Starting Mode parameter by using the Up/ Down keys, and press Enter.

FG : Parameter

Starting Mode

Ramp Time

8. Press Enter to select the option. Scroll to the option of your choice by using the Up/Down keys. For this example, we will choose Current Limit.

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

10.Scroll to the next parameter by using the Down key. Continue the process until all desired settings are entered.

(1) The display indicates that the second line is now active by highlighting the first character. If the LCD display does not provide

a highlighted cursor, then the controller is in the Display mode.

(2) The SMC Option advises you if any control option (such as Pump Control) is resident. This parameter is factory set and you

cannot modify it.

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Chapter 4 Programming

Soft Start

Current Limit Start

Use the parameters that are listed in Table 20 to adjust the voltage ramp supplied to the motor.

Table 20 - Soft Start (Voltage Ramp) Parameters

Parameter

No.

17 Starting Mode This must be programmed for Soft Start. Soft Start

19 Initial Torque

22 Kickstart Time

23 Kickstart Level

(1) If the controller senses that the motor has reached full speed before it completes the Soft Start, it automatically switches to

providing full voltage to the motor.

Parameter

Name

Ramp Time

Description Value

This programs the time period that the controller will ramp the

(1)

output voltage up to full voltage from the Initial Torque level programmed.

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

A boost of current is provided to the motor for the programmed time period.

Adjusts the amount of current applied to the motor during the kickstart time.

0…30 s

0…90% locked

rotor torque

0.0…2.0 s

0…90% locked

rotor torque

Use the parameters that are listed in Table 21 apply a current limit start to the motor.

Table 21 - Current Limit Start Parameters

Dual Ramp Start

Parameter

No.

17 Starting Mode This must be programmed for Current Limit. Current Limit

22 Kickstart Time

23 Kickstart Level

(1) If the controller senses that the motor has reached full speed before it completes the Current Limit Start, it automatically

switches to providing full voltage to the motor.

Parameter

Name

Ramp Time

Current Limit Level

(1)

Description Value

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

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

A boost of current is provided to the motor for the programmed time period.

Adjusts the amount of current applied to the motor during the kickstart time.

0…30 s

50…600% full

load current

0.0…2.0 s

0…90% locked

rotor torque

The SMC Flex controller lets you select between two Start profiles. The parameters that are listed in Table 22

are available in the Set Up menu. Ramp #1 parameters are in the "Basic Setup" menu. Ramp #2 parameters are in the "Dual Ramp" menu. Option Input 2 must be set to "Dual Ramp" to enable the second ramp parameters.

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

Chapter 4 Programming

The Ramp #2 parameters will be used if Option Input 2 is active at the time of the start. To obtain Dual Ramp control, Ramp #1 is located in the Setup menu Basic section and Ramp #2 is located in the Option Input 2 (Dual Ramp).

Table 22 - Dual Ramp Start Parameters

Full Voltage Start

Parameter

No.

18 Ramp Time

19 Initial Torque

20 Current Limit

26 Ramp Time 2

27 Initial Torque 2

28 Current Limit 2

(1) The Dual Ramp feature is available on the standard controller. (2) You can program Kickstart for both start modes.

Parameter

Name

Option Input 2 (Dual Ramp)

Start Mode

Start Mode 2

(2)

Description Value

"Option input 2" must be set to "Dual Ramp" to enable the dual

(1)

ramp feature. Selects the start mode for option #1. —

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

Lets you adjust the initial torque level applied to the motor at the beginning of the start maneuver for the first Soft Start setup.

Lets you adjust the current level applied to the motor during the start maneuver.

(2)

Selects the start mode for option #2. — Programs the time period during which the controller will ramp

the output voltage up to full voltage for the second Soft Start setup.

Lets you adjust the initial torque level applied to the motor at the beginning of the start maneuver for the secondSoft Start setup.

Lets you adjust the current level applied to the motor during the start maneuver for option #2.

—

0…30 s

0…90% locked

rotor torque

50…600% FLC

0…30 s

0…90% locked

rotor torque

50…600% FLC

You can program the SMC Flex controller to provide a full-voltage start (output voltage to the motor reaches full voltage within 1/4 second) with the parameters that are listed in Table 23

Linear Speed

Programming Parameters

Table 23 - Full-voltage Start Parameters

Parameter No. Parameter Name Description Value

17 Starting Mode This must be programmed for Full Voltage. Full Voltage

The SMC Flex controller lets you control the motor speed during starting and stopping maneuvers. A tachometer input is required. See

Table 24 - Linear Speed Acceleration and Deceleration Parameters

Parameter

No.

Parameter Name Description Value

17 Starting Mode This must be programmed for Linear Speed. Linear Speed

18 Ramp Time

22 Kickstart Time

23 Kickstart Level

This programs the time period that the controller will ramp from 0 speed to full speed.

A boost of current is provided to the motor for the programmed time period.

Adjusts the amount of current applied to the motor during the kickstart time.

page 10.

0…30 s

0.0…2.0 s

0…90% locked

rotor torque

Table 25 lists the option-specific parameters that correlate to each control

option. These parameters are in addition to those already discussed in the Basic Set Up and Metering groups.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 87

Chapter 4 Programming

Table 25 - Option-specific Programming Parameters

Option

Parameter

No.

Parameter Name Description Value

Standard

Soft Stop

14 SMC Option Identifies the type of control present and is not user programmable. Standard

33 Stop Time Lets you set the time period for the soft stopping function. 0…120 s

14 SMC Option Identifies the type of control present and is not user programmable. Standard

39 Slow Speed Select Lets you program the slow speed that best fits the application.

Preset Slow

Speed

Slow Speed Direction

Programs the slow speed motor rotational direction. Forward, Reverse

41 Slow Accel Current Lets you program the required current to accelerate the motor to slow speed operation. 0…450% FLA

Slow Running

Current

Lets you program the required current to operate the motor at the slow speed setting. 0…450% FLA

Pump Control

14 SMC Option Identifies the type of control present and is not user programmable. Pump Control

Pump Control

33 Stop Time Lets you set the time period for the pump stopping function. 0…120 s

17 Starting Mode Lets you program the SMC Flex controller for the type of starting that best fits the application.

Braking Control

SMB Smart

Motor Braking

14 SMC Option Identifies the type of control present and is not user programmable. Braking Control

(1)

Braking Current

Lets you program the intensity of the braking current applied to the motor. 0…400% FLA

14 SMC Option Identifies the type of control present and is not user programmable. Braking Control

39 Slow Speed Select Lets you program the slow speed that best fits the application.

41 Slow Accel Current Lets you program the required current to accelerate the motor to slow speed operation. 0…450% FLA

Accu-Stop

Slow Running Current

Braking Current

Stopping Current

Lets you program the required current to operate the motor at the slow speed setting. 0…450% FLA

(1)

Lets you program the intensity of the braking current applied to the motor. 0…400% FLA Lets you program the intensity of the braking current applied to the motor from slow speed

(1)

operation.

14 SMC Option Identifies the type of control present and is not user programmable. Braking Control

39 Slow Speed Select Lets you program the slow speed that best fits the application.

Slow Speed

with Braking

(1) All braking/stopping current settings in the range of 1…100% provide 100% braking current to the motor.

41 Slow Accel Current Lets you program the required current to accelerate the motor to slow speed operation. 0…450% FLA

Slow Running

Current Braking Current

Lets you program the required current to operate the motor at the slow speed setting. 0…450% FLA

(1)

Lets you program the intensity of the braking current applied to the motor. 0…400% FLA

Low: 7% – forward,

10% – reverse

High: 15% – forward,

20% – reverse

Pump Start, Soft Start,

Current Limit Start

Low: 7%

High: 15%

0…400% FLA

Low: 7%

High: 15%

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Chapter 4 Programming

Basic Setup

The Basic Setup programming group provides a limited parameter set, allowing quick startup with minimal adjustment. If you plan to implement some of the advanced features (such as Dual Ramp or Preset Slow Speed), select the Setup programming group. It provides the complete Basic Setup parameter set and the advanced set.

Table 26 - Basic Setup Parameters

Parameter

No.

133 Stop Input Lets you select the operation of terminal 18, Stop Input. Coast, Stop Option

132 Option Input 1 Lets you select the operation of terminal 16, Option Input #1.

107 Aux1 Config

108 Aux3 Config

109 Aux4 Config

(1) Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter. (2) Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter.

Parameter Name Description Value

14 SMC Option Displays the type of controller. This is factory set and not adjustable. Standard 15 Motor Connection Displays the motor type to which the device is being connected. Line or Delta 16 Line Voltage Displays the system line voltage to which the unit is connected.

17 Starting Mode

18 Ramp Time Sets the time period during which the controller will ramp the output voltage. 0…30 s 19

Initial Torque Current Limit

22 Kickstart Time A boost current is provided to the motor for the programmed time period. 0.0…2.0 s 23 Kickstart Level Adjusts the amount of current applied to the motor during kickstart. 0…90% of locked rotor torque

24 Option Input 2 Lets you select the operation of terminal 15, Option Input #2.

32 Stop Mode

33 Stop Time

44 Overload Class Lets you select the Overload Trip Class. Disable, 10, 15, 20, 30 45 Service Factor Lets you program the service factor from the motor nameplate. 0.01…1.99 46 Motor FLC Lets you program the FLC from the motor nameplate. 1.0…2200 47 OL Reset Lets you select the type of overload reset. Auto, Manual

110 Aux2 Config

115 Parameter Mgmt Recall of factory default parameter values. Ready, Load Default

Level

(2)

Lets you program the SMC Flex controller for the type of starting that best fits the application.

(1)

Establishes and adjusts the initial reduced voltage output level for the voltage ramp. 0…90% of locked rotor torque

The current limit level that is applied for the Ramp Time selected. 50…600% FLA

Lets you program the SMC Flex controller for the type of stopping that best fits the application.

Sets the time period during which the controller will ramp the voltage during a stopping maneuver.

Lets you configure the operation of the contacts that is located at terminals 19 and 20. Contact is provided as standard with the SMC Flex controller.

Lets you configure the operation of the contacts that is located at terminals 29 and 30. Contact is provided as standard with the SMC Flex controller.

Lets you configure the operation of the contacts that is located at terminals 31 and 32. Contact is provided as standard with the SMC Flex controller.

Lets you configure the operation of the contacts that is located at terminals 33 and 34. Contact is provided as standard with the SMC Flex controller.

Soft Start, Current Limit, Full Voltage, Linear

Speed

Disable, Coast, Stop Option, Fault, Fault NC,

Network

Disable, Slow Speed, Dual Ramp, Fault, Fault

NC, Network, Clear Fault

Disable, Soft Stop, Linear Speed

0.0…120 s

Normal, Up-to-speed, Fault, Alarm, Network

Control, External Bypass: (N.O.)

Normal, Up-to-speed, Fault, Alarm, Network

Control, External Bypass: (N.O.)

Normal, Up-to-speed, Fault, Alarm, Network

Control, External Bypass: (N.O.)

Normal, Up-to-speed, Fault, Alarm, Network

Control, External Bypass: (N.O.)

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 89

Chapter 4 Programming

Motor Protection

While the Basic Setup group lets you get started with a minimum number of parameters to modify, the Motor Protection group allows full access to the SMC Flex controller parameter set. Table 27

lists the additional setup

parameters that are provided in this group.

The majority of parameters have a Fault and an Alarm setting.

ATTENTION: For overload protection, you must enter the data as it appears on the motor nameplate.

Table 27 - Motor Protection Parameters

Protection

Type

Overload Lets you select the operation of the overload:

Determines the trip level as a percentage of the motor’s FLA, and the delay

Underload

Undervoltage

Overvoltage

Unbalance

Jam

(1)

period.

Determines the trip level as a percentage of the line voltage and the delay

(2)

period.

(2)

Determines the trip level as a percentage of line voltage and delay period.

(2)

Lets you set the voltage unbalance trip level and delay period.

(1)

Determines the trip level as a percentage of motor full load current and delay period.

Stall Lets you set the stall delay time. 71 Stall Delay

(3)

Ground Fault

Motor PTC

Phase Reversal

Restarts

(1) For Jam and Underload detection to function, the Motor FLC must be programmed in the Motor Protection group. See Chapter 5. (2) The delay time must be set to a value greater than zero when Undervoltage, Overvoltage, and Unbalance are enabled. (3) See page 22 (4) See page 23

Lets you enable the ground fault level in amps, delay time, and inhibit time.

(4)

Lets you connect a PTC to the SMC and enable a fault when it becomes active. 79 PTC Enable Determines the proper orientation of line connections to the SMC. If Enabled

and phases are out of sequence, a fault will be indicated. Lets you determine the maximum number of restarts per hour the unit can

experience, and delay time between consecutive starts.

. .

Description

No. Parameter Name No. Parameter Name

44 Overload Class, 48 OL Shunt Time 45 Service Factor 49 OL Trip Enable/Disable 46 Motor FLC 50 Overload A Lvl

47 Overload Reset

51 Underload Fault Level 53 Underload Alarm Level 52 Underload Fault Delay 54 Underload Alarm Delay 55 Undervoltage Fault Level 57 Undervoltage Alarm Level

56 Undervoltage Fault Delay 58 Undervoltage Alarm Delay

59 Overvoltage Fault Level 61 Overvoltage Alarm Level

60 Overvoltage Fault Delay 62 Overvoltage Alarm Delay

63 Unbalance Fault Level 65 Unbalance Alarm Level

64 Unbalance Fault Delay 66 Unbalance Alarm Delay

67 Jam Fault Level 69 Jam Alarm Level

68 Jam Fault Delay 70 Jam Alarm Delay

72 Ground Fault Enable 76 Ground Fault Alarm Enable 73 Ground Fault Level 77 Ground Fault Alarm Level 74 Ground Fault Delay 78 Ground Fault Alarm Delay 75 Ground Fault Inhibit Time

80 Phase Reversal

81 Starts Per Hour 83 Restart Delay

82 Restart Attempts

Setup Parameters

Table 28 - Example Settings

Protection Type Parameter No. Parameter Name Setting Value Trip Value

Undervoltage

Overvoltage

Jam

Underload

(1) The average value of the three phase-to-phase voltages is utilized. (2) The largest value of the three-phase currents is utilized. (3) The SMC Flex controller self protects.

(1)

(2) (3)

(2)

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

16 Line Voltage 480V

55 Undervoltage level 80%

16 Line Voltage 240V 59 Overvoltage level 115% 46 Motor FLC 150 A 67 Jam level 400% 46 Motor FLC 90 A

51 Underload level 60%

384V

276V

600 A

54 A

Metering

Esc

Main Menu

Parameter

Memory Storage

Main Menu

Parameter

Memory Storage

GP : File

Monitoring

Set Up

Chapter 5

Overview

View Metering Data

While the SMC Flex™ controller operates your motor, it also monitors several

(a)

different parameters, providing a full-function metering

package.

To access the metering information, follow the procedure in Table 29.

Table 29 - Access the Metering Information

Description Action Display

——

1. Press any of the following keys to access the Main Menu.

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

3. Press the Enter key to select the Parameter option. —

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

##.# Amps

### Volt

## %MTU

(a) See page 25 or Figure 74 for details on the metering functions.

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 91

Chapter 5 Metering

F P: Group

Metering

FG :P#4

Current Phase A

##.# Amps

FG :P#5

Current Phase B

##.# Amps

FG :P#6

Current Phase C

##.# Amps

FG :P#7

Watt Meter

##.# KW

FG :P#8

Kilowatt Hours

##.# KWH

FG :P#9

Elapsed Time

##.# Hour

FG :P#10

Meter Reset

FG :P#11

Power Factor

##.#

FG :P#12

Mtr ThermUsage

## %MTU

FG :P#3

Volts Phase C-A

### Volt

FG :P#2

Volts Phase B-C

### Volt

FG :P#1

Volts Phase A-B

### Volt

Table 29 - Access the Metering Information (Continued)

Description Action Display

5. Press the Enter key to access the Monitoring group. —

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

7. Scroll through the Metering parameters with the Up/Down keys to

access the desired information. Press the Enter key to view that parameter.

You can modify the metering values that are displayed on the SMC Flex controller to show your desired values by accessing Main Menu/Preferences.

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

Optional HIM Operation

Chapter 6

Overview

Human Interface Module

The SMC Flex™ controller offers a variety of unique control options that provide enhanced motor starting and stopping capabilities. (See Chapter 1

for

brief descriptions of each option.)

Only one option can reside in a controller.

The control buttons available with the Bulletin 20-HIM LCD Human interface modules are compatible with the SMC-Flex controller’s control options.

Table 30

through Table 32 detail the functionality of each button.

IMPORTANT

The logic mask port must be enabled prior to initiating control commands to the SMC Flex controller. See page 98.

IMPORTANT

Table 30 - Button Functions for Standard Operation Modes

Option Button Operation

Soft Stop

Current Limit

Full Voltage

Linear Speed

Preset Slow Speed

You must wire the control terminals according to Figure 44 or Figure 55.

Jog

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

The red stop button, when pressed, provides a coast stop, and/or resets a fault.

The jog button, when pressed, initiates the programmed maneuver.

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

The red stop button, when pressed, provides a coast stop and/or resets a fault.

The jog button is not active for Preset Slow Speed. You cannot operate Slow Speed via the HIM.

Table 31 - Button Functions for Pump Control Mode

Option Button Operation

Pump Control

Rockwell Automation Publication 150-UM008I-EN-P - October 2020 93

Jog

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

The red stop button, when pressed, provides a coast stop, and/or resets afault.

The jog button, when pressed, initiates a pump stop maneuver.

Chapter 6 Optional HIM Operation

Table 32 - Button Functions for Braking Control Modes

Option Button Operation

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

The red stop button, when pressed, provides a coast stop, and/or resets afault.

Smart Motor Braking

Accu-Stop

Slow Speed with

Braking

Jog

he jog button, when pressed, initiates a brake stop.

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

The red stop button, when pressed, will provide a coast stop, and/or reset a fault.

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

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

The red stop button, when pressed, provides a coast stop, and/or resets afault.

The jog button initiates a brake stop. You cannot operate Slow Speed via the HIM.

ATTENTION: The Bulletin 20-HIM LCD Human interface module’s stop push button is not intended to be used as an emergency stop. Refer to applicable standards for emergency stop requirements.

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Communication

Chapter 7

Overview

The SMC Flex™ controller provides advanced communication capabilities that let you control, configure and monitor the product through multiple devices and over multiple communication networks. The SMC Flex controller uses DPI as an internal method of communication bus; therefore, you can use all standard DPI communication devices that are used by other Rockwell Automation products (for example, PowerFlex® Drives) in the SMC Flex controller. SCANPort™ devices are not supported by the SMC Flex controller.

Standard DPI communication cards are available for various protocols, including EtherNet/IP™, DeviceNet, ControlNet, ModBus™, Remote I/O, and Profibus® DP. Other modules may be available in the future. For specific programming examples, configuration, or programming information, see the user manual for the communication module being used. Table 33 of available modules.

Table 33 - Communication Card Selection by Protocol Type

Protocol Type Cat. No. User Manual

DeviceNet 20-COMM-D 20COMM-UM002 ControlNet 20-COMM-C 20COMM-UM003 Remote I/O 20-COMM-R 20COMM-UM004 Profibus 20-COMM-P 20COMM-UM006 RS-485 20-COMM-S 20COMM-UM005 InterBus 20-COMM-I 20COMM-UM007 EtherNet/IP 20-COMM-E 20COMM-UM010 Dual Port EtherNet/IP 20-COMM-ER 20COMM-UM015 RS485 HVAC 20-COMM-H 20COMM-UM009 ControlNet (Fiber) 20-COMM-Q 20COMM-UM003 CANopen 20-COMM-K 20COMM-UM012

shows a list

Communication Ports

Human Interface Module

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The SMC Flex controller supports three DPI ports for communication. Ports 2 and 3 are supported through the DPI connection on the side of the device and are typically used to interface with a Human Interface Module (HIM). Port 2 is the default connection; port 3 is available by installing a splitter on port 2. Port 5 is supported by connecting one of the communication cards listed in Table 33 to the internal DPI comm card connection.

You can program the SMC Flex controller with the built-in keypad and LCD display or with our optional Bulletin 20-HIM LCD human interface modules. You can install a maximum of two HIM modules. Parameters are organized in a three-level menu structure and divided into programming groups.

Chapter 7 Communication

The human interface modules have two sections: a display panel and a control panel. The display panel dubplicates the 3-line, 16-character backlit LCD display and programming keypad found on the front of the SMC Flex controller.

You must use a Bulletin 20-HIM Rev3.002 or later with the SMC Flex controller.

IMPORTANT

Node addressing of the DPI communication card can be programmed via software or a hand-held DPI HIM. The on-board HIM cannot be used to address the communication card.

Keypad Descriptions

Table 34 describes the keys that are on the front of the SMC Flex controller.

Table 34 - SMC Flex Controller Keypad

Menu Button Name Function

Esc

Sel

Escape

Select

Up/Down

Arrows

Enter

For ease of programming values, after using the Enter key to edit, use the Sel key to jump to the digit that needs to be modified, then use the arrow keys to scroll through the digits.

Exit a menu, cancel a change to a parameter value, or acknowledge a fault/ alarm.

Select a digit, select a bit, or enter edit mode in a parameter screen. Will get to menu to change the language being displayed.

Scroll through options increase/decrease a value, or toggle a bit.

Enter a menu, enter edit mode in a parameter screen, or save a change to a parameter value.

If a human interface module is disconnected from the SMC Flex controller while the Logic Mask is set to 1, a “Coms Loss” fault occurs.

Extension cables are available up to a maximum of 10 m in total length.

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Chapter 7 Communication

Jog

Port 5 — DPI Communications

Port 2

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

The control panel of the 20-HIM module provides the operator interface to the controller. Table 35

Table 35 - 20-HIM Control Panel Buttons

Button Name Description

describes the buttons on the control panel.

Start

Stop The red stop button, when pressed, will halt motor operation and/or reset a fault.

The green start button, when pressed, will begin motor operation. (Proper setup of the HIM port is required.)

Jog

ATTENTION: The Bulletin 20-HIM interface module’s stop push button is not intended to be used as an emergency stop. See the applicable standards for emergency stop requirements.

ATTENTION: The external HIM has a similar programming operation to the built-in programmer, but note that there are differences.

The jog button is active only when a control option is present. Pressing the jog button will initiate the option maneuver (for example: Pump Stop).

All other controls available with the various human interface modules are nonfunctional with the SMC Flex controller.

Connect the Human Interface Module to the Controller

Figure 76 shows the connection of the SMC Flex controller to a human

interface module. Table 36

IMPORTANT

The SMC Flex controller only supports the use of DPI communication modules and DPI HIM LCD Modules. ScanPort devices are not supported by the SMC Flex controller.

provides a description of each port.

See Figure 44

for the control wiring diagram that enables start-stop control

from a human interface module.

Figure 76 - SMC Flex Controller with Human Interface Module

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Chapter 7 Communication

Table 36 - Description of Ports

Port # Description

1 Unused — not available for use 2 First 20-HIM module or 20-COMM card connected to SMC Flex controller 3 Second 20-HIM connected to SMC Flex controller 5 DPI Communication Board port

Control Enable

The Logic Mask parameter (Parameter 87) lets you configure whether a communication device (HIM or network connection) can perform control commands such as starting. you can enable or disable each communication port as required.

When a given device is enabled through the logic mask, that device is allowed to execute control commands. Disconnecting any device with the logic mask enabled results in a communication fault unless the communication fault is disabled.

When a given device is disabled through the logic mask, that device cannot execute control commands, but can still be used for monitoring. A device that is disabled through the logic mask can be disconnected without causing a fault.

IMPORTANT

Stop commands override all start commands and can be initiated from the hardwired inputs or any port regardless of the logic mask.

HIM and COMM Card Control Enable

To enable motor control from a connected human interface module or 20-COMM communication card, follow the procedure below with the connected human interface module’s programming keys.

You can start and stop the SMC Flex controller with the control panels of the Bulletin 20-HIM LCD human interface modules. However, the factory default settings disable control commands other than Stop through the serial communication port.

To enable motor control from a connected human interface module or communication module, you must take the following programming steps:

1. Disconnect the HIM and allow to power down.

2. Reconnect the HIM. On Initializing screen, the bottom right corner of LCD shows Port X

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

. Note this port number.

Chapter 7 Communication

3. Go to Logic Mask, found as follows:

Main Menu: Parameter/Communications/Comm Mask/Logic Mask (Parameter 87)

Loss of Communication and Network Faults

4. Set b0X equal to 1 (where X is the port number noted in step 2

IMPORTANT

You must set the Logic Mask to 0 before you disconnect a HIM from the

SMC Flex controller. If you do not do this, the unit faults on a “Coms Loss”

If you are enabling control from the built-in SMC Flex controller programmer, set the Logic Mask as shown in Table 37

Table 37 - Logic Mask (Parameter 87) Requirements

Mask Code

0 0000 0000 No external DPI devices are enabled 4 0000 0100 Only the 20-HIM on port 2 is enabled 8 0000 1000 Reserved for the 20-HIM-A3 Handheld HIM that is connected to Port 3

12 0000 1100 Two 20-HIMs are enabled on ports 2 and 3 32 0010 0000 Only the DPI communication card on port 5 is enabled 36 0010 0100 20-HIM on port 2 and the DPI communication card on port 5 are enabled 44 0010 1100 20-HIMs on ports 2 and 3 and the DPI communication card on port 5 are enabled

Mask Code

(Binary)

Description

The loss of communication fault will follow the functionality as defined in the DPI specification. There are separate faults for each device. Because three DPI ports are supported there will be three faults that can be generated.

SMC Flex Controllerspecific Information

DPI provides a separate network fault for each port. This fault can be generated directly by the peripheral and is separate from the Communications Loss fault (which is generated by the SMC Flex itself).

You can use the SMC Flex controller with all LCD-applicable DPI interfaces. Regardless of the type of interface being used, you can use the information in this section to configure the rest of the system.

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Chapter 7 Communication

Default Input/Output Configuration

The default configuration for I/O is 4 bytes in and 4 bytes out (TX = 4 bytes, RX = 4 bytes). The total size may very when used with a communication card. The default configuration is arranged according to the following table.

Produced Data (Status) Consumed Data (Control)

Word 0 Logic Status Logic Command

Word 1

(1) The feedback word is always Current in Phase A (Parameter 4). (2) The reference word is not used with the SMC Flex controller, however the space must be reser ved.

Feedback

(1)

Reference

(2)

IMPORTANT

The total size produced or consumed may vary, depending on the communication card being used. For more information, refer to the User Manual for the communication card.

Variable Input/Output Configuration

The SMC Flex controller supports 16-bit DataLink™, which means that you can configure the device to return additional information. The I/O message size depends on how many DataLinks are enabled. The following table summarizes the I/O data sizes.

Table 38 - I/O Data Size

Tx Size [bytes]

(8 for Ethernet options)

(12 for Ethernet options)

(16 for Ethernet options)

(20 for Ethernet options)

(24 for Ethernet options)

Rx Size

[bytes]

4 x x

8 x x x

12 x x x x

16 x x x x x

20 x x x x x x

Logic Status/

Command (16-bit)

Reference/

Feedback (16-bit)

DataLinks

A B C D

The increased transmisison sizes for Ethernet (and ControlNet) option modules is due to a required 2-word /4-byte overhead. To configure DataLink, see page 103

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

Rockwell Automation SMC Flex Soft Starters User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Preface

About This Publication

Ter mi no logy

View Parameters

Summary of Changes

Description

Operation

Starting Modes

Soft Start

Linear Speed Acceleration

Current Limit Start

Selectable Kickstart

Pump Control Mode

Dual Ramp Start

Full-voltage Start

Preset Slow Speed

Stopping Modes

Coast

Soft stop

Braking Control Modes

Slow Speed with Braking

Protection and Diagnostics

Overload

Underload

Undervoltage

Stall Protection and Jam Detection

Ground Fault

Ground Fault Trip

Ground Fault Alarm

Thermistor/PTC Protection

Excessive Starts/Hour

Overtemperature

Open Gate

Line Faults

Metering

Communication

Programming

Status Indication

Receive the Controller

Unpack the Controller

Inspect the Controller

Storage

Lifting

General Precautions

Degree of Protection

Heat Dissipation

Enclosures

Mounting

Power Factor Correction Capacitors

Protective Modules

Motor Overload Protection

Two-speed Motors

Multi-motor Protection

Electromagnetic Compatibility (EMC)

Enclosure

Wiring

Additional Requirements

New EMC Compliance – Conducted Emissions

Wiring Terminal Locations

Power Structure

Power Wiring

Line Connection

Power Lugs

Delta Connection

Control Power

Control Wiring

Controllers rated 5…480 A

Controllers rated 625…1250 A

Control Wire Specifications

Fan Terminations

Fan Power

Control Terminal Designations

Standard Controller Wiring Diagrams

Soft Stop, Pump Control, and SMB Smart Motor Braking

Preset Slow Speed