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1. 3 4 Troubleshooting 10 9 500 1000 Amp Refer to Figure 10 4 for control module removal reference 1 Disconnect all control wires to control modules 2 Loosen six control module screws 3 Unplug control module from interface board by pulling forward Figure 10 4 Removal of Control Module 500 1000A ee 6 kaa xlii pU ni di JI aa e e X 10 10 Troubleshooting Control Module Replacement The gold interconnection pins on the power modules and interface Protective Cover Removal boards are protected with a special contact lubricant Do not clean or wipe these pins ATTENTION When installing the control module make sure the power module or in
2. ShuntTrip Circuit Breaker L1 1 T1 2 e N 3 Phase e L2 3 T2 4 Input Power 135 T36 D Fast acting Branch SCR Fuses SMC Dialog Plus Protection optional Controller LA A aaa Stop e Q Q o Start i mu E Q e Q jd 32 13 14 15 We ay as a 20 SMC Dialog Plus Control Terminals eo a 22 23 2 as ae 27 28 29 W Auxiliary contac set for Fault and N O Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage 3 16 Wiring Standard Controller Figure 3 20 Typical Wiring Diagram for Single Speed Reversing Applications Wiring Diagrams cont Ld A un T12 3 Phase Input Power 4 L3r5 r3 6j R Bulletin 82 Fast acting Branch SMC Dialog Plus SCR Fuses eee Meta Optional gt Controller optional E ex ET EDO ub Reversing Contactors Uo FX OFF Stop FOR REV o Ox
3. A un ty2 3 Phase e d qr L2 3 T2 4 Input Power Pto L3 5 73 6 Magier are Fast actin Branch Existing Motor SCR Fuses SMC Dialog Plus Protection Starter optional Controller E NS Ke e P a e Up aa ib als Job pgs 16 17 18 19 20 Auxiliary contact set for Norma SMC Dialog Plus Control Terminals Internal Auxiliar Contacts Ql 22 283 22 25 we ae 298 85292 sw G Customer supplied Overload protection should be disabled in the SMC Dialog Plus controller amp Refer to the controller nameplate to verify the rating of the control power input voltage 3 12 Wiring Standard Controller Figure 3 16 Typical Wiring Diagram for Isolation Applications Wiring Diagrams cont e L1 1 T1 2 3 Phase e L2 3 T2 4 Input Power L3 5 T3 6 Isolation Fast acting Branch Contactor SCR Fuses SMC Dialog Plus Protection IC CO optional Controller CAL A pp SERI es WP e Stop e Start
4. cont e L1 1 71 2 pA e 3 Phase e L2 3 T2 4 Input Power L3 5 T3 6 Fast acting Branch SCR Fuses SMC Dialog Plus Protection optional Controller D ku man 9 lt Control Power 100 240 VA O H A 53 c X0 ne ji c 00x e 11 12 i e aS 16 17 18 19 20 e SMC Dialog Plus Control Terminals a 22 25 2A 2 28 29 30 Custom er supplied Refer to the controller nameplate to verify the rating of the control power input voltage Figure 7 6 Typical Wiring Diagram for Hand Off Auto SCANport Control Internal Auxiliar Contacts Options 7 11 Soft Stop Option Figure 7 7 Soft Stop Option Sequence of Operation 100 Motor Coast to rest Speed r Start a Run a Soft Stop Time seconds Push Button Start Closed Open Stop Closed l Open Soft Stop Closed Open Auxiliary Contacts Soft Stop Operation Fa Normal Coast to rest ea Up to speed ATTENTION The user is responsible for determining which stopping mode is best suited to th application and will meet applicable standards for operator safety on a particular machine 7 12 Options Pump Control Option Figure 7 8 Pump Control Option Seguence of Operation 10 Moto
5. Parameter Parameter Display Scale Minimum Maslmum Default User Description Number Units Factor Setting Setting Stall Delay 37 Seconds 10 0 0 10 0 0 Off Energy Saver 38 Off On Off Aux Contacts Land 2 39 Normal Up to speed Normal AW Ba 40 Normal Fault Normal Contact 3 Config 41 N O N C N O Parameter Ready Default Init Mgmt H E z Recll Frm EE Store In EE Ready Control Options Soft Stop Soft Stop Time 42 Seconds 1 0 60 0 Pump Control Starting Soft Start Current Limit Mode i 7 B and Pump Start soft Start Pump Stop Time 42 Seconds 1 0 120 Preset Slow Speed Slow Speed Select 44 Low High High Slow Speed Direction 45 Reverse Forward Forward Slow Accel Current 46 Yo FLC 1 0 450 0 Slow Running A Currant 47 Yo FLC 1 0 450 0 SMB Smart Motor Braking Braking s Current 48 FLC 1 0 400 0 Accu Stop Slow Speed Select 44 Low High High Slow Accel Current 46 Yo FLC 1 0 450 0 Slow Running Current 47 Yo FLC 1 0 450 0 Braking A Current 48 FLC 1 0 400 0 Stopping Current 51 Yo FLC 1 0 400 0 Group Basic Setup cont Advanced Setup Parameter Information B 3 Table B 1 cont Parameter List Parameter Parameter Display Scale Minimum Masini m Default User Description
6. ely It paz als puo pog 16 17 18 19 20 SMC Dialog Plus Control Terminals ON Internal Auxiliar Contacts Zi a 23 28 259 ae 2y 28 29 30 Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input rating Notes 1 Minimum transition time for reversing direction is 1 2 second 2 Phase Reversal protection must be disabled in reversing applications Wiring 3 17 Figure 3 21 Typical Wiring Diagram for Two speed Applications iL t LIA T1 2 CX 3 Phase X m L2 3 T2 4 4 tH Input Power l HT een L3 5 13 6 DS Branch SMC Dialog Plus H Mo Protection Controller au Fast acting YY SCR Fuses i au optional AA UWAN 4 Two speed Motor Starter MI E Stop High o 2 2 AA Bb H Po ae E o m 5 LO poe Jue G gt L e Tsee J u 9 e rd E it p32 p o9 px p 35 Wwe xy poe 9 20 SMC Dialog Plus B Control Terminals Internal Auxiliar Contacts 21 22 23 24 25 a 2 28 29 30
7. Customer supplied Note The Dual Ramp feature is available only with the standard control version 3 10 Wiring Standard Controller Figure 3 14 Typical Wiring Diagram for Start Stop Control via the SCANport Wiring Diagrams cont Note Use this wiring diagram when start stop will come from either a Bulletin 1201 human interface module or a Bulletin 1203 communication module connected to the SMC Dialog Plus controller s SCANport e L1 1 T1 2 a 3 Phase e L2 3 T2 4 Input Power 13 5 T36 Fast acting Branch SCR Fuses SMC Dialog Plus Protection optional Controller wise ey D NN e ES o t E 9 ial 12 13 14 15 16 17 18 19 20 SMC Dialog Plus Control Terminals M N Internal Auxiliary Contacts All 22 23 24 25 26 27 28 29 30 Customer supplied T Ifthe Soft Stop Pump Control or the SMB Smart Motor Braking option is installed place additional jumper to terminal 15 amp Refer to the controller nameplate to verify the rating of the control power input voltage Wiring 3 11 Figure 3 15 Typical Wiring Diagram for Retrofit Applications
8. Address 0123456789 Address 0123456789 N10 0 gt M0 1 100 N10 10 gt M0 1 110 N10 20 gt M0 1 120 N10 30 gt M0 1 130 N10 40 gt M0 1 140 N10 50 gt M0 1 150 N10 60 gt M0 1 160 N10 70 gt M0 1 170 8 14 Serial Communications Remote I O Examples cont BTR Datafile Forma A BTR Datafile must also be defined to accept the data read during the BTR operation For this example the BTR Datafile will begin at address N10 110 BTR Datafile Header Word PLC Decimal Value Number of Parameter Values to Read Y Starting Parameter Number Address 0 1 2 3 4 5 6 7 8 9 N10 110 AP Ba Ua N10 120 3 36 9 10 11 amp Message OK 1 Message Error 32767 Note The values of parameters 1 11 read from the SMC Dialog Plus controller are loaded into addresses N10 114 through N10 124 Data Path for the BTR Rung 2 5 of the sample ladder logic program that follows executes a COP instruction to copy the dat obtained from the BTR to program defined integer file Address 0123456789 Address 0123456789 M1 1 100 3 N10 100 M1 1 110 gt N10 110 M1 1 120 gt N10 120 M1 1 130 gt N10 130 M1 1 140 gt N10 140 M1 1 150 gt N10 150 M1 1 160 gt N10 160 M1 1 170 gt N10 170 Serial Communications 8 15 Example 2 Ladde
9. Bits 4 15 are not used when more than one bit is asserted Other bits will be ignored until the stop bit is reset Assert the Option Command bit to initiate an option maneuver such as Pump Stop Refer to Figure 3 14 on page 3 10 for the applicable wiring diagram to achieve start stop control via the SCANport 8 2 Serial Communications Control Enable Per factory programming stop is the only control command active on the SMC Dialog Plus controller when the SCANport is utilized To enable motor control from a programmable logic controlle through a communication module follow the programming procedur below Description Action Display STOPPED 0 0 AMPS Press any key to access CHOOSE MODE the Choose Mode n M function o v 2 Scroll with the Up Down keys until the Program n zd M i n option appears ee NU 3 Press the Enter key to access the Program PROGRAM option ua 4 Scroll with the Up Down keys to the Linear List n AE M Pvt option Press the Enter key to access the Linear List programming group a aa ear VOLTS PHASE A B 0 VOLTS 1 Scroll with the Up Down Note keys to parameter number n a M ree 0 85 85 Logic Mask Press the Select key to move the cursor to the SEL LOGIC MASK second line to modify the 0 85 parameter Press the Up key until the n LOGIC MASK value 4 appears a 4 85 Press the Enter key to
10. 1 8 Figure 1 9 JamDetection 1 8 Figure 1 10 ScanPort Location 1 11 Figure 1 11 Built in Keypad and LCD 1 11 Figure 1 12 Soft Stop Option 1 12 Figure 1 13 Pump Control Option 1 13 Figure 1 14 Preset Slow Speed Option 1 13 Figure 1 15 SMB Smart Motor Braking Option 1 14 Figure 1 16 Accu StopOption 1 15 Figure 1 17 Slow Speed with Braking Option 1 15 Figure 2 1 Dimensions 24 35 and 54 Amp Controllers 2 4 Figure 2 2 Dimensions 97 and 135 Amp Controllers 2 5 Figure 2 3 Dimensions 180 through 360 Amp Controllers 2 6 Figure 2 4 Dimensions 500 Amp Controller 2 7 Figure 2 5 Dimensions 650 1000 Amp Controllers 2 8 Figure 2 6 Typical Wiring Diagram for Power Factor Correction Capacitors 2 9 Figure 2 7 SMC Dialog Plus Controller with Human Interface Module 2 13 Figure 2 8 SMC Dialog Plus Controller with Communication Module 2 16 Figure 2 9 Converter Module Connection Interface 2 17 toc viii Table of Contents Figure 2 10 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 Figure 3 15 Figure 3 16 Figure 3 17
11. 6 0i 2 Pull back moving part connector body to disconnect AZ cable from the SCANport connection SDDL DDOL E TN p UDUNDUUDUUUU U NEC Allen Bradley SMC Dialog Plus MEE dl fem A F 7 Human Interface Modul Control Enable To enable motor control from a connected human interface module follow the procedure below with the connected human interface module s programming keys Series A and Series B human interface modules require different procedures Be sure to use the correct table Note 2 14 Installation Human Interface Module cont Series A Human Interface Module Description Action Display STOPPED 0 0 AMPS wa a 1 Press any key to access the Choose Mode function fsf a y fe CHOOSE MODE 2 Scroll with the Up Down keys until the Program option appears B u CHOOSE MODE PROGRAM QS 3 Press the Enter key to access the Program option PROGRAM 4 Scroll with the Up Down keys to the Linear List option PROGRAM LINEAR LIST er a 5 Press the Enter key to access the Linear List programming group fee TN VOLTS PHASE A B 0 VOLTS 1 po MC 6 Scroll with the Up Down keys to parameter n i M LOGIC MASK number 85 Logic 0 85 Mask
12. 3 15 Typical Wiring Diagram for Single Speed Reversing Applications 3 16 Typical Wiring Diagram for Two speed Applications 3 17 Typical Wiring Diagram for Hand Off Auto SCANport Control 3 18 Menu Structure Hierarchy 4 2 Memory Block Diagram 4 6 Typical Wiring Diagram 1 6 Typical Retrofit Wiring Diagram 1 1 Typical Wiring Diagram for Applications Requiring an Isolation Contactor 1 8 Typical Wiring Diagram for Applications Requiring a Bypass Contactor 1 9 Typical Wiring Diagram for Two wire Control or Programmable Controller Interfacing 1 10 Typical Wiring Diagram for Hand Off Auto SCANport Control 1 11 Soft Stop Option Sequence of Operation 1 12 Pump Control Option Sequence of Operation 7 13 Tables Figure 7 9 Figure 7 10 Figure 7 11 Figure 7 12 Figure 7 13 Figure 7 14 Figure 7 15 Figure 7 16 Figure 7 17 Figure 7 18 Figure 7 19 Figure 7 20 Figure 7 21 Figure 9 1 Figure 10 1 Figure 10 2 Figure 10 3 Figure 10 4 Figure 10 5 Figure 10 6 Figure 10 7 Figure 10 8 Figure 10 9 Table 2 A Table 2 B Table 2 C Table 2 D Table 3 A Table 3 B Table 3 C Table 3 D Table 3 E Table 4 A Table 5 A Table of Contents toc ix SMB Smart Motor Braking Sequence of Operation 7 14 Typical Wi
13. Customer supplied Q9 Two speed consequent pole installations amp Refer to the controller nameplate to verify the rating of the control power input voltage 3 18 Wiring Standard Controller Wiring Diagrams cont Figure 3 22 Typical Wiring Diagram for Hand Off Auto SCANport Control o L1 1 T1 2 3 Phase L2 3 T2 4 Input Power L3 5 T3 6 Fast acting Branch SCR Fuses SMC Dialog Plus Protection optional Controller ku H S n e o O O O oe Me iil a2 13 14 15 16 17 18 19 20 e SMC Dialog Plus Control Terminals Internal Auxiliar Contacts 21 22 23 24 25 26 27 28 29 30 Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage Copter 4 Programming Overview This chapter provides a basic understanding of the programming keypad built into the SMC Dialog Plus controller This chapter also describes programming the controller by modifying the parameters Keypad Description The keys found on the front of the SMC Dialog Plus controller ar described below Escape Pressing the Escape key causes the programming system ESC to move up one level in the menu
14. mum Allen Bradley SMC Dialog Plus Z 1203 GD1 No Bei pee TF 7 il U lu Communication Module SMC oe Plus Bulletin 1202 SCANport Cable Controller Qo Note Itis critical that during the system design phase that each device on the Remote I O link is allocated a unique segment of the PLC s I O image table This is accomplished by coordination of the devices rack address rack size and starting group address n 87654321 O Serial Communications 8 19 1203 GD1 Communication Module Switch Settings The following information is provided to explain the required 1203 GD1 communication module switch settings for this example Refer to the 1203 GD1 manuals for further details related to the switch settings Example Information Description Switch Setting MAS ya SUR or Sub off Starting Group Address 0 SW2 Switches 1 amp 2 On Last Rack No SW2 Switch 3 Off Hold Last State Yes SW2 Switch 4 On Fault on Comm Loss Yes SW2 Switch 5 On Fault Controller No SW2 Switch 6 Off R I O Baud Rate 115k SW2 Switch 7 On Switch 8 Off Block Transfer Yeso SW3 Switch 1 On Logic Cmd Status Yeso SW3 Switch 2 On Reference Feedback No SW3 Switch 3 Off Datalinks NooO SW3 Switch
15. Jam detection allows the user to determine the jam level up to 999 of the motor s FLC rating and the delay time up to 10 0 seconds for application flexibility Figure 1 8 Stall Protection 60 0 Percent Full Load Current lt Programmed Start Time Stall gt Time seconds Figure 1 9 Jam Detection Percent ee User Programmed Trip Level Current 100 Running Jam Time seconds Jam detection is disabled during slow speed and braking operation Product Overview 1 9 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 will attempt to start the motor a total of three times Line Faults The SMC Dialog Plus controller continually monitors line conditions for abnormal factors Pre start protection includes e Power Loss with phase indication Line Fault with phase indication Power loss Missing load connection Shorted SCR Running protection includes e Line Fault no phase indication Power loss Missing load connection Shorted SCR Additional programmable parameters are provided for the following protective features e Undervoltagec can be adjusted from 0 to 99 of the programmed line voltage and has a programmable delay time of
16. po O 6 i x2 x9 wt d XS iy xe 2 20 Auxiliary contact Set for Normal B SMC Dialog Plus Control Terminals Internal Auxiliar Contacts al 2 23 a as wae 927 2 2 ES Refer to the controller nameplate to verify the rating of the control power input voltage Customer supplied Internal Auxiliar Contacts Wiring Figure 3 17 Typical Wiring Diagram for Bypass Applications ts L1 1 T1 2 3 Phase t L2 3 T2 4 Input Power t L3 5 3 6 Bulletin 82 Fast actin P Branch ET SCR cee Tur tection odule j ic oO optional Controller Wakae ac Bypass Contactor BC ND e Stop D C QO Stat Z mO O gt iat 12 iss x34 15 16 17 18 19 20 Auxiliar contacts set fo Up to spee SMC Dialog Plus Control Terminals To Bulletin 82 Converter i Module A A a vs AA 2 a 27 28 29 30 Fanning Strip Customer supplied Q9 TheBUulletin 825 Converter Module is required when the SMC Dialog Plus controller will be providing motor overload protection
17. 7 Press the Select key to move the cursor to the SEL LOGIC MASK second line to modify 0 85 the parameter ll 8 Press the Up key until the value 4 appears LOGIC MASK 4 85 9 Press the Enter key to accept the new setting Zero and 4 are the only valid settings LOGIC MASK 4 85 M Note Ifahuman interface module is disconnected from the SMC Dialog Plus controller while the Logic Mask is set to 4 a Comm Fault will occur Description Installation Series B Human Interface Module Action 2 15 Display STOPPED 0 0 AMPS Press any key to access the Choose Mode function Bana Scroll with the Up Down keys until the Control Logic option is presented B i CHOOSE MODE CONTROL STATUS Press the Enter key to access Control Logic options t C CONTROL LOGIC DISABLE SS d Press the Select key to access the settings available CONTROL LOGIC DISABLE LL M M Note Use the Up Down keys to obtain the Enable n or M Sis LOGIC option Press the Enter key to CONTROL LOGIC accept ENABLE If ahuman interface module is disconnected from the SMC Dialog Plus controller while Control Logic is enabled a Comm Fault will occur 2 16 Installation Communication The Bulletin 1203 communication module allows the user to connect Modules the SMC Dialog Plus controller to var
18. 10 24 Gate and Thermistor Lead Identification 180 1000A 10 25 Maximum Heat Dissipation 2 2 Minimum Ventilation Openings 2 3 Recommended FUSES 2 10 Converter Module Selection Guide 2 16 Lug Wire Capacity 3 3 Tightening Torgue 3 3 Lug Wire Capacity and Tightening Torque 3 4 Heatsink Fan Control Power 3 4 Control Wiring and Tightening Torque 3 4 Parameter Linear List 4 4 Motor Codes 5 2 toc x Table of Contents Table 8 A Table 8 B Table 8 C Table 10 A Table 10 B Table 10 C Table 10 D Table 10 E Table B 1 Logic Control Data 8 1 SMC StatusData 8 3 Fault Code Cross reference 9 2 SMC Fault Display Explanation 10 3 Motor Will Not Start No Output Voltage to the MOtOr 10 4 Motor Rotates but does not accelerate to fullspeed 10 4 Motor Stops While Running 10 4 Miscellaneous Situations 10 5 Parameter Text Display Unit Cross Reference B 5 Description Operation Chapter 1 Product Overview The SMC Dialog Plus controller offers a full range of starting modes as standard e Soft Start with Selectable Kickstart
19. Pollution Degree 2 Appendix B Parameter Information Table B 1 Parameter List Parameter Parameter Display Scale Default User Group Description Number Units Factor Minimum Maximum Setting Setting Voltage Phase A B 1 Volts 1 Voltage Phase B C i E 7 7 E 5 Voltage zA Phase C A 3 Volts 1 Current Phase A 4 Amps 10 Current Phase B 5 Amps 10 Metering Current Phase C 6 Amps 10 Wattmeter 7 kW 10 Kilowatt 8 KWH 1 E B Hours papag 9 Hours 1 5 Time ed 10 7 100 7 Factor Motor Thermal 11 1 2 H a Usage Clear Fault 18 No Yes No Fault Buffer 1 i E E n i Fault Buffer 2 2 B 1 7 E E Faults Fault Buffer 3 a 2 gt Fault Buffer 44 22 E i E 7 z 7 Fault Buffer 5 23 Bi 1 z i E E Standard Soft Stop Pump Control Preset Slow SMC Option 14 Speed Smart Motor Braking Accu Stop or Slo Speed with Braking Starting Mode 28 Soft Stop Current Limit Soft Start Ramp Time 1 30 Seconds 1 0 30 10 Basic Setup initial 7 D TAE 31 LRT 1 0 90 70 1 currentiLimit 34 FLC 1 50 600 50 Level Kickstart Time 35 Seconds 10 0 0 2 0 0 0 Off Read only capability B 2 Group Basic Setup cont Parameter Information Table B 1 cont Parameter List
20. SMC Rating Line Voltage Part Number 24A 200 480V 40382 899 02 35A 200 480V3 40382 899 03 54A 200 480V 40382 899 03 97A 200 480V 40382 806 01 135A 200 480V 40382 806 03 180A 200 480V 40382 809 03 240A 200 480V 40382 809 05 360A 200 480V 40382 809 07 500A 200 480V 40382 810 01 650A 200 480V 40382 818 01 720A 200 480V 40382 818 03 850A 200 480V 40382 819 01 1000A 200 480V 40382 819 03 24A 200 600V 40382 899 04 35A 200 600V 40382 899 04 54A 200 600V 40382 899 04 97A 200 600V 40382 806 02 135A 200 600V 40382 806 04 180A 200 600V 40382 809 04 240A 200 600V 40382 809 06 360A 200 600V 40382 809 08 500A 200 600V 40382 810 02 650A 200 600V 40382 818 02 720A 200 600V 40382 818 04 850A 200 600V 40382 819 02 1000A 200 600V 40382 819 04 Renewal Parts Description SMC Rating Line Voltage Part Number 24 500A 200 480V N A 650A 200 480V 40382 811 01 720A 200 480V 40382 811 03 850A 200 480V 40382 812 03 1000A 200 480V 40382 812 01 Individual SCRs 24 500A 200 600V N A 650A 200 600V 40382 811 02 720A 200 600V 40382 811 04 850A 200 600V 40382 812 04 1000A 200 600V 40382 812 02 24 135A A N A 180 360A A 40382 805 01 Interface Board 500A A 40382 814 01 650 1000A A 40382 814 02 24 54A A N A 97 135A A 40382 807 01 Heatsink Fans 180 360A A 40382 804 01 500A A 40382 813 01 650 1000A A 40382 815 01 24 360A A N A MOV Fuse 500 1000A A 40382 816 01 24 360
21. Before you begin programming it s important to understand how the controller memory is e structured within the SMC Dialog Plus controlle e used on power up and during normal operation Refer to Figure 4 2 and the explanations below Figure 4 2 Memory Block Diagram EEPRO lt gt RAM lt ROM DEOM Random Access Memory RAM This is the work area of the controller after it is powered up When you modify parameters in the Program mode the new values are stored in RAM When power is applied to the controller paramete values stored in the EEPROM are copied to RAM RAM is volatile and the values stored in this area are lost when the controller is powered down Read only Memory ROM The SMC Dialog Plus controller comes with factory default parameter values These settings are stored in nonvolatile ROM and are displayed the first time you enter the Program mode Electrically Erasable Programmable Read only Memory EEPROM The SMC Dialog Plus controller provides a nonvolatile area for storing user modified parameter values in the EEPROM Programming 4 7 Using Parameter Management Description Action Display Saving to EEPROM To ensure that the newly modified parameters are notlost if control power is AAEM ETER MGMT STORE IN EE removed from the controller store the values into EEPROM Recalling from EEPROM Parameters stored in EEPROM can be manually brought to RAM
22. controller setup 4 11 advanced setup 4 12 controller temperature temp 9 5 current limit start description of 1 3 programming parameters 4 9 D datalinks 8 4 diagnostics 1 5 1 7 9 1 dimension drawings 180A 360A controllers 2 6 24A 35A and 54A controllers 2 4 500A controllers 2 7 650A 1000A controllers 2 8 97A and 135A controllers 2 5 dual ramp start description of 1 4 programming parameters for 4 10 wiring diagram of 3 9 E EMC 2 18 2 19 enclosures 2 2 2 3 energy saver 1 5 ESD effects of 2 2 excess starts per hour 1 10 Index F fan power 3 5 fan terminations 3 5 180A 500A 3 5 650A 1000A 3 5 97A and 135A 3 5 fault auxiliary contact 9 2 buffer 9 2 codes 9 2 definitions comm fault 9 5 controller temp 9 5 excess starts hour 9 5 jam detection 9 4 line fault 9 3 open gate 9 5 overload protection 9 4 overvoltage and undervoltage protection 9 3 phase reversal 9 3 power loss 9 3 stall protection 9 4 underload 9 4 voltage unbalance 9 4 display 9 1 full voltage start description of 1 4 programming parameters 4 10 fuses recommended 2 10 G grounding provision 3 6 H heat dissipation 2 2 human interface module 7 1 human interface module HIM 2 12 connecting the HIM to the controller 2 13 control enable 2 13 series A human interface modules 2 14 series B human interface modules 2 15 I inspection 2 1 installatio
23. 2 18 US egaa a a A 2 18 Grounding sswanaanana 2 18 WINO KA ee r A r S 2 19 Accessory Requirements aaa 2 19 Terminal Locations s 3 1 Power WIiring anawannans 3 3 Control POWer anaananaa 3 4 Control Voltage 3 4 Control Wiring 3 4 FaN POW III a A iaidieid iiss 3 5 Fan Terminations seansas on Ren 16e NR 3 5 Control Terminal Designations 3 6 Grounding Provision 3 6 Standard Controller Wiring Diagrams 3 7 BP eee eet ee eee T Pee eer er Tee eT errr rT eT e 4 1 Keypad Description 4 1 Programming Menu cscs se nee coma oco 4 1 Password TE TETTETETEEETEETTEETETE 4 5 BORIC Mer 4 5 ParameterManagement aas 4 6 Random Access Memory RAM 4 6 Read only Memory ROM ansauanaa 4 6 Electrically Erasable Programmable Read only Memory EEPROM 4 6 Using Parameter Management 4 7 Parameter Modification 4 8 SOM BIB nh neh eeeKatatadndadadabatadadedadasataes 4 9 C rrent III 4 9 Dual Ramp Slt vss s erer ER EY Oe Rer es 4 10 Full Voltage Start 4 10 Basie SB ee ee
24. Rockwell Automation SMC Dialog Plus User Manual Controller Bulletin 150 KASS BRE WS Sect pot eo I ROOD e Allen Bradley SMC Dialog Plus ee Neea y oO Co LL File Name AB SMCController 150 user D1098 Purpose of this Document Document Update Bulletin 150 SMC Dialog Plus Controller For 24 1000A Ratings This document updates information found in the SMC Dialog Plus User Manual Publication 150 5 3 January 1996 It addresses issues related to current measurement firmware releases 1 05L 1AOSL and IBO3L without the use of the Bulletin 825 converter module for IEC type motors Refer to the table below when viewing pages 5 1 and 5 2 of the User Manual Summary of Update Affected Action To Take Page s Add this information to the Motor Data Entry ATTENTION After you have programmed the controller settings you must save them to the controller s memory See pages 4 6 and 4 7 ATTENTION It is critical that you implement the conversions provided below to ensure proper thermal motor overload protection Addition Correction Program only horsepower ratings converting kW ratings if applicable See conversion example below Motor kW Rating Conversion To convert kW to horsepower multiply by 1 34 5 1 table under the paramelsr Example 132kW x
25. SW2 Logic Command Logic Status Set SW2 Switches 1 and 2 to On Switch Setting NE Starting Module Group 0 B Block Transfer On BN Starting Module Group 0 N Logic Cmd Sts On Last Rack Setting On o MM Reference Fdbk Off 0 NE v Hold Last State On ZEN Datalink a off E Fault on Comm Loss On BE Datalink B Off Fault Controller On B Datalink cor Lex N RIO Baud Rate 57 K B Datalink D off E RIO Baud Rate 57 K B Truncate Last Datalink Software Configuration Settings RIO Configuration Using G Files The block transfer operation requires that the G File of the 1747 SN scanner module be configured The scanner s G File settings are based on the devices that you have on the RIO link It consists of setting logical device starting addresses and the logical device image size of each physical device adapter with which the scanner communicates The G File is configured as part of the I O configuration procedure for the processor file You edit the data offline under the I O configuration menu only After the 1747 SN specialty I O module is assigned to a slot access the SPIO CONFIG F9 menu instruction in the Advanced Programming Software APS The configuration settings are set as follows 1 F5 ADVNCD SETUP to specify input size output size scanned input scanned output MO and MI file sizes This SMC Dialog application exampl
26. 25 lbs All dimensions are approximate and are not intended for manufacturing purposes Refer to the nearest Allen Bradley sales office for complete dimension drawings Installation 2 5 Figure 2 2 Dimensions 97 and 135 Amp Controllers C Power Terminal E M10 Bolt 4 H D 6 Places f o a HREHHREHHHHREHER Allen Bradley SMC Dialog Plus o C pL Esse OQ LA LPA S o OZ 2 Os Ge Ge Ground To Screw M6 g He Fan 1 28lin Terminals 0 7 14 mm rm es 4 Mtg Holes A B C Approx Unit Width Height Depth E d 6 H Ship Wt 97A mm 248 336 256 2 128 220 250 40 4 14 10 4 kg Controller in 9 49 64 13 15 64 10 3 32 5 3 64 8 21 32 9 27 32 1 39 64 9 16 23 Ibs 135A mm 248 336 256 2 128 220 250 40 4 14 11 8 kg Controller in 9 49 64 13 15 64 10 3 32 5 3 64 8 21 32 9 27 32 1 39 64 9 16 26 Ibs All dimensions are approximate and are not intended for manufacturing purposes Refer to the nearest Allen Bradley sales office for complete dimension drawings 2 6 Mounting cont Installation Figure 2 3 Dimen
27. B M Linear Metering Calibrat List a 5 Q4 Basic Setup q p Advanced Setup p Faults ep See 4 Language Chapter 6 Chapter 5 Esc GROUP LEVEL The SMC Dialog Plus controller does not support EEPROM Link Process or Start up modes Steps back one level Control Status and Search are only available when using a Series B Bulletin 1201 human interface module Password protected e 8 o English is currently the only available language Programming Figure 4 1 Cont Menu Structure Hierarchy eo D M Steps back one level English is currently the only available language For further information on parameters see Appendix B For further information on parameter management see pages 4 6 and 4 7 Linear so Calibrat gt see Basic Setup 4 y Advanced Setu p Faults See gt Language List Chapter 6 Chapter 5 Q GROUP LEVEL 4 4 Programming Programming Menu cont Table 4 A Parameter Linear List Parameter No Description Parameter No Description 1 Volts Phase A B 45 Slow Speed Dir 2 Volts Phase B C 46 Slow Accel Cur 3 Volts Phase C A 47 Slow Running Cur 4 Current Phase A 48 Braking Current 5 Current Phase B 49 Factor
28. Display CURRENT PHASE A THHE AMPS Scroll to the next parameter to save the Calibrate group settings PARAMETER MGMT READY Press the Select key Scroll with the Up Down keys to Store In EE selection Press the Enter key to save the settings to EEPROM PARAMETER MGMT STORE IN EE ATTENTION After calibration is completed program the desired overload class and save the setting to the controller s EEPROM ATTENTION This method of current measurement is not applicable to multi motor installations or resistive heating loads Utilization of the Bulletin 825 converter module is required for these applications if current measurement is required Overview Viewing Metering Data Metering Caper 6 While the SMC Dialog Plus controller operates your motor it also monitors several different parameters providing a full function meteringo package To access the metering information follow the procedure below Description Action Display AT SPEED Ht AMPS 1 Press any button to access the Choose Mode menu MM Bam 2 Scroll with the Up Down keys until the Display option is shown B u CHOOSE MODE DISPLAY _ 3 Press the Enter key to CHOOSE GROUP select the Display option 2 as Mh V ee 4 Scroll with the Up Down keys until the Metering n or M o ME option is displayed PA 5 Press the Enter key to access
29. Example Settings Programming 4 13 Parameter Option Phase Reversal This parameter allows the user to enable phase reversal Off On protection Starts Per Hour Allows the user to limit the number of starts during a one 0 99 0 is the Off setting hour period Restart Attempts Determines the number of attempts the controller will 0 to 5 make to automatically restart the motor after a fault Restart Delay Provides a delay period prior to a restart attempt VEO eos ETM Reset Allows the user to reset the accumulated value of the Off On elapsed time meter Parameter Management The newly programmed parameter values can be saved Ready Default Init Recll to memory or the factory defaults parameter values can Frm EE Store In EE be recalled The Auto Restart feature is not available The new programmed parameter values will not be stored to the EEPROM without the user s direction in parameter management Store In EE Undervoltage o With Line Voltage programmed for 480V and the Undervoltage level programmed for 80 the trip value is 384V Overvoltage With Line Voltage programmed for 240V and the Overvoltage level programmed for 115 the trip valueis 276V Jam o With Motor FLC programmed for 150 Amps and the Jam level programmed for 400 the trip value is 600 Amps Underload o With Motor FLC programmed for 90 Amps and the Underload level programmed for 60 the trip value is 54 Amps
30. Figure 1 1 Soft Start Percent Voltage 1 Initial Torque Start gt a Run gt Time seconds Product Overview 1 3 Selectable Kickstart This feature provides a boost at startup to break away loads that require a pulse of high torque to get started This is intended to provide a pulse of current that is 550 of full load current Selectable kickstart is user adjustable from 0 0 to 2 0 seconds Figure 1 2 Selectable Kickstart Percent Voltage Kickstart 100 Initial Torque 1 I 1 Li I I l 1 I i 1 1 Start Run gt Time seconds Current Limit Starto This starting mode provides a fixed reduced voltage start it is used when limiting maximum starting current is necessary The Current Limit level is user adjustable from 50 to 600 of the motor full load ampere rating and the current limit time is user adjustable from 0 to 30 seconds If the SMC Dialog Plus controller senses that the motor has reached the up to speed condition during the current limit starting mode the output voltage automatically switches to full voltage Figure 1 3 Current Limit Start Percent Full Load Current 600 50 lt Start gt Time seconds amp Kickstartis also available with Current Limit Start TheCurrent Limit Start mode design is based on a motor with a locked rotor current rati
31. JOG condition the jog button when pressed will initiate braking to slow speed operation The controller will maintain slow speed operation as long as the jog button is pressed The green start button when pressed will commence motor acceleration to full speed Slow Speed with Braking The red stop button when pressed will provide a coast stop With a stopped status the jog button when pressed will initiate slow speed motor operation From an at speed condition the jog button when pressed will initiate a brake stop rm o ATTENTION The Bulletin 1201 human interfac module s stop push button is not intended to be used as an emergency stop Refer to applicable standards for emergency stop requirements Programming Parameters Options 7 3 The following table provides the option specific parameters that are provided with each control option These parameters are in addition to those already discussed in the Basic Setup Advanced Setup Metering and Calibration groups Diagrams supporting the options described below are shown later in this chapter Option Soft Stop Parameter SMC Option This parameter identifies the type of control present and is not user programmable Range Soft Stop Soft Stop Time Allows the user to set the time period for the soft stopping function 0 60 seconds Pump Control Preset Slow Speed SMC Option This parameter identifies the type
32. The average value of the three phase to phase voltages is utilized The largest value of the three phase currents is utilized Overview Motor Data Entry Calibration Cape 5 The Calibrate programming group allows the user to set parameters to calibrate the controller to the connected motor It is important to correctly input the data to achieve the best performance from you controller ATTENTION For overload protection it is critical that the data be entered as it appears on the motor nameplate In the Program mode enter the correct values into the Calibrate group Parameter Overload Class The factory default setting disables overload protection To enable it enter the desired trip class in this parameter See pages 1 5 and 1 7 for further details and trip curves Option Off 10 15 20 30 Display OVERLOAD CLASS Overload Reset Allows the user to select either a oD ne kN OVERLOAD RESET manual or auto reset after an overload Manual Auto MANUAL fault Motor HP Rating TORRAIN T Enter the value from the motor s 0 0 6 553 5 HP EHE HP nameplate Motor kW Rating ya AA Enter the value from the motor s 0 0 6 553 5 kW MOTOR KW RATING nameplate PREK Line Voltage Enter the system voltage in this parameter This must be done to 1 9 999V LINE VOLTAGE ensure optimum motor performance THHHIOLTS and correct operation of undervoltage and overvoltage protection
33. 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 The following guidelines are provided for EMC installation compliance Enclosure Install the product in a grounded metal enclosure Grounding Connect a grounding conductor to the screw or terminal provided as standard on each controller Refer to Figure 2 1 through Figure 2 5 for grounding provision location Installation 2 19 Wiring Wire in an industrial control application can be divided into three groups power control and signal The following recommendations for physical separation between these groups is provided to reduce the coupling effect e Different wire groups should cross at 9 inside an enclosure e Minimum spacing between different wire groups in the same tray should be six inches 16 cm e Wire runs outside an enclosure should be run in conduit or have shielding armor with equivalent attenuation e Different wire groups should be run in separate conduits e Minimum spacing between conduits containing different wire groups should be three inches 8 cm Accessory Requirements When connection of the Bulletin 825 converter module or Bulletin 1202 communication cable is required a ferrite core suppressor Fair Rite PN 2643802702 or equal should be used in conjunction Mount the suppressor as
34. standard controller wiring diagrams 3 7 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 3 17 3 18 7 10 7 18 Starting modes 1 2 Status indication 1 11 storing the controller 2 1 T terminal locations 3 1 180 360A 3 2 24 54A 3 1 500A 3 2 650 1000A 3 3 97 and 135A 3 1 power wiring 3 3 24 544 3 3 97 1000A 3 3 trip curves 1 7 troubleshooting 10 1 fault display explanation 10 3 flowchart 10 2 troubleshooting tables 10 4 10 5 U underload 1 9 9 4 undervoltage 1 9 undervoltage protection 9 3 unpacking 2 1 V viewing metering data 6 1 voltage unbalance 1 9 9 4 W wiring 3 1 N Rockuvell Automation Rockwell Automation helps its customers receive a superior return on their investment by bringing M jogether leading brands in industrial automation creating a broad spectrum of easy to integrate products These are supported by local technical resources available worldwide a global network of system solutions providers and the advanced technology resources of Rockwell Worldwide representation Argentina Australia Austria Bahrain Belgium Bolivia Brazil e Bulgaria e Canada Chile China People s Republic of e Colombia Costa Rica Croatia e Cyprus Czech Republic Denmark Dominican Republic Ecuador Egypt El Salvador Finland France e Germany Ghana Greece Guatemala Honduras Hong Kong Hungary Iceland
35. 0 of the1747 SDN s command wor d word 0 1747 SDN Enable Bit O m Iu 0 Rung 1 When the START command is initiated at the RSView station the SLC processor sets the output bit mapped to the SMC Dialog Plus controller s logic control word start bit The branch provides a logic latched circuit which exerts the START command until input from the SMC Dialog Plus controller s status word indicates that it has received the command and has responded appropriately The SMC Dialog Plus controller will start if no STOP command is being issued by the SLC or any other contro device Start CMD SMC From START RSVIEW Command B3 Oe Tu Y al V 7 SMC SMC P START Running Command Bit Q I7 es 17 J E j E T 1 Rung 2 When the STOP command is initiated at the RSView station the SLC processor sets the output bit mapped to the SMC Dialog Plus controller s logic control word stop bit The branch provides a logic latched circuit which exerts the STOP command until input from the SMC Dialog Plus controller s status word indicates that it has received the command and has responded appropr iately Stop CMD SMC From STOP RSVIEW Command B3 O UL a V 272 0 SMC SMC STOP Running Command Bit QUIT li 17 zac j E 0 1 8 34 Serial Communications Rung 3 When the FAULT RESET command is initiated at the RSView station the SLC processor sets the output b
36. 0 to 99 seconds e Overvoltageo can be adjusted from 0 to 199 of the programmed line voltage and has a programmable delay time of 0 to 99 seconds e Phase reversal protection can be toggled either On or Off e Voltage unbalance protection can be programmed for trip levels of 0 to 25 with a programmable delay time of 0 to 99 seconds Underloads Utilizing the underload protection of the SMC Dialog Plus controller motor operation can be halted if a sudden drop in current is sensed The SMC Dialog Plus controller provides an adjustable underload trip setting from 0 to 99 of the programmed motor full load current rating Trip delay time can be adjusted from 0 to 99 seconds amp Undervoltage overvoltage and voltage unbalance protection are disabled during braking operation Phase reversal protection is functional only at pre start amp Underload protection is disabled during slow speed and braking operations 1 10 Product Overview Protection and Diagnostics cont Metering Excessive Starts Hour The SMC Dialog Plus controller allows the user to program th allowed number of starts per hour up to 99 This helps eliminate motor stress caused by repeated starting over a short time period Overtemperature The SMC Dialog Plus controller monitors the temperature of th SCRs by using internal thermistors When the power poles maximum rated temperature is reached SCR firing is inhibited An overtemperature
37. 1 The Energy Saver feature is not available when a bypass contactor is used 2 When Energy Saver and Phase Rebalance are both enabled Phase Rebalance takes precedence in operation With the Phase Rebalance feature enabled the SMC Dialog Plus controller continuously monitors the incoming three phase line voltage and automatically adjusts the output voltage to balance the three phase currents drawn by the motor Notes 1 Phase Rebalance requires that the Bulletin 825 converte module is utilized 2 Phase Rebalance is not active during bypass operation 3 When Phase Rebalance and Energy Saver are both enabled Phase Rebalance takes precedence in operation The SMC Dialog Plus controller provides the protective and diagnostic features described below Overload The SMC Dialog Plus controller meets applicable requirements as a motor overload protective device Thermal memory provides added protection and is maintained even when control power is removed The built in overload algorithm controls the value stored in Parameter 11 Motor Thermal Usage an Overload Fault will occur when this value reaches 100 The programming parameters below provide application flexibility and easy setup Parameter Range Overload Class Off 10 15 20 30 Overload Reset Manual Auto Motor FLC 1 0 999 9 Amps Service Factor 0 01 1 99 ATTENTION During slow speed and or braking operations current waveforms exhibit non sinusoidal cha
38. 1 programming parameters 7 3 keypad 1 11 protection and diagnostics 1 5 excessive starts hour 1 10 9 5 line faults 1 9 9 3 open gate 1 9 9 5 overload 1 5 overtemperature 1 10 Stall and jam 1 8 Index l 3 underload 1 9 9 4 protective cover removal 10 10 protective modules 2 11 pump control option description of 1 13 programming parameters for 7 3 sequence of operation 7 12 wiring diagrams 7 5 7 6 7 7 7 8 7 9 7 10 R receiving the controller 2 1 renewal parts C 1 S scale factor conversion 8 3 SCANport 8 1 location 1 11 search 4 5 selectable kickstart 1 3 serial communication 8 1 Slow Speed with Braking option description of 1 15 Slow speed with Braking option programming parameters for 7 4 sequence of operation 7 25 wiring diagrams 7 21 7 22 7 23 7 24 SMB Smart Motor Braking option description of 1 14 programming parameters for 7 4 sequence of operation 7 13 SMB Smart Motor Braking option wiring diagrams 7 5 7 6 7 7 7 8 7 9 7 10 SMC status data 8 3 soft start option description of 1 2 programming parameters 4 9 soft stop option description 1 12 Index programming parameters for 7 3 sequence of operation 7 11 wiring diagrams 7 5 7 6 7 7 7 8 7 9 7 10 soft stop pump control SMB smart motor braking options wiring diagrams 7 5 7 6 7 7 7 8 7 9 specifications A 1 Stall protection 9 4 Stall protection and jam detection 1 8
39. 1 34 177 HP HUE Molor ME Raning Note The Motor kW Rating parameter must have a 0 0 setting before the controller s programming system will allow modification to the Motor HP Rating parameter In the Motor Data 5 1 ay ee see Delete the entire row associated with this parameter parameter titled Motor kW Rating SMC Dialog Plus is a trademark of Allen Bradley Comnpany Inc Publication 150 5 3 DU April 1996 Bulletin 150 Addition Correction Program only a motor code letter converting LRC Ratio ratings if applicable See conversion table below LRC Ratio Conversion Use the following table to select the motor code letter that corresponds to your motor s LRC Ratio First you must convert the LRC Ratio to kVA HP using the following Anica Action To Take Page s Add this information to 5 2 the Motor Data Entry table under the parameter titled Motor Code Letter equation Note The LRC Ratio parameter must have a 0 0 setting when using the Motor HP Rating and Motor Code Letter parameter combination kVA HP 75 x LRC Ratio Efficiency x Power Factor Example Motor Data 7 0 LRC Ratio 85 Power Factor 86 Efficiency kVA HP 75 x 7 0 86 x 85 7 18 Code Letter J kVA HP Code kVA HP Code Letter Letter 0 3 15 A 9 0 10 0 L 3 15 3 55 B 10 0 11 2 M 3 55 4 0 C 11 2 12 5 N 4 0 4 5 D 12 5 14 0 P
40. 180A 660 Other Ratings UL CSA NEMA IEC EMC Emission Levels Conducted Radio Freguency Class A Emissions Radiated Emissions Class A EMC Immunity Levels Electrostatic Discharge 8kV Air Discharge Radio Freguency Electromagnetic Field Per IEC 947 4 2 Fast Transient Per IEC 947 4 2 Surge Transient Per IEC 947 4 2 Overload Characteristics Type Solid state thermal overload with phase loss Current Range 1 0 999 9 Amps Trip Classes 10 15 20 and 30 Trip Current Rating 120 of Motor FLC Number of Poles 3 Metering Accuracy Voltage 2 Current 5 02 kW 10 kWH 10 Displacement Power Factor 3 Converter Module Output Cat No 825 MCM20 78 8 mV A 825 MCM180 9 85 mV A 825 MCM630 1 231 mV A Assumes the Bulletin 825 converter module is utilized TheSMC Dialog Plus controller calculates th e current values to two decimal place resolution while displaying only to tenths of Amps The display accuracy provided is therefore reduced by the truncation The affect of truncation on accuracy will be dependent on the magnitude of the value Assumes a balanced supply Environmental Ratings Operating Temperature Range Specifications A 5 UL CSA NEMA IEC 0 C 50 C open 0 C 40 C enclosed Storage and Transportation Temperature Range 20 C 75 C Altitude 2000 meters Humidity 5 95 non condensing
41. 6 42N m 45N m 1000A 2 1 0 500 AWG 375 Ib in 400 Ib in Control Voltage Depending upon the catalog number ordered the SMC Dialog Plus controller will accept a control power input of e 100 240V AC 15 10 1 phase 50 60 Hz e 24V AC 15 10 1 phase 50 60 H e 24V DC 20 1096 1 phas Refer to the product nameplate Connect control power to the controller at terminals 11 and 12 The control power requirement for the control module is 40 VA For controllers rated 97A 1000A control power is also required for th heatsink fans as defined in Table 3 D Depending on the specifi application additional control circuit transformer VA capacity may be required Table3 D Heatsink Fan Control Power SMC Rating Heatsink Fan V 97 360A 45 500A 145 650 1000A 320 Control Wiring Table 3 E provides the control terminal wire capacity and the tightening torque requirements Each control terminal will accept maximum of two wires Table3 E Control Wiring and Tightening Torque Wire Size Torque 0 75 2 5 mm 18 14 8 N m 7 Ib in Wiring 3 5 Fan Power Controllers rated 97A 1000A have heatsink fan s Refer to Table 3 D for the control power VA requirements of the heatsink fans Fan Terminations See Figure 3 2 to Figure 3 4 for fan power connection locations ATTENTION The fan jumpers have been factory installed for 110 120 VAC input Refer to Figure 3 6 through Figure 3 8 for 220 240
42. 9 Converter Module Connection Interface L1 L2 L3 Converter Module T1 T2 T3 Cable provided as standard with the converter module 2 150 NF Fanning Strip Y 21 22 23 24 25 26 27 28 29 30 The converter module rating must be programmed in the calibration group for proper current measurement scaling Cable length is three meters Only the cable provided with the converter module is compatible with the SMC Dialog Plus controller Use of any other cable may result in faulty controller operation 2 18 Installation Converter Modules cont Electromagnetic Compatibility EMC For applications in which the motor s full load current rating is greater than 360A three additional current transformers with 5A secondaries are required The figure below illustrates the connection of the current transformers to the converter module Figure 2 10 CurrentTransformer Connection to Converter Modul CurrentTransformer 0 L1 L2 L3 Converter Module T T2 T3 Thecurrenttransformer CT ration must be programmed in the calibration group for proper current measurement scaling See page 5 2 for instructions on programming this parameter Another current transformer connects L2 and T2 and another connects L3 and T3 amp The converter module Cat No 825 MCM20 must be used in these applications ATTENTION
43. India Indonesia Iran Ireland Israel Italy e Jamaica Japan Jordan Korea Kuwait e Lebanon Macau Malaysia Malta Mexico Morocco The Netherlands New Zealand Nigeria e Norway Oman Pakistan Panama Peru Philippines Poland Portugal Puerto Rico Qatar e Romania Russia Saudi Arabia Singapore Slovakia Slovenia South Africa Republic of Spain Sweden Switzerland Taiwan Thailand Trinidad Tunisia Turkey United Arab Emirates United Kingdom United States Uruguay Venezuela Rockwell Automation Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Rockwell Automation European Headquarters SA NV avenue Herrmann Debrouxlaan 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 Rockwell Automation Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 0150 5 3 October 1998 40055 145 01 C Supersedes Publication 0150 5 3 September 1996 1998 Rockwell International All Rights Reserved Printed in USA
44. LOGIC MASK accept the new setting 4 85 Zero and 4 are the only valid settings If a communication module is disconnected from the SMC Dialog Plus controller while control is enabled Logic Mask 4 a Comm Fault will occur SMC Status Data Serial Communications 8 3 The information in Table 8 B provides the SMC Dialog Plus controller status information that can be sent to the logic controller s input image table Table 8 B SMC Status Data Logic Bits Description Definition 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 Enabled Enabled 0 Not Enabled 1 Running i Running 0 Not Running Not Used Not Used 1 Starting starting 0 Not Starting 1 Stopping Stopping 0 Not Stopping 1 Faulted n Faut 0 Not Faulted 1 At Speed X at DEEG 0 Not at Speed Bits 9 15 are not used When control power is applied th Reference Feedback Parameter Listing Scale Factor Conversion is bit is always set to 1 The SMC Dialog Plus controller does not support the analog reference feature of SCANport The SCANport analog feedback feature however is supported The feedback word will always be equal to Parameter number 4 Current Phase A Refer to Appendix B Table B 1 for a complete listing of the SMC Dialog Plus controller s parameters and groups In addition to th range of adjustments the paramet
45. Motor FLC Enter the value from the motor s 1 0 999 9A nameplate ee MS Service Factor Enter the value from the motor s 0 01 1 99 SERVICE FACTOR nameplate P Refer to the SMC Dialog Plus controller nameplate for maximum ratings Exceeding these could result in damage to the controller The controller s programming system will not allow both HP and kW to be programmed 5 2 Calibration Motor Data Entry cont Parameter Motor Code Letter Enter the value from the motor s nameplate If the motor nameplate does not provide this consult the moto manufacturer SeeTable 5 A for code etter definitions Option Display A V MOTOR CODE LETTER LRC Ratio 0 EC motors do not provide a motor code etter Consult the motor manufacturer for the motor s locked rotor current full oad current ratio LRC RATIO 0 0 19 9 Hd Converter Rating f a Bulletin 825 converter module will provide current feedback to the controller enter the converter s rating to ensure proper current measurement scaling None 20 180 630 CONVERTER RATING CT Ratio For controllers using external current transformers with the 20A converter module for current feedback current transformers with 5A secondaries are required Enter the current transformer ratio in this parameter 5 through 1200 5 The controller s programming system will not allow both Motor Code Letter and LRC Ratio to be programmed Tab
46. Refer to the controller nameplate to verify the rating of the control power input voltage Customer supplied Note Refer to Chapter 3 for typical power circuits 7 22 Options Figure 7 18 Typical Retrofit Wiring Diagram for the Slow Speed with Braking Option S 5 Control Power ae m Stop o EENI mo e Brake Slow Speed 2d pe NEC Start _ O O gt db 32 ig 34b Jo 3 19 20 Auxiliary contacts se for Norma SMC Dialog Plus Control Terminals 210102700 02380 a Aa ae ay 28 2 3 Customer supplied T Overload protection should be disabled in the SMC Dialog Plus controller Internal Auxiliar Contacts amp Refer to the controller nameplate to verify the rating of the control power input voltage Note Refer to Chapter 3 for typical power circuits Options 7 23 Figure 7 19 Typical Wiring Diagram for the Slow Speed with Braking Option with an Isolation Contactor L ri S Control Power gt m Stop e e A Ne e Brake e Slow Speed O O Start roO CF d 32 13 14 15 IG iy we ag 20 Auxiliary contacts se for Norma Yi SMC Dialog Plus T Control Ter
47. VAC fan wiring Note that 220 240 VAC fan wiring is not available for th 650A 1000A controllers After wiring for the 97A and 135A controllers is complete replace control terminal strip cover Figure 3 6 97A and 135AFan Terminations Factory Set Optional 110 120 VAC 220 240 A A 1 1 7 0 0 2 LUN Suppi 2 Suppl J umpers r J umper 3 3 4 4 Y Y Figure 3 7 180A to 500A Fan Terminations Factory Set Optional 110 120 VAC 220 240 VAC To To Supply Supply J umpers J umper Y 1 12 3145 1 2 3 4 5 Figure 3 8 650A to 1000A Fan Terminations Factory Set 110 120 VAC To Supply Note 220 240 VAC is not available 3 6 Wiring Control Terminal As shown in Figure 3 9 the SMC Dialog Plus controller contains 20 Designations control terminals on the front of the controller Figure 3 9 SMC Dialog Plus Controller Control Terminals 322255252522 5 J SISSE Terminal Terminal Number Description Number Description M Control Powernpt 21 NotUsed 12 Control Power Common 22 Not Used 13 Controller Enable Input 23 Not Used 14 Logic Ground 24 Not Used 15 Dual Ramp Option Input 25 C
48. VDC 2096 41090 Rated Insulation Voltage N A 240 V Rated Impulse Voltage N A 3000 V Dielectric Withstand 1600 VAC 2000 Y Operating Frequency 50 60 Hz 50 60 Hz Protection Against Electrical Shock N A IP20 Power Requirements Control Module 40VA Heatsink Fan s 24A 35A 54A 97A 45VA 135A 45VA 180A 45VA 240A 45VA 360A 45VA 500A 145 VA 650A 320VA 720A 320VA 850A 320VA 1000A 320VA Maximum Heat Dissipation watts Controller Rating 24A 110 35A 150 54A 200 97A 285 135A 490 180A 660 Refer to product nameplate Electrical Ratings Control Circuit Specifications A 3 UL CSA NEMA IEC Rated Operation Voltage 100 240 VAC 15 10 100 240 V 15 10 24 VAC 1596 10 24 VDC 20 10 24 V 1596 10 24 VDC 2096 10 Rated Insulation Voltage N A 240 V Rated Impulse Voltage N A 3000 V Dielectric Withstand 1600 VAC 2000 Y Operating Frequency 50 60 Hz 50 60 Hz Protection Against Electrical Shock N A IP20 Power Requirements Control Module 40VA Heatsink Fan s 24A 35A 54A 97A 45VA 135A 45VA 180A 45VA 240A 45VA 360A 45VA 500A 145VA 650A 320VA 720A 320VA 850A 320VA 1000A 320VA Maximum Heat Dissipation watts Controller Rating 24A 110 35A 150 54A 200 97A 285 135A 490
49. ag 2 Auxiliary contacts se for Up to speed Y SMC Dialog Plus Control Terminals To Bulletin 82 Fanning Strip Internal Converter Auxiliar Module Contacts A 02700 19 320 92420 02520 2 G2 77 2908 1829320 93 n Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage amp Soft Stop Pump Stop or Brake Note Refer to Chapter 3 for typical power circuits Options 7 9 Figure 7 5 Typical Wiring Diagram for Two wire Control or Programmable Controller Interfacing Control Power Two wire device ib a2 35 Ne pm 16 17 18 19 20 SMC Dialog Plus Control Terminals Internal Auxiliar Contacts Ak 22 23 2420 02500 2 620 ay 28 29 30 i Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage Notes 1 Refer to Chapter 3 for typical power circuits 2 The OFF state leakage current for a solid state device must be less than 6 mA 7 10 Options Soft Stop Pump Control and SMB Smart Motor Braking Options
50. by PAMER AT directing the controller to recall the values stored in its EEPROM Recalling Defaults After parameter values have been modified and PARAMETER MGMT saved to EEPROM factory DEFAULT INT default settings can still be re initialized 4 8 Programming Parameter Modification All parameters are modified using the same method The basic steps to performing parameter modification are described below Note Parameter values modified while the motor is operating are not valid until the next start sequence begins Description Action Display ii t STOPPED 0 0 AMPS GE l Press any key to go from the CHOOSE MODE status display to the Choose Bana DISPLAY Mode menu 2 Scroll with the Up Down keys until the cinia i n or M PH MORE PROGRAM appears SOLE MEETS 3 Press the Enter key to access PROGRAM the Program menu METERING GI 4 Scroll with the Up Down keys until the option you want to use Basic ium rine Setup n or M PROGRAM J BASIC SETUP etc appears For this example Basic Setup will be used 5 Press Enter to select the Basic SMC OPTION Setup group STANDARD Cee ARC ATO LIE D S m EN STARTING MODE 6 Scroll to the next parameter by SOFT START using the Up key ee Options Soft Start Current Limit 7 To modify the parameter press ee ea the Sim rds to RE SEL STARTING MODE SOFT START cursor to the second line 8 Scr
51. contain error checking and handling Refer to the SLC 500 and 1747 SN scanner manuals for this documentation 2 For this example Allen Bradley s APS programming software is used Serial Communications 8 13 BT Control Buffer Layout The following table maps integer files starting at N10 0 with the associated MO file location as defined in the sample ladder logic program that follows BT Control Datafile Control Flags BT Length Y 0 BT Logical Address 1 2 3 4 Address 0 N10 0 BT logical address format logical rack group slot slot is always 0 for the 1203 GD1 Logical address examples Logical Rack 0 Group 0 Slot 0 0 Logical Rack 2 Group 4 Slot 0 240 This word is set by the ladder logic program Refer to the 1747 SN scanner manual for Control Flag Definitions BTW Datafile Format A four word data file is required to accomplish a Continuous Parameter Value Read For the example that follows the BTW Datafile will begin at address N10 10 BTW Datafil Message Length PLC Decimal Value Number of Parameter Values to Read Starting Parameter Number This is a fixed value associated with the Continuous Parameter Value Read function Data Path for the BTW Rung 2 6 of the sample ladder logic program that follows executes a COP instruction to the MO file to load the necessary data for the BTW
52. during bypass operation amp Refer to the controller nameplate to verify the rating of the control power input voltage 3 14 Wiring Standard Controller Figure 3 18 Typical Wiring Diagram for Bypass with Isolation Applications Wiring Diagrams cont Bulletin 825 Converter Module e L1 1 T1 2 3 Phase e L2 3 T2 4 Mo Input Power rt L3 5 T3 6 pe Fast acting Branc ontactor SCR Fuses SMC Dialog P Protection IC optional pane j UJ o I 33 eee Bypass Contactor BC BC INI e Stop D O Start O O ib ae 3 34 5 X5 ay 9 39 20 Auxiliary contact SMC Dialog Plus set for Up to spee Control Terminals rc iu e Een Bulletin 82 Converter Module 4 2L 22 23 28 25 25 2 28 29 30 Auxiliary contac Fanning Strip Set for Normal and N O Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage Wiring 3 15 Figure 3 19 Typical Wiring Diagram for Shunt Trip Applications
53. functional characteris tics for serial binary communication circuits in a point to point link An EIA standard that specifies electrical characteristics of balanced voltage digital interface circuits in a point to point link An EIA standard that specifies electrical characteristics of balanced voltage digital interface circuits in a multi point link The vertical movement of data on a display screen caused by the dropping of one line of displayed data for each new line added at the opposite end Pertaining to time sequential transmission of storage of or logic operations on da ta using the same facilities for successive parts When used on a motor nameplate a number which indicates how much above the nameplate rating a motor can be loaded without causing serious degradation i e a motor with 1 15 S F can produce 15 greater torque than one with 1 0 S F to adjust measured loads in an attempt to compensate for conditions which are diffi cult to measure or define A solid state switch sometimes referred to as a thyristor The SCR has an anode SCR cathode and control element called the gate The device provides controlled rectification since it can be turned on at will The SCR can rapidly switch large cur rents at high voltages They are small in size and low in weight An Allen Bradley programmable controller with a name that includes the letters SLC See Programmable Controller Glossary 4 Status Surge Protection Tog
54. of control present and is not user programmable Pump Control Pump Stop Time Allows the user to set the time period for the pump stopping function 0 120 seconds Starting Mode Allows the user to program the SMC Dialog Plus controller for the type of Starting that best fits the application SMC Option This parameter identifies the type of control present and is not user programmable Pump Start Soft Start Current Limit Start Preset Slow Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 forward 10 reverse High 15 forward 20 reverse Slow Speed Direction This parameter programs the slow speed motor rotational direction Forward Reverse Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting 0 450 of full load current 7 4 Options Programming Parameters cont SMB Smart Motor Braking SMC Option This parameter identifies the type of control present and is not user programmable SMB Braking Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 400 of full load current Accu Stop Slow Speed with Braking SMC Opti
55. output level for the voltage ramp is established and adjusted with this parameter 0 to 90 of locked roto torque Current Limit Level This parameter provides adjustability for the reduced output voltage level provided to the motor 50 to 600 full load current Kickstart Time A boost of 550 of full load current is provided to the motor for the programmed time period 0 0 to 2 0 seconds Stall Delay Allows the user to program the stall protection delay time The delay time begins after the start time has timed out 0 0 to 10 0 seconds Energy Saver The Energy Saver feature monitors the motor load phasing back the voltage output to the motor when the motor is lightly loaded or unloaded Off On Aux Contacts 1 amp 2 Form C contacts are provided as standard with the SMC Dialog Plus controller These contacts are located at terminals 18 19 and 20 Aux Contacts 1 amp 2 allows the user to configure the operation of the contacts Normal Up to speed Aux Contact 3 A third auxiliary contact is provided between terminals 29 and 30 Aux Contact 3 allows the user to program Normal Fault the operation of the contact Contact 3 Config This parameter provides the user with the ability to N O N C program the powered up state of the third auxiliary contact Parameter Mgmt The newly programmed parameters values can be saved to memory or the factory default parameter values can be recal
56. rating of the control power input voltage amp Slow Speed or Accu Stop Note Refer to Chapter 3 for typical power circuits 7 18 Options Preset Slow Speed and Accu Stop Options cont 3 Phase LA T1 2 Input Power L2 3 T2 4 Branch Protection Fast acting SCR Fuses optional Hand Stop olo SMC Dialog Plus Controller Hand Start aa owe QD ign Option Command zip Figure 7 14 Typical Wiring Diagram for Hand Off Auto SCANport Control 13 5 T3 6 11 12 13 14 15 16 iy aks 39 20 Auxiliary contact set for Nor SMC Dialog Plus Control Terminals mal Internal Auxiliar Contacts 21 22 23 24 2 a5 ai 29090 M79 30 Customer supplied Slow Speed or Accu Stop Refer to the controller nameplate to verify the rating of the control power input voltage 7 19 Options Figure 7 15 Preset Slow Speed Option Seguence of Operation Preset Slow Speed Option m TO c O c BD c Ei Ex z o D D Oo D D D c pao eo oo u 290 oco 5 e gg E
57. seconds Overvoltage Level Determines the trip level as a percentage of line voltage 0 to 199 0 is the Off setting Overvoltage Delay Provides a delay period prior to a trip occurrence 0 to 99 seconds Jam Level Determines the trip level as a percentage of the motor s full load current 0 to 999 0 is the Off setting Jam Delay Provides a delay period prior to a trip occurrence 0 0 to 10 0 seconds Unbalance Level Allows the user to set the voltage unbalance trip level 0 to 2596 0 is the Off setting Unbalance Delay 9 Provides a delay period prior to a trip occurrence 0 to 99 seconds Rebalance Allows the user access to enable the Rebalance feature See page 1 5 for a description Off On Underload Level Determines the trip level as a percentage of the motor s full load current 0 to 99 0 is the Off setting Underload Delay Provides a delay period prior to a trip occurrence 0 to 99 seconds TheDual Ramp feature is available only with the standard controller The delay time must be set to a value greater than zero wh Unbalance are enabled group See Chapter 5 for instructions en Undervoltage Overvoltage and For am and Underload detection to function the Motor FLC must be programmed in the Calibration amp Toenable Rebalance the Converter Rating parameter in the Calibrate programming group must be set for 20 180 or 630
58. structure Select The Select key has two functions SEL e Pressing the Select key alternately causes the top o bottom line of the display to become active indicated by flashing first character In parameter modification with series A FRN 3 00 or greater and series B human interface modules Select moves the cursor from the least significant digit to the most significant Up Down These keys are used to increment and decrement a Arrows parameter value or to scroll through the different modes groups and parameters Enter When pressed a mode or group will be selected or a parameter value will be entered into memory After a parameter value has been entered into memory the top line of display will automatically become active allowing the user to scroll to the next parameter ua Programming Menu Parameters are organized in a four level menu structure for straightforward programming Figure 4 1 details the programming menu structure and the four level hierarchy 4 2 Programming Programming Menu cont Figure 4 1 Menu Structure Hierarchy Power up an Status Display MAA Choose Mod OPERATION LEVE MODE LEVE B M 1 Control lt gt Display gt Program Password Ds sa Status read only read write See page 4 5 See page 4 5 ESC Control Logic Fault Queue
59. the microprocessor turns off the SCRs and displays the appropriate fault code An overtemperature condition could indicate the presence of inadequate ventilation high ambient temperature overloading or excessive cycling If an overtemperature condition exists at start up the SCR gate signals will be inhibited and the controller will trip and indicate the fault The fault can be immediately reset However the motor cannot be restarted until after the controller temperature falls below trip levels Comm Fault The SMC Dialog Plus controller disables control through the serial communication port as the factory default To enable control the Logic Mask parameter 85 found in the Linear List programming group must be set to 4 With Series B human interface modules this can also be accomplished by enabling control logic through the Control Status programming group If a Bulletin 1201 human interface module or Bulletin 1203 communication module is disconnected from the SMC Dialog Plus controller when control is enabled a Comm Fault will occur Copter 10 Troubleshooting Introduction For safety of maintenance personnel as well as others who might be exposed to electrical hazards associated with maintenance activities follow the local safety related work practices for example the NFPA 70E Part II in the United States Maintenance personnel must be trained in the safety practices procedures and requirements that pertain
60. the controller power modules may be damaged and require replacement Supplementary SCR fusing however is not required by the NFPA 70 National Electric Code Table2 C Recommended Fuses SMC Fuse Manufacturer Cat No Rating Bussman Shawmut Edison Brush Ferraz Littlefuse 24A BLUE NT0P70 XL70F080 A070F060 L70560 35A True NT0P100 XL70F125 A070F100 L705100 54A Eine A70P200 XL70F200 A070F150 L705150 97A EA A70P300 XL70F300 A070F300 L705300 135A E M AT0P300 XL70F300 070F300 L705300 180A SOMOS aes AT0P400 XL70FA00 A070F400 L705400 240A UA A70P500 XL70F500 A070F400 L705400 360A o AT0P800 XL70F600 A070F800 L705600 500A PM NT0P1000 XL70F500 A070F800 L705800 650A COME Ian AT0P1000 XL70F500 A070F800 L705500 720A es A70P1200 XL70F600 A070F800 L705500 850A mM AT0P1000 A070F1200 L705800 1000A ene A70P1000 2 A070F1200 L705800 Note Fuse size listed is for 230V 460V or 575V Fuse manufacturer s cross reference of the fuse Cat Nos listed here may not provide proper coordination Two fuses per phase are required for these controller ratings ATTENTION The fast acting current limiting fuses specified in Table 2 C may not provide branch circuit protection Branch circuit protection in accordance with applicable electrical codes may require additional fusing or a circuit breaker even though fast acting current limiting fuses are used ATTENTION Applica
61. the logical device image size of each physical device adapter with which the scanner commu nicates The control element of an SCR silicon controlled rectifier commonly referred to as a thyristor When a small positive voltage is applied to the gate momentarily the SCR will conduct current when the anode is positive with respect to the cath ode of the SCR Current conduction will continue even after the gate signal is re moved Jogging is a means of accomplishing momentary motor movement by repetitive closure of a circuit using a single push button or contact element A short conductor with which you connect two points Liquid crystal display which is a reflective visual readout device commonly used in digital watches and laptop computers The minimum torque that a motor will develop at rest for all angular positions of the rotor with rated voltage applied at rated frequency A selected method of operation Example run test or program A set of contacts on a relay or switch that are closed when the relay is de energized or the switch is de activated They are open when the relay is energized or the switch is activated A set of contacts on a relay or switch that are open when the relay is de energized or the switch is de activated They are closed when the relay is energized or the switch is activated 1 An Allen Bradley programmable controller 2 An Allen Bradley programmable controller with a name that includes th let
62. through password protection This feature is a disabled with a factory set parameter with a default setting of 0 To modify the password or login after a password is programmed complete the procedure below Description Action Display STOPPED 0 0 AMPS L l Press any key to go n DEAE REESE RS from the status display n M CHOOSE MODE to the Choose Mode DISPLAY menu 2 Scroll with the Up Down keys until the n or M CHOOSE MODE Password option PASSWORD LLLA appears 3 Press the Enter key to PASSWORD access the Password MODIFY menu Options Login Modify Logout 4 Press the Enter key ENTER TASS WORD 5 Press the Up Down keys to enter the desired number If you n or M ENTER PASSWORD are modifying the THHHHE password make a note of it as displayed 6 Press the Enter key after you have CHOOSE MODE completed modifying PASSWORD the password After you have completed the programming process re enter the Password mode to log out This will eliminate unauthorized access to the programming system Note If you lose or forget the password contact your nearest Allen Bradley sales office You can also call 1 800 765 SMCS 765 7627 for assistance The Search mode allows the user to view only those parameters that have settings other than the factory default values This mode is available only when using Bulletin 1201 human interface module 4 6 Programming Parameter Management
63. to the motor ATTENTION SMB Smart Motor Braking is not intended to be used as an emergency stop Refer to applicable standards for emergency stop requirements Accu Stop Option This option combines the benefits of the SMB Smart Motor Braking and Preset Slow Speed options For general purpose positioning th Accu Stop option provides a brake from full speed to the preset slow speed setting then brakes to stop Figure 1 16 Accu Stop Option 10 B 1 D Spee 7 or 15 m Slow Speed l Braking Coast P 2 glow v Speed S Slow gt Run Accu Stop Speed Start Time seconds 1 16 Product Overview Slow Speed with Braking Option The Slow Speed with Braking option provides a jog speed for process set up and braking to stop at the end of the cycle Figure 1 17 Slow Speed with Braking Option 100 Motor Speed 7 or 15 Slow gt lt gt Run um Stop Start Spese Time seconds ATTENTION Accu Stop and Slow Speed with Braking are not intended to be used as an emergency stop Refer to applicable standards for emergency stop requirements Receiving Unpacking Inspecting Storing cap 2 Installation It is the responsibility of the user 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 the responsibility of the us
64. 0 M N o N co e 0 N10 130 N10 140 N10 150 N10 160 N10 170 N10 180 N10 190 oc joo o o o o oc joo o o o o oc joo olo o o o oc joo olo o o o oc joo olo o o o oc joo olo o lo o oc joo olo o o N10 200 oco o olooj oo 0 1 Fi 3300 0 2 Fi 0 3 Fi 0 4 Fi Ll Fi 1 2 Fi 1 3 Fi 1 4 Fi Address Data G1 0 Radix BINARY 2020 0001 000F 8 18 Serial Communications Remote I O Examples cont Example 3 PLC 5 20 5 40 5 60 and 5 80 This example demonstrates PLC control of an SMC Dialog Plus controller with the Pump Control option Use of the Option Command bit to initiate the pump stop maneuver is also shown Finally the SMC fault bit is monitored as a conditional logic input for the block transfer of the associated fault code stored in the SMC Dialog Plus controller s Parameter 19 Fault Buffer 1 Many of the selections shown are example specific Some changes by the user may be necessary to apply the concepts of this example to a specific application System Configuration PLC 5 20 5 40 5 60 or 5 80 x oo Remote 1 0 Link
65. 26 Serial Communications After you have your network project configured in the DeviceNet Manager software perform a Network Who the following screen will appear Network Who ml xi Devices Identified J Node_62 62 DeviceNet Help EZE Notice that the SMC Dialog Plus controller is identified as node 13 which was configured by setting the DIP switches on the 1203 GK5 communication module Double click the Master node 0 on the DeviceNet network th following screen will appear 1747 SDN Module Configuration SDN x m Module Settings Project Name Network Name Module Name Node Address 0 Access DeviceNet M Slot Zz Load From 1 0 Comms v Enabled Interscan Delay 2 ms sw Ee Module Defaults SaveTo SDN File il Foreground to Bkad Poll Ratio Assign Wemes tom project Select the Edit Scan List option by clicking on the button th following screen will appear Serial Communications 8 27 1747 SDN Scan List Editor SDN Node 0 0 Mapped Active AxSize TxSize Type m Load From Yes Yes Yes SDN File Name Save To SDN File Add Devices From Pray Who m Edit Selection Scan List Tools Active Ih Scanlist Prod Type Electronic K Auta Map Vendor ectronic Key Cat No Jn Device Type Datatable Map Revision taverns isplay Filters me ECENEE J
66. 3 GD1 Communication Module Switch Settings The following information is provided to explain the required 1203 GD1 communication module switch settings for this example Refer to the 1203 GD1 manuals for further details related to the switch settings Example Information Description Switch Setting SMC Rack Address 02 S ced SMS Starting Group Address 0 SW2 Switches 1 amp 2 On Last Rack No SW2 Switch 3 Off Hold Last State Yes SW2 Switch 4 On Fault on Comm Loss Yes SW2 Switch 5 On Fault Controller No SW2 Switch 6 Off R I O Baud Rate 115k SW2 Switch 7 On Switch 8 Off Block Transfer No SW3 Switch 1 Off Logic Cmd Status Yes SW3 Switch 2 On Reference Feedback Yes SW3 Switch 3 On Datalinks No SW3 Switch 4 8 Off This configuration requires a 1 4 rack size allocation The SMC Dialog Plus controller does not support Datalinks Switch Setting EN Not Used BH Starting Module Group 0 E Block Transfer On N Not Used HB Ss Starting Module Group 0 B S Logic cma Sts On EB 7 o NEN 7 LastRack Setting Off eo BH S Reference Fdbk Of On t Hold Last State On S Datalink A Of n n n EN On NH Fault on Comm Loss On BE Datalink B Of EN o EN Fault Controller Off B Datalink c of aud Rate atalin EM o BH 0 Baud Rate 115k EN Datalink D of EN o o E RIO Bau
67. 4 UNA aaa 9 4 OpenGate swwananswnn 9 5 Excess Starts HOW saaaawanswanswa anauza 9 5 Controller Temp cce tee E ER 9 5 COMM Fault auae a n E ACC wavaa esas aa 9 5 Introduction S ree EEEP EUMD dad 10 1 Control Module Removal 0000 cc cee eee eee 10 6 241 139 AND ii ne cana cee fi onde ER RE 10 7 Appendix A Appendix B Appendix C Appendix D Figures Table of Contents toc vii 180 360 AMp amanama nan 10 8 500 1000AMp saaaaaaamanana 10 10 Control Module Replacement 10 11 Protective Cover Removal aauun 10 12 650 1000 AMp nananaa 10 12 MOV Fuse Replacement nuanua a 10 13 500 1000 AMP s amaaaaananaanasa 10 13 Power Module and Interface Board Resistance Check 10 13 24 135 AMP nnaaanaaaannsa 10 14 180 1000 Amiin 10 23 Specifications Parameter Information Renewal Parts Accessories Figure 1 1 SoftStart 1 2 Figure 1 2 Selectable Kickstart 1 3 Figure 1 3 Current Limit Start 1 3 Figure 1 4 Dual Ramp Start s 1 4 Figure 1 5 Full VoltageStartt 1 4 Figure 1 6 Overload Trip CUVeS 1 7 Figure 1 7 Restart Trip Curves after Auto Reset 1 7 Figure 1 8 Stall Protection
68. 4 5 5 0 E 14 0 16 0 R 5 0 5 6 F 16 0 18 0 S 5 6 6 3 G 18 0 20 0 T 6 3 7 1 H 20 0 22 4 U 7 1 8 0 J 22 4 and up V 8 0 9 0 K kVA HP includes the lower figure up to but not including the higher figure In the Motor Data Entry table see parameter titled LRC Ratio 9 Rockwell Automation Allen Bradley Publication 150 5 3 DU April 1996 For example 3 14 is designated by letter A and 3 15 by letter B Delete the entire row associated with this parameter 40055 166 01 A Copyright 1996 Allen Bradley Company Inc Printed in USA Please Read Important User Information This manual is intendedto guid gualified personnel in th installation and operation of this product Because of the variety of uses for this eguipment and because of the differences between this solid state eguipment and electromechanical eguipment the user of and those responsible for applying this eguipment must satisfy themselves as to the acceptability of each application and use of the eguipment In no event will Allen Bradley Company Inc be responsible or liable for indirect or conseguential damages resulting from the use or application of this eguipment The illustrations shown in this manual are intended solely to illustrate the tezt of this manual Because of the many variables and reguirements associated with any particular installation the Allen Bradley Company Inc cannot assume
69. 4 8 Off This configuration requires a 1 4 rack size allocation The SMC Dialog Plus controller does not support Datalinks Switch Setting Not Used BH Starting Module Group 0 BH Block Transfer On Not Used EB ing Module Group 0 BB Logic Cma Sts On On BB 75 LastRack Setting Off oBEE Reference Fdbk Off On Zi MS Hold Last State On S Catalink a off On NH Fault on Comm Loss On EE Datalink B Off On EN Fault Controller Off B Datalink C Off Off BH RIO Baud Rate 115k EM Datalink D off On EN o RIO Baud Rate 115k B Truncate Last Datalink 1 0 Addressing The 1203 GD1 communication module uses 1 slot addressing Based on the module switch settings as described above the discrete I O can be mapped to the PLC I O Image as shown below PLC 1 0 Group Number Output Image Input Image 0 Block Transfer Block Transfer 1 Logic Command Logic Status 8 20 Serial Communications Remote 1 0 Examples cont Addressing Format 1 02 0 12 I for input or O for output 2 digit I O rack number 1 0 group number 0 7 Input or output number octal bit address 0 7 10 17 Communication Module Block Transfer Status Word Addresse Bit Description lorO Rack Group Bit Address Block Transfer Ready BT READY 02 0 10 020 10 Block Transfer Write in Progress 02 0 11 020 11 BTW IN PROG Block Transfer Read Availabl
70. 6 5 11 32 901bs All dimensions are approximate and are not intended for manufacturing purposes Refer to the nearest Allen Bradley sales office for complete dimension drawings 2 8 Installati Mounting cont on Figure 2 5 Dimensions 650 1000 Amp Controllers A D 56 Dia 14 2 G 2 Lifting Holes E F F L 5 Dia 12 7 H 6 Holes N ES 105 Steel Sheet 2 67 e o 15 Dia 19 1 2 Holes 9 2 0 4 0 B 50 8 lt 101 6 H ars if 31 Tema 13 1 PIT W Y i 8 Dia Typ 5 Feu K 1 312 33 3 1 312 33 3 g e 650 720 Amp T 50 oip r 68
71. 8 e d Ft 175 E 64 9 e4 16 3 y AE er Typ 64 He 16 3 61 16 3 5 850 1000 Amp Typical Line and Load Bu Grounding Lug wide range 6 solid to 250 MCM stranded A B C Unit Width Height Depth D E F G H J K L M N P Q R 650and mm 320 60 0 15 83 30 25 60 1213 875 875 2 0 5825 9 935 5475 75 329 3175 246 1 720A Controller in 812 8 1524 0 402 1 768 35 152 4 308 0 22 22 22 23 50 8 1479 55 252 35 139 06 19 05 13 12 5 9 69 850and mm 320 60 0 15 83 30 25 6 0 1213 875 875 20 5825 9 935 5475 75 383 375 246 1 1000A Controller in 812 8 1524 0 402 1 768 35 152 4 308 0 22 22 22 23 50 8 1479 55 252 35 139 06 19 05 15 1475 9 69 All dimensions are approximate and are not intended for manufacturing purposes Refer to the nearest Allen BradleyAllen Bradley sales office for complete dimension drawings Power Factor Correction Capacitors Installation 2 9 The controller can be installed on a system with power factor correction PFC capacitors The capacitors must be located on the line side of the controller This must be done to prevent damage to the SCRs in the SMC Dialog Plus controller When discharged a capacitor essentially has zero impedance Fo switching sufficient impedance should be connected in series with the capacitor bank to limit the
72. A 200 480V 500 1000A 200 480V 40382 817 01 MOV 24 360A 200 600V 500 1000A 200 600V 40382 817 02 amp One piece provided per part number Protective modules are available as a fieldfinstalled accessory See Appendix D Appendix D Accessories Description Description Used With Cat No 24 54A 480V 150 N84 24 54A 600V 150 N86 Protective Modules 97 360A 480V 150 N84L 97 360A 600V 150 N86L 97 360A 199 LF1 Terminal Lugs 500 720A 199 LG1 850 1000A 199 LJ 1 97 135A 150 NT1 IEC Terminal Covers 180 360A 150 NT2 P30 Type 1 Door Mount Bezel Kit 1201 DMA IP30 Type 1 Programmer Only 1201 HAP Human Interface P65 Type 4 12 Programmer Only 1201 HJ P Module P30 Type 1 Analog Control Panel 1201 HA1 P30 Type 1 Digital Control Panel 1201 HA2 IP65 Type 4 12 Digital Control Panel 1201 H 2 Remote I O 1203 GD1 DH 485 or RS 232 422 485 DF 1 Tate De communication DeviceNet 1203 GK5 Modules 1203 FB1 Flex I O 1203 FM1 SLC Communication Module 1201 SM1 1 3 meter Male Male 1202 C03 Communication 1 meter Male Male 1202 C10 Cables 3 meter Male Male 1202 30 9 meter Male Male 1202 C90 1 12 5A 825 MCM120 9 100A 825 MCM180 Converter Modules 64 360A 825 MCM630 Fanning Strip 150 NFS AC AC Contacto Ambient Temperatur American Wire Gauge AWG Block Transfer BTR BTW Buffer Contactor Reversing
73. COP Cursor Cycle Gossary Alternating current An alternating current AC contactor is designed for the specific purpose of estab lishing or interrupting an AC power circuit Ambient temperature is the temperature of air water or a surrounding medium where equipment is operated or stored A standard system used for designing the size of electrical conductors Gaug numbers have an inverse relationship to size larger numbers have a smaller cross sectional area However a single strand conductor has a larger cross sectional area than a multi strand conductor of the same gauge so that they have the same current carrying specification Block Transfer is the method used by a PLC to transfer data that does not require continuous updates To perform this function the module provides a status word to the PLC during normal discrete transfer scan This status word occupies the first module group in the PLC I O image table for the designated rack The status word is then used by the PLC program to control the BTW and BTR functions of the PLC A PLC Block Transfer Read instruction A PLC Block Transfer Write instruction 1 In software terms a register or group of registers used for temporary storage of data to compensate for transmission rate differences between the transmitter and receiving device 2 In hardware terms an isolating circuit used to avoid the reaction of one circuit with another A method of reversing motor rotati
74. CRs between windings and supply Number of Poles Eguipment designed for three phase loads only Rated Operation Voltage Ue 200 480 VAC 15 10 200 600 VAC 15 10 200 4 15VY 15 10 200 500VY 15 10 Rated Insulation Voltage Ui N A 500V Rated Impulse Voltage Uimp N A 4000V Dielectric Withstand 2200 VAC 2500V Repetitive Peak Inverse Voltage Rating 200 480 VAC 1400V 200 600 VAC 1600V 200 415 1400V 200 500V 1600V Operating Frequency 50 60 Hz 50 60 Hz Utilization Category MGI AC 53a Protection Against Electrical Shock N A IP 00 open device DV DT Protection RC Snubber Network Metal Oxide Varistors 220 J oules 24 360A Transient Protection 220 J oules 9 480V 500 1000A 300 J oules 480V 500 1000A Short Circuit Protection SCPD Performance Type 1 SCPD List Maximum Fuse or Circuit Breaker Device Operational KA Current Rating le Arms sym 24A 5000 80A 35A 5000 125A 54A 5000 200A 97A 10 000 350A 135A 10 000 500A 180A 10 000 600A 240A 18 000 700A 360A 18 000 1000A 500A 30 000 1200A 650A 30 000 1600A 720A 42 000 2000A 850A 42 000 2500A 1000A 85 000 3000A Specifications Electrical Ratings Control Circuit UL CSA NEMA IEC Rated Operation Voltage 100 240 VAC 15 10 24 VAC 1596 10 24 VDC 2096 10 100 240 V 15 10 24 V 1596 10 24
75. Define Nature of Trouble Motor will not start no output voltage t motor Motor rotates but does not accelerate to ful speed Motor stops while running Miscellaneou situations See Table 10 on pag 10 See Table 10 on pag 10 See on pag 10 Table 10 Table 10 on pag See 10 See Table 10 on pag 10 Troubleshooting 10 3 Table 10 A SMC Fault Display Explanation Display ae Possible Causes Possible Solutions p F1 F2 F3 Missing supply phase as indicated Check for open line i e blown line fuse ower Loss i E F30 F31 Converter module and or cable failure Inspect converter module cable connections with phase indication amp F32 Missing supply phase Check for open line i e blown fuse Line Fault F11 F12 Motor not connected properly Check for open load lead with phase indication F13 F26 Shorted SCR Check for shorted SCR replace if necessary F27 amp F28 Converter module and or cable failure Inspect converter module cable connections Consult the factory Line Fault F15 and Missing supply phase Check for open line i e blown fuse no phase indication F29 Motor not connected properly Check for open load lead Shorted SCR Check for shorted SCR replace if necessary Supply un
76. Figure 3 18 Figure 3 19 Figure 3 20 Figure 3 21 Figure 3 22 Figure 4 1 Figure 4 2 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Current Transformer Connection to Converter Module 2 18 Wiring Terminal Locations 24 to 54 Amp 3 1 Wiring Terminal Locations 97 and 135 Amp 3 1 Wiring Terminal Locations 180 to 360 Amp 3 2 Wiring Terminal Locations 500 Amp 3 2 Wiring Terminal Locations 650 to 1000 Amp 3 3 97A and 135A Fan Terminations 3 5 180A to 500A Fan Terminations 3 5 650A to 1000A Fan Terminations 3 5 SMC Dialog Plus Controller Control Terminals 3 6 Grounding Provision 3 6 Typical Wiring Diagram for Standard Controller 3 7 Typical Wiring Diagram for Two Wire Control or Programmable Control Interfacing 3 8 Typical Wiring Diagram for Dual Ramp Applications 3 9 Typical Wiring Diagram for Start Stop Control via the SCANport 3 10 Typical Wiring Diagram for Retrofit Applications 3 11 Typical Wiring Diagram for Isolation Applications 3 12 Typical Wiring Diagram for Bypass Applications 3 13 Typical Wiring Diagram for Bypass with Isolation Applications 3 14 Typical Wiring Diagram for Shunt Trip Applications
77. NA AI ZS o6 ja eo Neo Noo 5656669565 Remote 1 0 Link amp e e mnuuuuuuuuuuuuu e Allen Bradley SMC Dialog Plus E ues o 1203 GD1 BPP JF J 7 MJ Communication Module sae Bulletin 1202 SCANport Cable 1203 GD1 Communication Module Switch Settings The following information is provided to explain the required 1203 GD1 communication module switch settings for this example Refer to the 1203 GD1 manuals for further details related to the switch settings Example Information Description Switch Setting Starting Group Address 0 SW2 Switches 1 amp 2 On Last Rack Yes SW2 Switch 3 On Hold Last State Yes SW2 Switch 4 On Fault on Comm Loss Yes SW2 Switch 5 On Fault Controller Yes SW2 Switch 6 On RIO Baud Rate 57k SW2 Switches 7 amp 8 Off Block Transfer Yes SW3 Switch 1 On Logic Cmd Status Yes SW3 Switch 2 On Reference Feedback No SW3 Switch 3 Off Datalinks No SW3 Switches 4 8 Off TheSMC Dialog Plus controller does not support Datalinks mn 87654321 O Not Used Not Used On On On On On On Serial Communications 8 11 SLC Image Table Map Block Transfer Block Transfer
78. Number Units Factor Setting Setting Slow Speed with Braking sy n 44 Low High High umes 46 FLC 1 0 450 0 Slow Running 47 FLC 1 0 450 0 Current M 48 FLC 1 0 400 0 Dual Ramp 29 No Yes No PA 32 Seconds 1 0 30 10 uu 33 LRT 1 0 90 70 UE Undervolt 52 Yo Line 1 0 99 0 Off Level Voltage poa 53 Seconds 1 0 99 0 EX Overvolt 54 Yo Line 1 0 199 0 Off Level Voltage p 55 Seconds 1 0 99 0 J am Level 56 FLC 1 0 999 0 Off Jam Delay 57 Seconds 10 0 0 10 0 0 oda 58 1 0 25 0 Off ie d 86 Seconds 1 0 99 0 Rebalance 59 Off On Off os 60 FLC 1 0 99 0 Off used 61 Seconds 1 0 99 0 As 62 2 Off On off Reversal a 63 1 0 99 0 Off Restart Attempts 64 i 1 9 2 Restart Delay 65 Seconds 1 0 60 0 ETM Reset 15 Off On Off Parameter Ready Default Init Management H B i Recll Frm EE Store In EE Ready B 4 Group Calibrate Parameter Information Table B 1 cont Parameter List Parameter Parameter Display Scale Minimum Masimum Default User Description Number Units Factor Setting Setting WA 36 Off 10 15 20 and 30 Off Class ads 88 Manual Auto Manual Reset jud 79 HP 10 0 0 6 553 5 0 0 Rating MST 80 kW 10 0 0 6 553 5 0 0 Rating Line Voltage 69 Volts 1 0 9999 480 Motor FLC 70 Amps 10 1 0 999 9 1 0 pals 84 z 100 0 01 1 99 1 15 Factor Motor Code 7 E 7 AB CD ERGHJ KL G Letter M N P R S T U an
79. Off 0 59 Rebalance On 1 Off 0 62 Phase Reversal On 1 Pump Startis only available with the Pump Control option Q DualRamp is only available with the standard controller Slow Speed Select is only available with the Preset Slow Speed and Accu Stop options Slow Speed Direction is only available with the Preset Slow Speed option B 6 Parameter Information Table B 2 cont Parameter Text Display Unit Cross Reference Parameter Number Description Setting Text Display Unit A 0 B 1 C 2 D 3 E 4 F 5 G 6 H 7 J 8 72 Motor Code Letter K 9 L 10 M 11 N 12 P 13 R 14 S 15 T 16 U 17 V 18 None 0 74 Converter Rating zA 180 2 630 3 5 5 0 50 5 1 75 5 2 100 5 3 150 5 4 200 5 5 250 5 6 75 CT Ratio 300 5 7 400 5 8 500 5 9 600 5 10 700 5 11 800 5 12 1000 5 13 1200 5 14 88 Overload Reset Manua Auto 1 Control Modules Description Standard Renewal Parts SMC Rating All Soft Stop All Pump Control All Preset Slow Speed All 24 54A 97 135A 180 360A 500 650A 720 1000A Accu Stop 24 54A 97 135A 180 360A 500 650A 720 1000A Slow Speed with Braking Standard 24 54A 97 135A 180 360A 500 650A 720 1000A All Soft Stop All Pump Control All Preset Sl
80. Plus controller s Fault Buffer 1 BTW Datafile Message Length PLC Decimal Value Y 0 Parameter Number Address 1 2 3 4 5 6 7 8 9 N10 10 This is a fixed value associated with the Parameter Value Read function BTR Datafile Header Word 1 PLC Decimal Value Parameter Number Y Parameter Value Address 0 1 2 3 4 5 6 7 8 9 amp There is no significance to the number returned to Header Word 1 Message OK 769 Message Error 31999 Ifa message error occurs the error code will be presented here See Table5 A of the Bulletin 1203 Remote I O Communication Module Reference Manual Publication 1203 5 0 for a listing of the error codes and descriptions Serial Communications 8 23 Example 3 Ladder Logic Program First Rung When the Machine START push button is pressed the PLC sends a START command to the SMC Dialog Plus controller The SMC Dialog Plus controller will start if no STOP command is being issued by the PLC or any other control device The start button is a normally open contactinthis example Machine SMC START START Push Button Command 016 O 021 iE 11 01 Second Rung When the Machine STOP push button is pressed the PLC sends an OPTION command pump stop in this example to the SMC Dialog Plus controller The stop button is a normally closed contact in this example The branch provides a logic latche
81. SO ooo SO i 2 og 5 o O 20 D8 zs zuo m u Sa I lt c e z zs bri a G 3 xc o gt 5 S 2 2 So z gt a wn wn wn o 7 20 Options Accu Stop Option Figure 7 16 Accu Stop Option Seguence of Operation 100 Braking Motor Speed l Slow Speed Braking Coast Push Buttons Start Closed Open Stop Closed Open Accu Stop Closed Open Auxiliary Contacts Normal Up to speed Slow Speed WA Time seconds gt a Run gt lt Accu Stop If Stopping Current is set to 0 When Accu Stop push button is closed start stop function is disabled ATTENTION The user is responsible for determining which stopping mode is best suited to th application and will meet applicable standards for operator safety on a particular machine Slow Speed with Braking Option Options 7 21 Figure 7 17 through Figure 7 21 show the different wiring for the Slow Speed with Braking option Figure 7 17 Typical Wiring Diagram for the Slow Speed with Braking Option Control Power O r Stop Brake T Slow Speed Goo E e O O Start rO O e jb 32 ils Wey als NG ay als 1 20 SMC Dialog Plus Control Terminals Internal Auxiliary Contacts Zl a2 22320 wt ay we ay 28 29 30 T
82. This identifies the size of the transaction body in bytes The transaction body begins at word 3 The maximum size is 58 bytes The Size data size is one byte Service This code specifies the type of request being delivered The Service data size is one byte Mac ID The DeviceNet network node address of the device for which the transaction is intended is identified here The slave device must be listed in the scanner module s scan list and be on line for the Explicit Message transaction to be completed Class The desired DeviceNet class is specified here The Class data size is one word Instance This code identifies the specific instance within the object class towards which the transaction is directed The value zero is reserved to denote that the transaction is directed towards the class itself versus a specific instance within the class Serial Communications 8 31 Attribute This code identifies the specific characteristic of the object towards which the transaction is directed The Attribute data size is one word Examples The following table lists the most common codes for each given transaction type Transaction Type Service Class Instance Attribute Single Parameter Read 0E OF Par 1 Single Parameter Write 10 OF Par 1 Scattered Parameter Read 32 93 0 0 Scattered Parameter Write 34 93 0 0 The numerical values are in a hexidecimal format Q This is the actual
83. ally open contactinthis example Machine SMC SIRE START Push Butto Command Lel O 1 16 j E 0 1 Second Rung When the Machine STOP push button is pressed the SLC sends a STOP command tothe SMC Dialog Plus controller The stop button is a normally closed contact in this example The branch provides a logic latched circuit which exerts the STOP command until the feedback from the SMC Dialog Plus controller indicates that it has received the command and has responded appropriately Machine SMC STOP STOP Push Button Command za O 1 16 j E 1 SMC SMC STOP Running Command Bit O 116 l 1 16 4 E JE 0 1 Third Rung The SMC Dialog Plus controller s Current Phase A value returned by the analog feedback word I 1 17 in this example is moved every scan to integer file 7 element MOV MOVE Source I1 17 Dest N7 2 8 10 Serial Communications Remote I O Examples cont Example 2 SLC 500 Controller with Block Transfer This example demonstrates a block transfer of the SMC Dialog Plus controller s metering group parameters 1 11 to an SLC500 Many of the selections shown are example specific Some changes by th user may be necessary to apply the concepts of this example to a specific application System Configuration SLC 5 02 or higher s gt 1747 SN Scanner 5 e oo BB BH BH oo na EX SA
84. ary Failed control module Replace control module Starting Two or three power phases are missing e Failed control module Check power system Replace control module Troubleshooting 10 5 Table 10 E Miscellaneous Situations Situation Motor current and voltage fluctuates with steady load Possible Cause Motor Energy Saver Erratic Load Possible Solutions Verify type of motor as a standard squirrel cage induction motor Set Energy Saver Off then restart If problem stops replace control module If problem persists shut off all power to controller and check connections Check load conditions Erratic operation Loose Shut off all power to controller and connections check for loose connections Accelerates too fast Starting time ncrease starting time Initial torque Lower initial torque setting Current limit Decrease current limit setting setting Kickstart Lower kickstart time or turn off Accelerates too Starting time Decrease starting time slow Initial torque ncrease initial torque setting Current limit ncrease current limit setting setting Kickstart ncrease kickstart time or turn off Fan does not Wiring Check wiring and correct if operate necessary 97 1000A Failed fan s Replace fan s Motor stops too Time setting Verify the programmed stopping quickly with time and correct if or increase Soft Stop option Motor stops too Stopping time Verify the pro
85. ase Reversal Phase reversal is indicated when the incoming power to the SMC Dialog Plus controller is in any sequence other than ABC This pre start protective feature can be disabled Overvoltage and Undervoltage Protection Overvoltage and undervoltage protection are user defined as a percentage of the programmed line voltage The SMC Dialog Plus controller continuously monitors the three supply phases The calculated average is then compared to the programmed trip level amp Phaseloss overvoltage and undervoltage protection are disabled during braking operation 9 4 Diagnostics Fault Definitions cont Voltage Unbalance Voltage unbalance is detected by monitoring the three phase supply voltages The formula used to calculate the percentage voltage unbalance is as follows Vu 100 Vq Va V Percent voltage unbalance Va Maximum voltage deviation from the average voltage V Average voltage The controller will shut down when the calculated voltage unbalance reaches the user programmed trip percentages Stall Protection Stall protection is enabled at the end of the programmed ramp tim after a motor has been started If the controller senses that the motor is not up to speed at the end of ramp it will shut down after the user selected delay time has elapsed Jam Detection Jam detection operates when the SMC Dialog Plus controller status is at speed The controller will shut down when the motor c
86. ate amount of time to restart EXCESS Starts hr rog exceeded the value programmed Turn off the Starts Hr feature Controller ventilation blocked Check for proper ventilation Controller duty cycle exceeded Check application duty cycle Fan failure if used Replace fan Controller Temperature F8 Ambient temperature limit exceeded Wait for controller to cool or provide external cooling Failed thermistor Replace power module Failed control module Replace control module Communication disconnection at the serial Check for a communication cable Comm Fault F21 port disconnection to the SMC Dialog Plus controller F128 amp Internal control module hardware failure Replace control module System Faults above MPU Comm Fault Internal control module hardware failure Replace control module Converter module cable disconnection Inspect converter module cable and Curr Fdbk Loss F20 Prestart fault indication connections To further define this fault the user can clear the fault and re initiate a start signal If the fault condition is still preent the controller will display either a Power Loss ora Line Fault with the ph ase indicated Troubleshooting Table 10 B Motor Will Not Start No Output Voltage to the Motor Display Fault displayed Possible Cause Possible Solutions Display is blank Stopped 0 0 Amps Seefault description See Table 10 A addressing fault conditions e Control voltage is e Check control wi
87. balance is greater than the user Check power system and correct if necessary Voltage Unbalance F10 programmed value Extend the delay time to match the The delay time is too short for the application application requirements Incoming supply voltage is not in the Check power wiring Buse RENATA E18 expected ABC sequence Supply voltage is less than user programmed Check power system and correct if necessary Undervolt F4 value Correct the user programmed value The delay time is too short for the application Extend the delay time to match the application requirements Supply voltage is greater than user Check power system and correct if necessary Overvolt F5 programmed value Correct the user programmed value Motor overloaded Check motor overload condition Overload F7 Overload parameters are not matched to the Check programmed values for overload class motor and motor FLC Motor has not reached full speed by the end Correct source of stall Stall F6 of the programmed ramp time Motor current has exceeded the user Correct source of jam Jam F19 programmed jam level Broken motor shaft Repair or replace motor Underload F9 Broken belts toolbits etc Check machine Pump cavitation Check pump system Open gate circuitry Perform resistance check replace power Open Gate F23 F25 module if necessary with phase indication Loose gate lead 180 1000A Check gate lead connections to the interface board Number of starts in a one hour period has Wait an appropri
88. chieve successful data transmissions BTW BTR BLOCK TRNSFR WRITE EN BLOCK TRNSFR WRITE L EN Rack 02 Rack 02 Group 0 L DN Group 0 DN Module 0 Module 0 Control Block BT11 0 ER Control Block BT11 1 ER Data File N10 10 Data File N10 90 Length 64 Length 64 Continuous N Continuous N Rack The number reported here should correspond to the communication module s rack assignment as selected via DIP switch group one SW1 Group The number reported here should correspond to the communication module s starting group address via DIP switch group two SW2 switches 1 and 2 Module In all cases with regards to the 1203 GD1 communication module the number 0 should be reported here Control Block For this example a block transfer file type BT o one element is used for the control block An integer file type N of five contiguous words could also be used Data File The first word of the datafile integer Type N selected for the BTW or BTR block is reported here Length The block transfer message length number of words is reported here Itis critical that care is given to all file assignments to ensure that no overlapping or overwriting occurs 8 22 Serial Communications Remote I O Examples cont Block Transfer Datafiles The tables below provide the necessary data file configuration for a parameter value read of the SMC Dialog
89. close to the controller as practical wrapping th cable twice through the suppressor Caper 3 Wiring Terminal Locations The SMC Dialog Plus controller wiring terminal locations are shown in Figure 3 1 through Figure 3 4 Make wiring connections as indicated in the typical connection diagrams Connect the line to terminals L1 1 L2 3 and L3 5 Connect the load to terminals T1 2 T2 4 and T3 6 For controllers rated 24 135A a grounding screw is provided to ground the heatsink per applicable codes For controllers rated 180A 1000A a grounding lug is provided on the mounting plate Figure 3 1 Wiring Terminal Locations 24 to 54 Amp O Qt e Quy Mo pit fone onnections T TTT TIT E 13 14 15 7 8 19 20 w EEE ee EEE EE eme 21 22 23 24 25 26 27 28 29 30 Connections Allen Bradley SMC Dialog Plus Ec is v e z Output Power O e n e 5 e 1 Connections Figure 3 2 Wiring Terminal Locations 97 and 135 Amp e 6 6 B Input Power O O O Connections ee C eO e O amp eo leo leo amp 2999099989 aagssedeaal E Control age enone ooo C
90. condition can indicate inadequate ventilation high ambient temperature overloading or excessive cycling Afte the SCR temperature is reduced to allowable levels the fault can be cleared see page 9 1 for instructions Power monitoring parameters include e Three phase current e Three phase voltage e Power in kW e Power usage in kWH e Power factor Motor thermal capacity usage e Elapsed tim Notes 1 The current sensing capability of the SMC Dialog Plus controller is disabled during bypass operation A Bulletin 825 converter module is required to maintain th three phase current kW kWH and motor thermal capacity measurements Current measurement is not available during the slow speed and or braking operations of the Preset Slow Speed SMB Smart Motor Braking Accu Stop and Slow Speed with Braking control options 3 Voltage measurement is not available during the braking operation of the SMB Smart Motor Braking Accu Stop and Slow Speed with Braking control options 4 The power factor parameter is provided as a displacement power factor value Power factor measurement is disabled during bypass operation 5 The elapsed time and kWH values are automatically saved to memory every 12 hours 6 Motor thermal capacity usage is determined by the built in electronic thermal overload protection system An overload fault occurs when this value reaches 10090 2 Product Overview 1 11 Communication A seria
91. cription Fault Code Description F1 F30 Power Loss A F12 F27 Line Fault B F2 F31 Power Loss B F13 F28 Line Fault C F3 F32 Power Loss C F15 F29 Line Fault F4 Undervoltage F16 Phase Reversal F5 Overvoltage F19 Jam F6 Stall F21 Comm Fault F7 Overload F23 Open Gate A F8 Controller Temp F24 Open Gate B F9 Underload F25 Open Gate C F10 Volt Unbalance F64 Excess Starts Hr F11 F26 Line Fault A F128 138 System Faults The auxiliary contact is located at terminals 29 and 30 This contact can be programmed as either Normal or Fault Note that the state that this contact takes upon power up normally open or normally closed can be programmed These parameters can be found in either Basic Setup Advanced Setup or the Linear List groups when modifying parameters in the Program mode Fault Definitions Diagnostics 9 3 Power Loss Power loss indicates that an input power phase is not present The controller s LCD display will identify the missing phase Note If all three phases are absent when a start command is issued the LCD will display Starting without motor rotation Line Fault Line fault with the affected phase displayed identifies three possible pre start conditions e Phase loss e Load loss Shorted SCR Line fault with no phase indication is displayed when one of the following conditions occurs while the SMC Dialog Plus controller is in the run mode e Phase loss e Load loss e Shorted SCR Ph
92. d circuit which exerts the OPTION command until the feedback from the SMC Dialog Plus controller indicates that it has returned to a stopped status not running Machine SMC STOP OPTION Push Button Command 016 O 021 j E 12 2 SMC SMC OPTION Running Command Bit O 021 021 J E J E 02 01 Third Rung The SMC Fault Bit initiates a PLC block transfer write to the communication module requesting a parameter value read SMC Dialog Plus controller Parameter 19 Fault Buffer 1 in this example BT BT SMC Read Write Fault Available Available Bit BTR_AVAIL BTW_AVAIL 021 020 020 BTW qJ E 4 E J E EN d dicm d E BLOCK TRNSFR WRITE Rack 02 Group 0 DN BT Module 0 Error Control Block BT11 0 ER BT ERROR Data File N10 10 Length 3 Continuous N 020 3 E RR Fourth Rung A block transfer read occurs whenever the communication module s BT Read Available status bit is true in this example the communication module responds to the PLC request BTW in the third rung by supplying the value stored in Parameter 19 BT Read Available BTR_AVAIL 020 BTR aie BLOCK TRNSFR READ EN 12 Rack 02 Group 0 Module o UN Control Block BT11 1 ER Data File N10 90 Length 4 Continuous N 8 24 Serial Communications DeviceNet Examples Example 1 SLC 500 Controller with Explicit Messaging This example demonstrates
93. d Rate 115k B Truncate Last Datalink O Serial Communications 8 7 G File Configuration The SLC system uses G files to configure the R I O link G files are configured through the SLC programming software The configuration is based on the devices connected to the R I O link Fo this example the following G file configuration map for the scanner s 1 0 image file of the SMC Dialog Plus controller applies Address 15 Data 0 Description G1 0 XXXX XXXX XXXX XXXX Word 0 cannot be edited G1 1 0000 0001 0000 0000 Logical device address rack 2 start group 0 G1 2 0000 0001 0000 0000 Logicalimage size 1 4 rack Words 3 and 4 do not require configuration since the communication module does not support Complimentary 1 0 1 0 Addressing The 1203 GD1 communication module uses 1 slot addressing Based on the module switch settings as described above the discrete I O can be mapped to the PLC I O Image as shown below SLC I O Image Table Map SLC 1 0 Group Number Output Image Input Image 0 Logic Command Logic Status 1 Reference Feedback Theoutputimage word that maps to the Reference word O 1 17 in this example must have the value 0 to insure proper SMC Dialog Plus controller operation Addressing Format l 1 0 2 I for input or O for output mi Slot number Word number Input or output number bit identifier 0 15 8 8 Serial Communications Remote I O Examples cont SMC Dialog P
94. d V LRC Ratio 81 10 0 0 19 9 0 0 Converter 74 None 20 180 630 None Rating 5 50 75 100 150 200 CT Ratio 75 250 300 400 500 600 750 5 5 800 1000 1200 5 Calibration 76 Off Activate Off ENET Calp 77 Amps amp 0 01 999 9 0 0 Amps Current Phase A 1 Amps n wi E Parameter Ready Default Init Mgmt H E n Recll Frm EE Store In EE Ready Read only capability The scale factor is 100 when Motor FLC parameter 70 has a programmed value of up to 10 0 Amps above 10 0 Amps the scale factor is 10 Parameter Information B 5 Table B 2 Parameter Text Display Unit Cross Reference Parameter Number Description Setting Text Display Unit Standard 0 Soft Stop 1 Pump Control 2 14 SMC Option Preset Slow Speed 3 Smart Motor Braking 4 Accu Stop 5 Slow Speed with Braking 6 15 ETM Reset at 9 On 1 Ready 0 17 Parameter Mgmt MEER P Recall From EE 2 Store In EE 3 No 0 18 Clear Fault Yes 1 Current Limit 0 28 Starting Mode Soft Start 1 Pump Start 2 No 0 29 Dual Ramp 0 Yes 1 Off 0 10 1 36 Overload Class 15 2 20 3 30 4 Off 0 38 Energy Saver On 1 Normal 0 39 Aux Contacts 1 amp 2 Up to speed 1 Normal 0 40 Aux Contact 3 Fault 1 41 Contact 3 Confi ES 2 i 9 N C 1 M Slow Speed Select Low 0 High 1 45 Slow Speed Reverse 0 Direction amp Forward 1
95. discreet control of the SMC Dialog Plus controller in addition to use of the explicit messaging function for transferring parameter data to an SLC500 The DeviceNet Manage revision 3 001 software is used in this example for network and node configuration RSView is used as the man machine interface in this example Many of the selections shown are example specific Some changes by the user may be necessary to apply the concepts o this example to a specific application System Configuration SLC 5 04 1747 SDN Scanner et A BE BB BB 9 n DADANT NI SS o6 ja yA DeviceNet trunk TUDO OUD UID Allen Bradley SMC Dialog Plus Qo CE A 1203 GKS SIEJETF TC nl U ear Communication Module SMC Dialog Plus Bulletin 1202 SCANport Cable Controller L co Notes 1 1747 SDN scanner firmware revision 3 01 or late required 2 1203 GK5 module firmware revision 1 9 or later required 1203 GK5 Communication Module Switch Settings The following information is provided to explain the required 1203 GK5 communication module switch settings for this example Refer to the 1203 GK5 manual for further details relat
96. e BTR AVAIL 02 0 12 020 12 Block Transfer Wait BT WAIT 02 0 13 020 13 Block Transfer Error BT ERROR 02 0 14 020 14 Block Transfer Write Available BTW AVAIL 02 0 15 020 15 SMC Dialog Plus Controller Logic Control Addresses Bit Description lorO Rack Group Bit Address Stop 0 02 1 00 0 021 00 Start 0 02 1 01 0 021 01 Option Command 0 02 1 02 0 021 02 Clear Fault 0 02 1 03 0 021 03 SMC Dialog Plus Controller Status Addresse 0 Bit Description lorO Rack Group Bit Address Enabled 02 1 00 I 021 00 Running 02 1 01 1 021 01 Starting 02 1 04 1 021 04 Stopping 02 1 05 1 021 05 Fault 02 1 07 1 021 07 At Speed 02 1 109 I 021 10 Theaddresses shown are example specific Addresses for any given installation can be determined based upon the 1203 GD1 communication module switch settings for rack address starting group number block transfer logic command status and reference feedback by applying the 1 0 addressing format for PLC 5 controllers Refer to Figure 3 1 of the Bulletin 1203 Remote I O Communication Module Refer to Table 8 A Refer to Table 8 B This is the octal address representation for this bit 6 amp 8 Serial Communications 8 21 Block Transfer Instructions Block transfer operations with the 1203 GD1 communication module require coordinated block transfer write BTW and block transfe read BTR instructions to a
97. e Current Limit Start with Selectable Kickstart Dual Ramp Start e FullVoltage Start Other features that offer further user benefit include e Expanded protective features e Metering e Communication capability Innovative starting and stopping options provide enhanced performance e Soft Stop e Pump Control e Preset Slow Speed e SMB Smart Motor Braking e Accu Stop e Slow Speed with Braking These modes features and options are further described in this chapter The SMC Dialog Plus controller can operate three phase squirrel cag motors rated 1 1000A 200 480V AC or 200 600V AC 50 60 Hz Depending upon the catalog number ordered the controller will accept a control power input of either 100 240V AC or 24V AC DC If the control power input option is 100 240V AC the controller s microprocessor will self adjust to the input control voltage 1 2 Product Overview Starting Modes Soft Start This mode has the most general application The motor is given an initial torque setting which is user adjustable from 0 to 90 0 locked rotor torque From the initial torque level the output voltage to the motor is steplessly increased during the acceleration ramp time The acceleration ramp time is user adjustable from 0 to 30 seconds If the SMC Dialog Plus controller senses that the motor has reached the up to speed condition during the voltage ramp operation the output voltage automatically switches to full voltage
98. e utilizes the following settings Maximum Input Words 32 fixed cannot modify Maximum Output Words 32 fixed cannot modify Scanned Input Words 32 default valuea Scanned Output Words 32 default valu 0 MO Length 3300 size is set for block transfer operation MI Length 3300 size is set for block transfer operation Setting the scanned input and scanned output words to less than 32 can reduce the processor scan time by transferring only part of the input and output image that your application requires It is important that you do not set either of these values to 0 8 12 Serial Communications Remote I O Examples cont 2 F7 G FILE SIZE to specify the number of words required for the I O module 3 for standard operation 5 if using complemen tary I O In this application example G File size 3 3 F6 MODIFY G FILE Word 0 of the G File is configured automatically by the processor according to the particular specialty I O module Word 0 cannot be edited Word 1 Primary Normal Logical Device Address Specifies the logical starting address of each primary normal RIO link device The logical address consists of the logical rack number 0 1 2 or 3 and starting logical group 0 2 4 or 6 Each bit in this word represents a logical address To specify an address in binary mode you place a at the bit corresponding to the starting logical address of each logical device For this SMC Dialog examp
99. ecial applications require consideration bypass two speed motors and multi motor protection Bypass In a bypass configuration the SMC Dialog Plus controller loses current sensing capability It is recommended that a Bulletin 825 converter module be used to provide current feedback to the SMC Dialog Plus controller for these applications to maintain the thermal memory and to maintain the SMC Dialog Plus controller s power monitoring capability It is possible however to use a traditional electromechanical overload relay for bypass configurations Two speed Motors The SMC Dialog Plus controller has overload protection available for single speed motors When the SMC Dialog Plus 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 Multi motor Protection If the SMC Dialog Plus controller is controlling more than one motor individual overload protection is required for each motor 2 12 Installation Human Interface Module The Bulletin 1201 human interface modules may be used to program and control the SMC Dialog Plus controller The human interface modules have two sections a display panel and a control panel Th display panel duplicates the 2 line 16 character backlit LCD display and programming keypad found on front of the SMC Dialog Plus controller Refer to Chapter 4 for a description of the programming keys refer t
100. ed to the switch settings Serial Communications 8 25 Example Information Description Switch Setting Node Address 13 SW2 Switches 1 3 amp 4 On Switches 2 5 amp 6 Off Data Rate 125k SW2 Switches 7 amp 8 Off Datalinks No SW1 Switches 1 4 Off Zero data to logic command on Yes SW1 Switch 6 Off fault Fault on comm loss Yes SW1 Switch 7 Off Fault on PLC SLC program idle Yes SW1 Switch 8 Off modes The SMC Dialog Plus controller does not support Datalinks Switch Setting BN disabled Datalink A Of B BEN Disabled Datalink B Of EN I BN Disabled Datalink C Of S El ol disabled Datalink D Of a E si BN Not Used off EN o BH Zero Data Off EH o B Faulton Comm Loss Off EN co Faulton Program ldle Of o O lt O 1 0 Mapping Node Address 13 On Node Address 13 Off Node Address 13 On Node Address 13 On Node Address 13 Off Node Address 13 Off Data Rate 125k Off fData Rate 125k Off The SMC Dialog Plus controller s first two words of data are pre configured in the 1203 GK5 communication module as follows Word Output Data Input Data 1 Logic Command Logic Status 2 Reference Feedback TheSMC Dialog Plus controller does not utilize this feature a value of zero should be given The feedback word is the value of parameter 4 Current Phase A 8
101. ee oe LU LS LU CE 4 11 Advanced Setup saaaamanawanan 4 12 Chapter 5 Calibration Chapter 6 Metering Chapter 7 Options Chapter 8 Serial Communications Table of Contents toc v Example Settings ios sc ORCI ex eaten sre ne neon aaa wa 4 13 Undervoltage an 4 13 Overvoltage 4 13 MUM oe ee eee ee eT a 4 13 Underload 0 cect cece eee n mnn 4 13 Overv eW Lr d La dad ass y 1994 adul adu agone qiiis s 5 1 Motor Data Entry eee eret emn ens 5 1 Calibration Procedure 5 3 UD m 6 1 Viewing Metering Data 6 1 DUE UD AA AA aE 7 1 Human Interface Module 7 1 Programming Parameters 7 3 Control Wiring for SCANport Control 7 5 Soft Stop Pump Control and SMB Smart Motor Braking Options 7 6 Soft Stop Option 7 12 Pump Control Option 7 13 SMB Smart Motor Braking Option 7 14 Preset Slow Speed and Accu Stop Options 7 15 Preset Slow Speed Option 7 20 Accu Stop Option awanaaananna 7 21 Slow Speed with Braking Option 7 22 OUCIVIOW 25 5 5505 545046 e556 d 4449 LA LULU NA MAGUNIA 8 1 Log
102. een the line and load terminals of each phase on the controller Resistance should be greater than 10 000 ohms Feedback Resistance 1 Measure resistance between e pins J17 and J18 for phase L1 T1 e pins J12 and J13 for phase L2 T2 e pins J4 and J5 for phase L3 T3 Each resistance should be approximately 20K Q 2 Measure resistance between e pins J14 and J21 for phase L1 T1 e pins J9 and J20 for phase L2 T2 e pins JI and J19 for phase L3 T3 Each resistance should be approximately 20K O If any of the measurements read open replace the interface board Figure 10 8 Pin Locations for Power Pole Resistance Check 180 1000A J13 J5 J11 J3 J9 Ji J10 J2 12 4 p m J20 J19 J8 J7 Gate Lead Resistance 1 Measure resistance between e pins J16 and J18 for phase L1 T1 e pins J11 and J13 for phase L2 T2 e pins J3 and J5 for phase L3 T3 The resistance should be approximately 100 Q 10 14 Troubleshooting Power Module and Interface Board Resistance Check cont 2 Measure resistance between pins J14 and J15 for phase L1 T1 e pins J9 and J10 for phase L2 T2 e pins JI and J2 for phase L3 T3 The resistance should be approximately 100 Q If any of the resistances measure greater than 1009 recheck th re
103. elect the lowest stopping time setting that will satisfactorily stop the pump Preset Slow Speed Option This option can be used in applications that require a slow speed jog for general purpose positioning Preset Slow Speed provides either 7 of base speed low or 15 of base speed high settings in the forward direction Reverse can also be programmed and offers 10 of base speed low and 20 of base speed high settings 1 14 Product Overview Control Options cont Figure 1 14 Preset Slow Speed Option TONS 15 Hig zi 7 Low Time seconds lt Start Run gt 2 10 Low pL ATTENTION Slow speed running is notintended fo continuous operation due to reduced motor cooling SMB Smart Motor Braking Option This option can be used in applications that require reduced stopping times The SMC Dialog Plus controller incorporates a microprocessor based system that applies braking current to standard squirrel cage induction motor without any additional equipment This option offers a user adjustable braking current setting from 0 to 400 of the motor s full load current rating Further it provides automatic shut off at zero speed detection Figure 1 15 SMB Smart Motor Braking Option 10 Motor Speed Time seconds Automatic Zero Speed Shut off Product Overview 1 15 Note All braking current settings in the range of 1 100 will provide 100 braking current
104. er 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 th responsibility of the user 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 Remove all packing material from the heat sink After unpacking check the item s nameplate catalog number against the purchase order The controller should remain in its shipping container prior to installation If the equipment is not to be used for a period of time it must be stored according to the following instructions in order to maintain warranty coverage e Store in a clean dry location e Store within an ambient temperature range of 20 C to 75 C 4 F to 167 F e Store within a relative humidity range of 0 to 95 noncondensing e Do not store equipment where it could be exposed to a corrosive atmosphere e Do not store equipment in a construction area 2 2 Installation General Precautions In addition to the precautions listed throughout this manual the following statements which are general to the system must be read and understood ATTENTION The controller contains ESD electrostatic discharge sensitive parts and assemblies Static control precautions are reguired whe
105. ers units are provided The parameter values of the SMC Dialog Plus controller are stored as unscaled numbers When reading parameter data in the PLC SLC s input image table divide this number by the scale factor shown in Appendix B Table B 1 to arrive at the proper value When writing from the PLC SLC s output image table to the SMC Dialog Plus controller the scale factor must be taken into consideration to ensure that the proper value is sent 8 4 Serial Communications Display Unit Eguivalents Datalinks Interfacing Processing Time Some parameter setting options use a text description when viewed from the built in LCD display or a human interface module An example is the parameter Starting Mode which has the available settings of Soft Start and Current Limit Table B 2 found in Appendix B provides the required display unit decimal equivalent for use when sending a command from a logic controller to the SMC Dialog Plus controller The SMC Dialog Plus controller does not offer Datalinks Refer to the appropriate communication module manual for detailed information regarding communication module installation DIP switch settings block transfer instructions and communication module troubleshooting The typical time for the SMC Dialog Plus controller to process single parameter data request i e block transfer via the SCANport is approximately 100 msec Keep this value in mind when determining the message lengt
106. functions and some protective features of the controller may no longer be available See Figure 3 17 on page 3 13 for this configuration 2 4 Installation Mounting The controller is convection cooled Additionally units rated for 97A and above are fan cooled It is important to locate the controller in position that allows air to flow vertically through the power module The controller must be mounted with heatsink fins in a vertical plane and have a minimum of six inches 15 cm free space abov and below the controller Dimensions Figure 2 1 Dimensions 24 35 and 54 Amp Controllers 9 28 in 7 14 mm 4 Mtg Holes i d d Q4 i Geo meo peo 9 22 in fii 5 56mm id E 4 Mtg Holes RARRARARAAARNRANRARAN Alon Badoy SC Disi Pise G F B i SEET Jl Y ji 7 Ground Scre d E 10 32 A A A B C Approx Unt Width Height Depth d E J H J Ship Wt 24A mm 154 180 185 50 140 160 140 10 20 4 5 kg Controller in 6 1 16 7 3 32 7 19 64 1 31 32 5 33 64 6 5 16 5 33 64 13 32 51 64 10 Ibs 35A mm 214 240 195 60 200 200 180 20 30 6 8 kg Controller in 8 7 16 9 39 64 7 11 16 2 23 64 7 7 8 7 7 8 7 3 32 51 64 1 3 16 15 Ibs 54A mm 244 290 225 90 230 240 200 25 45 11 3 kg Controller in 9 39 64 11 22 64 8 7 8 3 35 64 9 1 64 9 29 64 7 7 8 63 64 1 25 32
107. gle Transient UL The condition at a particular time of any numerous entities within a system These conditions may be represented by values in a status line The process of absorbing and clipping voltage transients on an incoming AC line or control circuit MOVs Metal Oxide Varistors and specially designed R C net works are usually used to accomplish this To switch alternately between two possible selections A momentary deviation in an electrical or mechanical system Underwriters Laboratories an approval agency A accessories D 1 Accu Stop option wiring diagrams 7 14 7 15 7 16 7 17 Accu Stop description of 1 15 Accu Stop option programming parameters for 7 4 sequence of operation 7 20 B Bulletin 825 converter module description 2 16 2 17 2 18 for metering 1 10 in a bypass configuration 2 11 part numbers of D 1 rating of 5 2 with fanning strip connection 3 6 D 1 with overload protection 1 5 with phase rebalance 1 5 C calibration 5 1 procedure 5 3 clear fault 9 1 communication 1 11 8 1 communication comm fault 9 5 communication modules 2 16 8 4 control enable 8 2 control module removal 10 6 10 7 10 8 10 9 180 360 amp 10 7 10 8 24 135 amp 10 6 500 1000 amp 10 9 control module replacement 10 10 control options 1 12 1 13 1 14 1 15 Index control power 3 4 control voltage 3 4 control wiring 3 4 control terminals 3 6 controller overview 1 1
108. grammed stopping slowly with setting time and correct if necessary Soft Stop option Misapplication The Soft Stop option is intended to extend the stopping time for loads that stop suddenly when power is removed from the motor Fluid surges with pumps still occur with the Soft Stop option Misapplication Soft Stop ramps voltage down over a set period of time In the case of pumps the voltage may drop too rapidly to prevent surges A closed loop system such as Pump Control would be more appropriately Suited Refer to Publication 150 911 Motor overheats Duty cycle Preset Slow Speed and Accu Stop options Extended operation at slow speeds reduces motor cooling efficiency Consult motor manufacturer for motor limitations Smart Motor Braking option Check duty cycle Consult motor manufacturer for motor limitations Motor short circuit Winding fault Identify fault and correct Check for shorted SCR replace if necessary Ensure power terminals are secure 10 6 Troubleshooting Control Module Removal ATTENTION To avoid shock hazard disconnect main power before working on the controller motor or control devices such as Stop Start push buttons ATTENTION Make sure that wires are properly marked and that programmed parameter values are recorded ATTENTION Whenremoving control module make sure power module or interface board pins do not bend ATTENTION The 500 amp device is e
109. gure 1 6 Overload Trip Curves Class 10 Class 15 Class 20 Class 30 1000 10000 0 10000 0 10000 0 e e 1000 1000 e gt s e e 100 0 m e cd e 100 0 gt m e e e e m e e Approximate Trip Time seconds Approximate Trip Time seconds Approximate Trip Time seconds Approximate Trip Time seconds 0 1 1 2 3 4 5678910 9 2 1o 3 4 5678910 1 2 3 4 5678910 1 2 3 4 5678910 Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC Approximate trip time for 3 phase balanced Approximate trip time for 3 phase balanced condition from cold start condition from cold start Figure 1 7 Restart Trip Curves after Auto Reset 100000 1000 100 X AI 2 A 10 N Class 1 z Class 15 NA kaa aha Class 20 Ra gt Class 30 1 4 Auto Reset Times Class 10 90s Class 15 135s Class 20 180s Class 30 270s 0 10096 100096 Percent Full Load Current Setting 1 8 Product Overview Protection and Diagnostics cont Stall Protection and J am Detection The SMC Dialog Plus controller provides both stall protection and jam detection for enhanced motor and system protection e Stall protection is user adjustable from 0 0 to 10 0 seconds in addition to the ramp time programmed
110. h of multiple parameter value read or write operations Serial Communications 8 5 Remote 1 0 Ekamples Example 1 SLC 500 Controller without Block Transfer This example demonstrates discreet control of an SMC Dialog Plus controller from an SLC 500 logic controller Additionally the SLC controller reads the Current Phase A from the SMC Dialog Plus controller via the analog feedback word Many of the selections shown are example specific Some changes by the user may b necessary to apply the concepts of this example to a specifi application System Configuration SLC 5 02 or higher z E 1747 SN Scanner o oo BB BB BH na na Remote 1 0 Link PAYOUT LIL Allen Bradley SMC Dialog Plus f s 1203 GD1 J emane U Communication Module SMC Dag Plus Bulletin 1202 SCANport Cable Controller Qo t3 Note Itis critical that during the system design phase that each device on the Remote I O link is allocated a unique segment of the SLC s I O image table This is accomplished by coordination of the devices rack address rack size and starting group address 8 6 Serial Communications Remote I O Examples cont 120
111. he next Explicit Message operation a Explici Explici Message Message Response Response Availabl COP 1 Copy File Source M1 1 224 15 Dest N11 50 Length 32 EQU MVM Equal Masked Move Source A N11 0 USE dem 257 lt Mask OOFFh Source B N11 50 255 lt 257 lt Dest M0 1 224 lt Overview Fault Display Clear Fault Caper 9 Diagnostics This chapter describes the fault diagnostics of the SMC Dialog Plus controller Further this section describes the conditions that caus various faults to occur Protection Programming Many of the protective features available with the SMC Dialog Plus controller can be enabled and adjusted through the programming parameters provided For further details on programming refer to the Advanced Setup section in Chapter 4 Programming The SMC Dialog Plus controller comes equipped with a built in two line 16 character LCD The LCD displays the fault message on th first line and the fault code on the second line Figure 9 1 Fault Display OVERLOAD F7 Note The fault display will remain active as long as control power is applied If control power is cycled the fault will be cleared the controller will re initialize and the display will show a status of Stopped Important Resetting a fault will not correct the cause of the fault condition Corrective action must be taken before resetting the fau
112. ial Torque 1 The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter 0 to 90 locked rotor torque Kickstart Time A boost of 550 full load current is provided to the 0 0 to 2 0 seconds motor for the programmed time period G Ifthe controller senses that the motor has reached full speed before completing the voltage ramp it will automatically switch to providing full voltage to the motor To apply a fixed reduced output voltage to the motor the following parameters are provided for user adjustment Parameter Option Starting Mode This must be programmed for Current Limit aoit start Current Eimit Ramp Time 1 0 This programs the time period that the controller will hold the fixed reduced output voltage before switching to full voltage 0 to 30 seconds Current Limit Level This parameter provides adjustability for the reduced 50 to 600 full load current output voltage level provided to the motor Kickstart Time A boost of 550 full load current is provided to the 0 0 to 2 0 seconds motor for the programmed time period Ifthe controller senses that the motor has reached full speed before completing the current limit start it will automatically switch to providing full voltage to the motor 4 10 Programming Dual Ramp Start Full Voltage Start The SMC Dialog Plus controller provides the user with the ability to select between tw
113. ic Control Data 8 1 Control WINING IIIA 8 1 Control ENADE Aa 8 2 SMC Status Data aaa 8 3 Reference Feedback 8 3 Parameter Listing 8 3 Scale Factor Conversion 8 3 Display Unit Equivalents 8 4 DRAWS ER 8 4 IN ii IAA EIA 8 4 Processing TIMe swaanans 8 4 Remotel OEkamples s 8 5 Example 1 SLC 500 Controller without Block Transfer 8 5 1203 GD1 Communication Module Switch Settings 8 6 G File COMMGUIGHOM aaa 8 7 MO Addressing n eee eee eee eee eee eens 8 7 Example 1 Ladder Logic Program 8 9 Example 2 SLC 500 Controller with Block Transfer 8 10 1203 GD1 Communication Module Switch Settings 8 10 Example 32 Ladder Logic Program 8 15 toc vi Table of Contents Chapter 9 Diagnostics Chapter 10 Troubleshooting Example 3 PLC 5 20 5 40 5 60 and 5 80 8 18 1203 GD1 Communication Module Switch Settings 8 19 YO Addr ssing icc ux Rc E ee x tx ERR Keys 8 19 BlockTransfer Instructions 8 21 BlackTransier Datafiles 8 22 Example 3 Ladder Logic Program 8 23 DeviceNet Examples 0 cece eee teen nn 8 24 Example 1 SLC Controller with E
114. 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 e 250V 6 inch diameter coil 6 loops e 480 600V 6 inch diameter coil 8 loops Take care in mounting the coils so that they are not stacked directly on top of each other stacking will cause a canceling effect Also mount the coils on insulated supports away from metal parts so they will not act as induction heaters If an isolation contactor is used put capacitors in front of contactor Note For further instructions consult the PFC capacitor vendor Figure 2 6 Typical Wiring Diagram for Power Factor Correction Capacitors o9 IC e uy mp 12 3 T2 4 31 Motor 13 5 73 6 Branch Circuit Protection SMC Dialog Plus Customer supplied YA Va Q Not required Power Factor Correction Capacitors 2 10 Installation Fast Acting Current limiting Fuses Short circuit protection guidelines are provided in Appendix A of this manual Enhanced SCR protection may be obtained with the use of fast acting current limiting fuses Table 2 C provides a listing of fuses that are coordinated to protect the controller SCRs in the event of a ground fault or short circuit at the connected load If SCR fusing is not used
115. ious networks and communication protocols The figure below shows how the controller and the communication module connect Figure 2 8 SMC Dialog Plus Controller with Communication Module K R LLALL DALA S SUIT 9 e D SS L3 7 o 601 N90 oo a ua eb EDO ces PD pe PLLLLS pi d L Pull back moving part connector body to disconnect SIE l cable from the SCANport connection Bspssb sPPs oudoduDubuuuuUUU e Allen Bradley SMC Dialog Plus o ups Q A ra 9 oO PIS eL A v a Ed 1 Communication Modu SMC Dialog Plus Controller Converter Modules The Bulletin 825 converter module provides three phase current feedback to the SMC Dialog Plus controller for metering and overload protection during phase rebalance and bypass operation Select the converter module based on the motor full load current FLC rating Table 2 A details the information for proper selection Table 2 A Converter Module Selection Guide Motor FLC Range Cat No 1 12 5A 825 MCM20 9 100A 825 MCM180 64 360A 825 MCM630 Installation 2 17 Figure 2 9 shows the connection between the controller and the module Figure 2
116. ircuit Connections aay uch d o EE EOR rE ee b Output Power d a 9 alo Connections 0 Fan 2 Mice Power Wa Connections ole g HO 3 2 Wiring Terminal Locations cont Figure 3 3 Wiring Terminal Locations 180 to 360 Amp trol Wiring A TTE un L2 3 L3 5 Control Wiring Access Door Connections n Ais 6 5 onnections ws IODO Control Bu tee M A Circuit Connections 2350503539 1 C ABE Output Power Connections t172 12 4 13 6 Figure 3 4 Wiring Terminal Locations 500 Amp Input Power LIA L2 3 L3 5 lt Ceca lx Fan Power Connections 500 Amp Unit 55855558555 jen 555860285551 7C Control Circuit TUI t au ut uuu yp Connections EIFE Output Power 11 2 T2 4 13 6 Connections Wiring 3 3 Figure 3 5 Wiring Terminal Locations 650 to 1000 Amp LIA L2 3 L3 5 T1 2 T2 4 T3 6 Input an Output Power 650 1000 Amp Unit EODRIGEuONS Control Circuit SSSESESSES Connections IT m uumunuuuuuuu Q mn m lt l
117. ired according to Figure 3 14 on page 3 10 Option Action Operation Soft Stop The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop The jog button when pressed will initiate a soft stop maneuver c je O Pump Control The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop The jog button when pressed will initiate a pump stop maneuver rm je o 7 2 Options Option Action Operation Preset Slow Speed The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop The jog button when pressed will initiate slow speed motor operation from a stopped status rm o Smart Motor Braking The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop The jog button when pressed will initiate a brake stop rm e Accu Stop The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop With a stopped status the jog button when pressed will initiate slow speed motor operation From an at speed
118. it mapped to the SMC Dialog Plus controller s logic control word clear faults bit The branch provides a logic latched circuit which exerts the FAULT RESET command until input from the SMC Dialog Plus controller s status word indicates that it has received the comand and has responded appropriately The SMC Dialog Plus controller s CLEAR FAULT bit functions as long as all other logic c dal bits have been reset to zero FAULT RESET SMC From CLEAR FAULT RSVIEW Command B3 Os a p E We 27 SMC SMC CLEAR FAULT Fault Command Bit O 17 UIS 3 Se Rung 4 When bit B3 0 0 is set the 32 words beginning at N11 0 from the SLC processor are copied to the 1747 SDN scanner s MO file The 1747 D scanner sends this message out over the DeviceNet trunkline The unlatch branch instruction resets B3 0 0 to zero for the next processor scan Explici Message Initiate Request Explici Message COP B3 0 Copy File Source N11 0 PEE Dest M0 1 224 Length 32 B3 Qu U 0 Rung 5 When the 1747 SDN scanner has an Explicit Message response available it sets bit 15 of its status word 1 1 15 in this example The Explicit Message response is then copied from the 1747 SDN scanner s M1 file to the SLC processor s N11 file beginning at word 50 The branch copies command byte of 4 into the 1747 SDN scanner s MO file which directs it to discard the response data to prepare it for t
119. l interface port called SCANport is provided as standard which allows connection to the Bulletin 1201 human interface modules and the Bulletin 1203 communication modules Figure 1 10 SCANport Location ESC SEL Iv 1 SCANport ATTENTION Only one peripheral device can be connected to the SCANport The maximum output current through the SCANport is 100 ma Programming Setup is easy with the built in keypad and two line sixteen characte backlit LCD Parameters are organized in a four level menu structure using a text format for straightforward programming Figure 1 11 Built in Keypad and LCD Qo AA ESC E A v Status Indication Three programmable hard contact outputs are provided as standard The first two contacts are Form C and programmable for Normal Up to speed The third contact is programmable as Normal Fault 1 12 Product Overview Control Options The SMC Dialog Plus controller offers the control options described below Important The options listed in this section are mutually exclusive and must be specified when ordering An existing controller may be upgraded to another control option by replacing the control module Consult your nearest local Allen Bradley sales office Soft Stop Option This option can be used in applications tha
120. le 5 A Motor Codes pesignaton AAA RPG A 0 3 15 L 9 0 10 0 B 3 15 3 55 M 10 0 11 2 C 3 55 4 0 N 11 2 12 5 D 4 0 4 5 P 12 5 14 0 E 4 5 5 0 R 14 0 16 0 F 5 0 5 6 S 16 0 18 0 G 5 6 6 3 T 18 0 20 0 H 6 3 7 1 U 20 0 22 4 J 7 1 8 0 V 22 4 and up K 8 0 9 0 Locked kVA per horsepower range includes the lower figure up to but not including the higher figure For example 3 14 is designated by letter A and 3 15 by letter B Calibration Procedure Calibration 5 3 For current measurement accuracy Use the procedure below to calibrate the SMC Dialog Plus controller to the connected motor A clamp on ammeter which provides a true rms measurement and has published accuracy of 1 Fluke model 33 or equal is required to perform this procedure Notes 1 If you plan to use the Bulletin 825 converter module for current feedback to the SMC Dialog Plus controller this calibration procedure is not necessary 2 An unbalanced three phase system may affect th accuracy of the calibration measurements at overload trip levels 3 It is recommended that Parameter 36 Overload Class is programmed to OFF during the calibration procedure Calibration requires the motor to be operated at full speed Additionally the motor must be connected to its load in order that the motor draw as near to its full load current FLC rating as possible This is necessary so that maximum accuracy is achieved for cu
121. le application Word G1 16 1 indicating logical rack 0 starting group 0 Word 2 Primary Normal Device Logical Image Size Specifies the logical image size amount of scanner I O image of th devices set inWord 1 As with Word 1 these bits correspond to RIO logical rack and logical group numbers To specify imag size in binary mode you place a at each group a device occupies This SMC Dialog example is using 1 4 rack size Word G1 33 1 Word 3 and Word 4 refer to Complementary I O Configuration if G File size is set to 5 which is not used in this sample application Please reference the RIO Scanner User Manual Publication 1747 6 6 and the Advanced Programming Software APS User Manual Publication 1746 6 4 for further information on any of the above settings or operations SLC 500 Ladder Logic Program Terms used BTBlock Transfer BTR Block Transfer Read BTW Block Transfer Write The sample ladder logic program that follows performs a consecutive parameter value read of the SMC Dialog Plus controller s metering group parameters 1 11 by using a BTW BTR pair The BT operation defines to the Bulletin 1203 communication module the type of parameter read write operation Continuous Parameter Valu Read for this example and identifies the parameters to be polled Execution of the BTR operation allows the communication module to respond providing the requested data Notes 1 The ladder logic program does not
122. led direction in Parameter Management Store In EE Ready Default Init Recll Frm EE Store In EE Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter amp The new programmed parameter values will not be stored to the EEPROM without the user s 4 12 Programming Advanced Setup While the Basic Setup group allows the user to get started with minimum number of parameters to modify the Advanced Setup group allows full access to the SMC Dialog Plus controller s powerful parameter set Following is a listing of the additional setup parameters provided Note All of the Basic Setup parameters are available in th Advanced Setup group The parameters shown below are in addition to the parameters in Basic Setup Parameter Dual Ramp Allows the user the option to choose between two Soft Start profiles Option Off On Ramp Time 2 Determines the soft start time for the second ramp of the Dual Ramp feature 0 to 30 seconds Initial Torque 2 Provides the initial torque setting for the second ramp of the Dual Ramp feature 0 to 90 locked rotor torque Undervoltage Level Determines the trip level as a percentage of line voltage 0 to 99 0 is the Off setting Undervoltage Delay Provides a delay period prior to a trip occurrence 0 to 99
123. liary contacts se for Norma e SMC Dialog Plus Control Terminals 21 22 23 24 25 26 27 28 29 30 Customer supplied Overload protection should be disabled in the SMC Dialog Plus controller Soft Stop Pump Stop or Brake Note Refer to Chapter 3 for typical power circuits T Refer to the controller nameplate to verify the rating ofthe control power input voltage 7 7 Options Figure 7 3 Typical Wiring Diagram for Applications Reguiring an Isolation Contactor JI m Control Power Stop e O Option Stop e O Start _ O ij a2 39 Ta pu 16 17 18 19 20 Auxiliary contacts se i for Normal YA SMC Dialog Plus Control Terminals Internal Auxiliar Contacts Hi a 2s 2 2 we 27 28 29 30 Customer supplied Q amp Soft Stop Pump Stop or Brake Note Refer to Chapter 3 for typical power circuits T Refer to the controller nameplate to verify the rating ofthe control power input voltage 7 8 Options Figure 7 4 Typical Wiring Diagram for Applications Requiring a Bypass Contactor Control Power gt EM E e Option Stop e O Start roO O jd 32 338 34 pum io p ay de
124. locked rotor torque The Dual Ramp feature is available only with the standard controller The SMC Dialog Plus controller may be programmed to provid full voltage start output voltage to the motor reaches full voltage within 1 4 second with the following programming Parameter Starting Mode This must be programmed for Soft Start Option Ramp Time 1 This must be programmed for 0 seconds for a full voltage start Initial Torque 1 This must be programmed for 90 for a full voltage Start Kickstart Time This must be programmed for 0 0 seconds for a full voltage start Basic Setup Programming 4 11 The Basic Setup programming group provides a limited paramete set allowing quick start up with minimal adjustment If the user is planning to implement some of the advanced features i e Dual Ramp Phase Rebalance etc then the Advanced Setup programming group should be selected It provides all the Basi Setup parameter set plus the advanced set Parameter SMC Option Displays the type of controller This is factory set and not adjustable Option Standard Starting Mode Allows the user to program the SMC Dialog Plus controller for the type of starting that best fits the application Soft Start Current Limit Ramp Time 1 This sets the time period during which the controller will ramp the output voltage 0 to 30 seconds Initial Torque 1 The initial reduced voltage
125. lt You can clear a fault using any of several methods e Program the SMC Dialog Plus controller for a Clear Fault which can be found in the Faults and Linear List groups e Ifa human interface module is connected to the controller press the Stop button Note The stop signal will not clear a fault if Control Logic is disabled Logic Mask parameter 85 equals 0 9 2 Diagnostics Clear Fault cont Fault Buffer Fault Auxiliary Contact e Cycle control power to the SMC Dialog Plus controller Notes 1 An overload fault cannot be cleared in this way for firmware releases prior to the following Standard Option 1 07L Soft Stop Option 1A07L Pump Control Option 1BOSL 2 A communication fault F21 cannot be cleared in this way for firmware releases prior to 1 04C Important An overload fault cannot be reset until the Motor Thermal Usage parameter 11 value is below 75 See page 1 7 for further details The SMC Dialog Plus controller stores in memory the five most recent faults Display the fault buffer by selecting the Faults group and scrolling through the fault buffer parameters The information is stored as fault codes To determine what faults have occurred use th fault code cross reference below Fault Codes Table 9 A provides a complete cross reference of the available fault codes and corresponding fault descriptions Table 9 A Fault Code Cross reference Fault Code Des
126. lus Controller Logic Control Addresses Bit Description loro Slot Word Bit Address Stop 0 1 16 00 0 1 16 00 Start 0 1 16 00 0 1 16 01 Option Command 0 1 16 02 0 1 16 02 Clear Fault 0 1 16 03 0 1 16 03 SMC Dialog Plus Controller Status Addresse Bit Description lorO Slot Word Bit Address Enabled 1 16 00 1 16 00 Running 1 16 01 1 16 01 Starting 1 16 04 1 16 04 Stopping 1 16 05 1 16 05 Fault 1 16 07 1 16 07 At Speed 1 16 08 1 16 08 SMC Dialog Plus Controller Feedback Address lor Oo Theaddresses shown are example specific Addresses for any given installation can be determined based upon the 1203 GD1 communication module switch settings for rack address starting group number block transfer logic command status and reference feedback by applying the I O addressing format for SLC 500 controllers Q The1747 SN scanner resides in slot 1 Based on the 1203 GD1 communication module switch settings rack 2 starting group 0 Refer to the 1747 SN User Manual Publication 1747 6 6 Referto Table 8 A Refer to Table 8 B Serial Communications 8 9 Example 1 Ladder Logic Program First Rung When the MachineSTART push button is pressed the SLC sends a START command to the SMC Dialog Plus controller TheSMCDialog Plus controller will start if no STOP command is being issued by the SLC or any other control device The start button is a norm
127. mation to the 1747 SN for execution COP COPY FILE Source N10 0 Dest M0 1 100 Length 74 Rung 2 7 END Serial Communications 8 17 The information in the data table listed below was obtained from a 150 Hp motor 1800 RPM rated at 480 volts The motor has been operating continuously for a period of 72 hours Parameter Parameter Display Parameter Parameter Display Description Number Value Description Number Value Voltage Phase A B 1 470 Wattmeter 70 90 0 Voltage Phase A B 2 474 Kilowatt Hours 8 82 Voltage Phase A B 3 469 Elapsed Time 9 72 Current Phase A 40 120 0 Power Factor 100 92 Current Phase B 50 120 0 AN 1 80 Current Phase C 60 120 0 Refer to Appendix B and apply the scale factor to above parameters in the data table below Address Data B3 0 Address Data N10 0 Radix BINARY 0000 0000 Radix BINARY 128 64 0000 e N10 10 m un N10 20 N10 30 N10 40 N10 50 N10 60 N10 70 N10 80 N10 90 oco 00 0009650505 ia AE A II N10 100 o o o o oj o ojlo oj gt Caan B a a BE a BE gt O gt S lt e AR 5 E e A e o o 0 0 o o ojojoj ojo E r a E S O Cc AR GAE e DEE a BE m S E ee oo o o olooo o o o o o o o o o oo o o o S o S O AA GE e DE a N ma E e N10 110 pi Un C1 oo oo olooooo mn o 470 474 469 1200 1200 1200 N10 120 90
128. minals Internal Auxiliar Contacts A a2 29 25 25 We 2g 28 29 30 Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage Note Refer to Chapter 3 for typical power circuits 7 24 Options Figure 7 20 Typical Wiring Diagram for the Slow Speed with Braking Option with a Bypass Contactor JI lt Control Power gt m Stop O Pe Brake Slow Speed _ Q Start 0 roO Q e d 32 18 mA 38 16 17 18 19 20 Auxiliary contacts se for Up to speed 1 SMC Dialog Plus Control Terminals E e Bulletin 82 Fanning Strip Internal used Auxiliar odule Contacts 2w 2 a 24 25 26 2 28 29 30 Customer supplied Tm Q Refer to the controller nameplate to verify the rating of the control power input voltage Note Refer to Chapter 3 for typical power circuits 100 gt Motor Speed Push Button Start Closed Open Stop Closed Open Slow Speed Closed Open Auxiliary Contacts Normal Up to speed Options 7 25 Figure 7 21 Slow Speed with Braking Option Sequence of Operation Braking Time seconds gt Start R
129. n 2 1 interfacing 8 4 J jam detection 9 4 K keypad description 1 11 4 1 L ladder logic program 8 9 8 15 line fault 1 9 9 3 logic control data 8 1 M metering 1 10 6 1 motor data entry 5 1 motor codes 5 2 motor overload protection 2 11 bypass configuration 2 11 multi motor protection 2 11 series A human interface modules 2 14 series B human interface modules 2 15 two speed motor connection 2 11 mounting 2 4 dimensions 2 4 2 5 2 6 2 7 2 8 MOV fuse replacement 10 11 0 open gate 1 9 options 7 1 overload protection 1 5 overvoltage protection 9 3 P parameter electrically erasable programmable read only memory EEPROM 4 6 listing of 4 4 8 3 B 1 management of 4 6 modifying of 4 8 random access memory RAM 4 6 read only memory ROM 4 6 using parameter management 4 7 phase rebalance 1 5 phase reversal 1 9 9 3 power factor correction capacitors 2 9 power loss 9 3 power module and interface board resistance check 10 11 10 12 10 13 10 14 feedback resistance 10 12 10 13 gate lead resistance 10 12 10 13 preparation 10 11 Shorted SCR test 10 12 10 13 thermistor resistance 10 12 10 14 precautions 2 2 preset slow speed option description of 1 13 programming parameters for 7 3 sequence of operation 7 19 wiring diagrams 7 14 7 15 7 16 7 17 programming advanced 4 12 4 13 basic 4 11 example settings 4 13 password 4 5 programming menu 4
130. n 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 o implement the installation start up and subsequent maintenance of the system Failureto do this may result in personal injury and or equipment damage Heat Dissipation The following table provides the maximum heat dissipation at rated current for the controllers For currents lower than rated value heat dissipation will be reduced Table 2 4 Maximum Heat Dissipation ses Taa Taa Taa Tam waa Tama Tam wa T som T e aa Tam Taoa Enclosures The open style design of the SMC Dialog Plus controller reguires that it be installed in an enclosure The internal temperature of the enclosure must be kept within the range of 0 C to 50 C Ventilated Enclosures Installation 2 3 For Type 1 IP42 enclosures the following guidelines are recommended to limit the maximum controller ambient temperature There should be a clearance of at leas
131. nce Monday through Friday from 8 00 a m to 12 00 noon and 1 00 p m to 4 30 p m central time zone Areas outside the United States and Canada can call 001 414 382 4650 for assistance Chapter 1 Product Overview 1 1 Chapter 2 Installation Table of Contents Uca PETIT 1 1 Operaatio scs praLEXZAGXGAZXGXGXS3XGAGGG4S4XRGXGGSXGx238 1 1 Starting Modes ss 1 2 SOM ii 1 2 Selectable Kickstart 1 3 Current Limit Start 1 ice i eco g 1 3 Dual RampStartt ss 1 4 Full Voltage Start 1 4 Energy Saver lt 6 tora cice pr Garp rh eee hry dir 1 5 Phase Rebalance 1 5 Protection and Diagnostics 1 5 Overload ouaa 1 5 Stall Protection and J am Detection 1 8 Open Gate nunua a 1 9 Line Faults ies a ue cs apc Seok es ede KN OE HA NAN Ha 1 9 Underload 1 9 Excessive Starts HOUr o a 1 10 Overtemperature 1 10 MN IIIA 1 10 Communication sao dne Rad eode dieat 1 11 Programming PEPPER TERES 1 11 Status WNMICGUON ictrcctoriteraveaeeeeneeeenenteares 1 11 Control ODE OS aaa 1 12 Soft APP CETT 1 12 Pump Control Option 1 13 Preset Slow Speed Option 1 13 SMB o Smart Motor Braking Option 1 14 Accu S
132. ng that is 600 of the full load current rating 1 4 Product Overview Starting Modes cont Dual Ramp Starto This starting mode is useful on applications that have varying loads and therefore varying starting torgue reguirements Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torgue settings Figure 1 4 Dual Ramp Start Percent Voltage 10096 gt Initial Torgue 2 Initial Torque 1 Start 1 gt lt Run Zi gt Start 2 Run 2 gt Time seconds Full Voltage Start This starting mode is used for applications requiring across the line starting The output voltage to the motor will reach full voltage within 1 4 second Figure 15 Full Voltage Start 10096 Percent Voltage Time seconds Dual Ramp Start is available only with the standard controller Energy Saver Phase Rebalance Protection and Diagnostics Product Overview 1 5 The Energy Saver feature is typically used in applications where the motor is lightly loaded or unloaded for extended periods of time With the Energy Saver feature enabled the SMC Dialog Plus controller continuously monitors motor load with its internal feedback circuitry Because SCRs control the output voltage motor power losses may be reduced by decreasing the motor terminal voltage Notes
133. o Appendix D for a listing of human interface modul catalog numbers that are compatible with the controller The control panel provides the operator interface to the controller JOG gt Start The green start button when pressed will begin moto operation Stop The red stop button when pressed will halt motor operation Jog The jog button is active only when a control option is present Pressing the jog button will initiate the option maneuver for example Pump Stop ATTENTION The Bulletin 1201 human interfac module s stop push button is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements All other controls available with the various human interface modules are non functional with the SMC Dialog Plus controller oO Oo SMC Dialog Plus Controller IN Installation Connecting the Human Interface Module to the Controller Figure 2 7 shows the connection of the SMC Dialog Plus controller to a human interface module See Figure 3 14 on page 3 10 for th control wiring diagram that enables start stop control from a human interface module Figure 2 7 SMC Dialog Plus Controller with Human Interface Module G RAAMI NM N DA 5 60 Bulletin 120 L3 Os ITI Latching Mechanism e Il Cable
134. o Products Y Edit B Parasian HEGYE Print to File Close Help Select All SDN Slave Mode Notice that the SMC Dialog Plus controller node 13 has an active status This means that it is active in the scan list and will communicate with the 1747 SDN scanner on the network You will also notice that Yes is listed twice under the Mapped column The leftYes indicates that input data is mapped from the SMC Dialog Plus controller to the SLC 500 The right Yes indicates that output data from the SLC 500 is mapped to the SMC Dialog Plus controller Configure the 1747 SDN if No is displayed To view the actual areas inside the SLC 500 processor where the device data will be transferred to and from select th Datatable Map by clicking on the button the following screen will appear 1747 SDN Datatable Map x 154 IA IAEA a e a T a 00 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 Display Mode Data Entry Browse Double click on word to display bit mapping Device Select 13 Unknown product Unknown catalog number rl Data Map Input C Output Map Segment 41 C2 C3 C4 Map Data From Poll Message Apply segment Delete Segment B B NeBi 2 Print to File Map Data To Discrete 8 28 Serial Communications This indicates that the SMC Dialog Plus controller s inp
135. o Soft Start settings The parameters below ar available in the Advanced Setup programming mode to obtain Dual Ramp control Parameter Advanced Setup The user must select the Advanced Setup programming mode to obtain access to the Dual Ramp parameters Option Starting Mode This must be programmed for Soft Start Dual Ramp This allows the user the option to choose between two Soft Start profiles defined by 1 Ramp Time 1 Initial Torque 1 and 2 Ramp Time 2 Initial Torque 2 When this feature is turned on the ramp time initial torque combination is determined by a hard contact input to terminal 15 When this input signal is low ramp time initial torque 1 are selected When this input is high ramp time initial torque 2 are selected No Yes Ramp Time 1 This programs the time period during which the controller will ramp the output voltage up to full voltage for the first Soft Start setup 0 to 30 seconds Initial Torque 1 This parameter establishes and adjusts the initial reduced output voltage level for the first Soft Start setup 0 to 90 locked rotor torque Ramp Time 2 This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Soft Start setup 0 to 30 seconds Initial Torque 2 The initial reduced output voltage level for the second Soft Start setup is established and adjusted with this parameter 0 to 90
136. ogrammed parameter values are recorded 10 12 Troubleshooting Power Module and Interface Board Resistance Check cont 24 135 Amp Remove the control module per the instructions beginning on page 10 6 Refer to Figure 10 7 for power module pin identification Shorted SCR Test 1 Using an ohmmeter measure the resistance between the line and load terminals of each phase on the controller The resistance should be greater than 10 000 ohms Feedback Resistance 1 Measure resistance between pins 1 and 2 Resistance should be 19 000 ohms 5 2 Measure resistance between pins 7 and 8 Resistance should be 19 000 ohms 5 Gate Lead Resistance 1 Measure resistance between pins 2 and 3 Resistance should less than 100 ohms 2 Measure resistance between pins 6 and 7 Resistance should be less than 100 ohms Thermistor Resistance 1 Measure resistance between pins 4 and 5 Resistance should be less than 150 ohms If the power module fails any of the above tests replace it Figure 10 7 Pin Locations for Power Module Resistance Check o We O SI 2 3 m 1 OT O 6 4 1 ET 5 8 gt F oo Troubleshooting 10 13 180 1000 Amp Remove the control module per the instructions beginning on page 10 6 Refer to Figure 10 8 for interface board pin identification Shorted SCR Test Using an ohmmeter measure the resistance betw
137. ollto the option of your choice by using the Up Down STARTING MODE or keys For this example we will n M CURRENT LIMIT choose Current Limit 9 Press the Enter key to accept STARTING MODE the new setting CURRENT LIMIT 10 Scrollto the next parameter by using the Up key Continue the n RAMP TIME 1 process until all desired settings 10 SEC are entered fo TN ll Press the Enter key to save the PARAMETER MGMT new settings to EEPROM STORE IN EE Ifthe Choose Mode menu does not provide the Program option then you must enter your password Q Thefirstparameter displayed advises the user if any control option i e Pump Control is resident This parameter is factory set and cannot be modified by the user amp Thedisplay will indicate that the second line is now active by flashing the first character If the LCD display does not provide a flashing cursor then the controller is in the Display mode amp You will now notice that the cursor has returned to flashing the first character of the first line Soft Start Current Limit Start Programming 4 9 The following parameters are specifically used to adjust the voltage ramp supplied to the motor Parameter Option Starting Mode This must be programmed for Soft Start SOR Start GUMENE LI MIE Ramp Time 1 This programs the time period that the controller will ramp the output voltage up to full voltage from the Initial Torque level programmed 0 to 30 seconds Init
138. on This parameter identifies the type of control present and is not user programmable Accu Stop Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 High 15 Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting 0 450 of full load current Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 400 of full load current Stopping Current Allows the user to program the intensity of the braking current applied to the motor from slow Speed operation SMC Option This parameter identifies the type of control present and is not user programmable 0 40096 of full load current Slow Speed Brake Slow Speed Select Allows the user to program the slow speed that best fits the application Low 796 High 1596 Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 45096 of full load current Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting 0 45096 of full load current Braking Current Allows the user to program the intensit
139. on by the use of two separate contactors one of which produces rotation in one direction and the other produces rotation in the op posite direction The contactors are electrically and mechanically interlocked so that both cannot be energized at the same time This instruction copies data from one location into another It uses no status bits If you need an enable bit program a parallel output using a storage address The intensified or blinking element in a video display A means for indication where data entry or editing occurs 1 Asequence of operations that is repeated regularly 2 The time it takes for one sequence of operations to occur Glossary 2 DH 485 Link Disable Duty Cycle Enable Fault G File Gate Jogging Jumper LCD Locked Rotor Torgue Mode Normally Closed Contacts Normally Open Contacts PLC Controller Data Highway 485 link An Allen Bradley token passing baseband link for a local area network based on the RS 485 standard To inhibit logic from being activated The relationship between the operating and rest times or repeatable operation at different loads To allow an action or acceptance of data by applying an appropriate signal to th appropriate input Any malfunction that interferes with normal system operation G File configuration is based on the devices that you have on the RIO link G File configuration consists of setting logical device starting addresses and
140. onverter Module Fanning Strip Connection 0 16 Start Input 26 Converter Module Fanning Strip Connection 0 17 Stop Input 27 Converter Module Fanning Strip Connection 0 18 Auxiliary Relay Common 28 Converter Module Fanning Strip Connection 19 N O Auxiliary Contact 1 Normal Up to speed I L 29 N O N C Auxiliary Contact 3 Normal Faul 20 N C Auxiliary Contact 2 Normal Up to speed 30 N O N C Auxiliary Contact 3 Normal Fault T Donotconnect any additional loads to these terminals These parasitic loads may cause problems with operation which may result in false starting and stopping When control power is absent from terminals 11 and 12 this contactwill be normally open Upon application of control power he contact will take the state normally open or normally closed as programmed Grounding Provision for connecting a field installed grounding conductor is Provision provided on each controller It is shown in Figure 3 10 and is located on the heatsink This symbol is the ground connection identification symbol as defined by IEC Publication 417 Symbol 5019 If the protective conductor is not connected to the heatsink the plating and or paint must be cleaned from the four mounting holes o four star washers tooth lock washers must be used Figure 3 10 Grounding Provision Standard Controller Wiring Diagrams Wiring 3 7 Figure 3 11 through Figure 3 22 show typical wiring for
141. ow Speed All 24 54A 97 135A 180 360A 500 650A 720 1000A Accu Stop 24 54A 97 135A 180 360A 500 650A 720 1000A Slow Speed with Braking amp One piece provided per part number 24 54A 97 135A 180 360A 500 650A 720 1000A Input Control Voltage 120 240V AC 24V AC DC Appendix C Part Number 40888 490 01 S1FX 40888 490 01 A1FX 40888 490 01 B1FX 40888 490 01 C1FX 40888 490 01 D1AX 40888 490 01 D1BX 40888 490 01 D1CX 40888 490 01 D1DX 40888 490 01 D1EX 40888 490 01 E1AX 40888 490 01 E1BX 40888 490 01 E1CX 40888 490 01 E1DX 40888 490 01 E1EX 40888 490 01 F1AX 40888 490 01 F1BX 40888 490 01 F1CX 40888 490 01 F1DX 40888 490 01 F1EX 40888 490 01 S2FX 40888 490 01 A2FX 40888 490 01 B2FX 40888 490 01 C2FX 40888 490 01 D2AX 40888 490 01 D2BX 40888 490 01 D2CX 40888 490 01 D2DX 40888 490 01 D2EX 40888 490 01 E2AX 40888 490 01 E2BX 40888 490 01 E2CX 40888 490 01 E2DX 40888 490 01 E2EX 40888 490 01 F2AX 40888 490 01 F2BX 40888 490 01 F2CX 40888 490 01 F2DX 40888 490 01 F2EX C 2 Renewal Parts Description Power Modules One piece provided per part number
142. parameter number as listed in Appendix B of this manual Sequence of Events Use the following sequence of events as a guide for establishing explicit messages in your SLC ladder logic 1 Put the Explicit Message Request data into an integer N file of the SLC 500 processor 2 Use the file copy instruction COP to copy the Explicit Messag Request data entered in step one to the MO file words 224 through 256 3 Use the examine if closed instruction KIC to monitor bit 15 o the scanner s Module Status Register for an indication that it has received a response from the 1203 GK5 communication module 4 Copy the data from the MI file words 224 through 256 into a file in the SLC 500 processor using the file copy instruction COP 5 Usethe move instruction MOV to copy a one word file from the SLC 500 processor into word 224 of the MO file The upper byte of the word should contain the TXID value for this transaction and the lower byte should contain the value 4 which is the com mand for the scanner to clear its response buffer After the move is completed bit 15 of the scanner s Module Status Register should go toa value of zero allowing the next explicit message to be executed 8 32 Serial Communications Setting Up the Data File In this example the data file for the Explicit Message Request begins at N11 0 Following is the structure for a Get Attribute Multiple of the SMC Dialog Plus controller s Metering gro
143. plete dimension drawings Installation 2 7 Figure 2 4 Dimensions 500 Amp Controller e M 531 in 13 5 ES for 1 2 Bolts Typ Se RTN WA F J Y K G A VI q y Of cl q o gt CEESESI Cer stay CISESTSI o 312 in 7 9 Jl ES 6 Mto Holes Jo joo le 0 Q n Ground Nut B 1 4 20 C i A B C Approx Unit Height Width Depth D E F G H J K L M N P Q Leg mm 588 4 508 310 7 183 514 508 469 9 489 19 1969 3937 38 9 18 6 175 136 40 8 kg in 23 11 64 20 12 15 64 7 13 16 2 1 32 2 18 1 2 19 1 4 3 4 7 3 4 15 1 2 1 17 32 47 64 11 1
144. quipped with two shields that must be in place when power is applied to the controller gt DDD The control module is not intended for field repair The entire module must be replaced if a failure occurs Follow the applicable procedur for control module removal 24 135 Amp Refer to Figure 10 2 for control module removal reference 1 Remove all control wires and serial port cables 2 Loosen six mounting screws 3 Unplug control module from the power structure by pulling forward Figure 10 2 Removal of Control Module 24 135A 165558554 OU Ais Bradey SHE Diag Pus Troubleshooting 10 7 180 360 Amp Refer to Figure 10 3 for control module reference 1 2 3 Remove controller access door and serial port cable Remove controller cover Remove all control wires and loosen six control module mounting screws Unplug control module from the interface board by pulling for ward 10 8 Troubleshooting Figure 10 3 Removal of Control Module 180 360A COJN ly Dy a Sw 00 e eO e X leQf ec s o
145. r Speed Push Button Start Closed Open Closed Open Pump Stop Closed Open Auxiliary Contacts Normal Up to speed Coast to rest X N X N X N N I I l li li i li i T j I I Start Run lt Soft Stop Time seconds ATTENTION The user is responsible for determining which stopping mode is best suited to th application and will meet applicable standards for operator safety on a particular machine Options 7 13 SMB Smart Motor Braking Option Figure 7 9 SMB Smart Motor Braking Sequence of Operation 1 EP NS l N ES Smart Motor Braking Motor oe Coast to rest Speed Re ge ue lt Start Run Brake gt l ane 4s Automatic Zero Speed l ime seconds i hut of Push Button SEE Start Closed Open t 1 f sop Closed Open Ll Brake Closed Open LJ Auxiliary Contacts Smart Motor Braking Operation Normal Coast to rest operation S i Up to speed ATTENTION The user is responsible for determining which stopping mode is best suited to th application and will meet applicable standards for operator safety on a particular machine 7 14 Options Preset Slow Speed and Figure 7 10 through Figure 7 14 shows the different wiring for the Accu S
146. r Logic Program Rung 2 0 This rung clears the Virtual BT Command word on the first scan First Scan MOV 5 MOVE ALE Source Qe Dest N10 0 128 Rung 2 1 Copy the BT Status Bits from the 1747 SN into the Virtual BT Status Buffer MOV MOVE Source M1 1 100 Dest N10 100 0 Rung 2 2 This rung sets up the BT buffer for a BTW User BTR_Avail BTW_Avail Virtual Virtual Logic BT_Enable BTW 20 Bit BTR 1 B3 0 1 1 0 11 0 N10 0 N10 0 4 E 3 E 34 Ht u 1 1 1 1 d Virtual BT Enable Bit N10 0 15 Rung 2 3 This rung turns off the Virtual BT Enable when a BTW has completed Virtual Virtual Virtual BTW 0 BT Done BT Enable BTR 1 Bit Bit N10 0 N10 100 N10 0 1 E JE u 7 13 15 8 16 Remote I O Examples cont Serial Communications Example 2 Ladder Logic Program cont Rung 2 4 This rung sets up the BT buffer for a BTR and sets the Virtual BT_Enable User BTR_Avail Virtual Logic BTW 0 BTR 1 B3 0 1 1 0 N10 0 J Ei U 1 10 Virtual BT Enable Bit N10 0 e 15 Rung 2 5 This rung copies the BTR data from the 1747 SN clears the Virtual BT_Enable and clears the User LogicBit BTR_Avail Virtual Virtual BTW 0 BT Done BTR 1 Bit 1 1 0 N10 0 N10 100 COP l E IF J F COPY FILE BAT Gre Ss Source M1 1 100 10 l 13 Dest N10 100 Length 74 Virtual BT Enable Bit N10 0 v 15 User Logic B3 0 u 1 Rung 2 6 This rung copies the BT infor
147. racteristics These non sinusoidal characteristics inhibit the controller s current measurement capability To compensate for additional motor heating that may result the controller uses motor thermal modeling which increments motor thermal usage This compensation takes place when these options are in use Preset Slow Speed Smart Motor Braking Accu Stop and Slow Speed with Braking 1 6 Product O verview Protection and Diagnostics cont Notes 1 2 3 4 The factory default setting for Overload Class which is Off disables overload protection An overload trip class and the motor s full load current rating must b programmed to enable overload protection The current sensing capability of the SMC Dialog Plus controller is disabled during bypass operation Using a Bulletin 825 converter module in these applications is recommended to provide current feedback Otherwise separate overload relay is required Motors with full load current ratings of 5 Amps and below may require the use of the converter modul Cat No 825 MCM20 for improved current measurement accuracy Automatic reset of an overload fault requires the start input to be cycled in a 2 wire control scheme This applies to the following firmware releases 1 07 standard 1A07L Soft Stop and 1BOSL Pump Control or earlier Figure 1 6 and Figure 1 7 provide the overload trip curves for th available trip classes Product Overview 1 7 Fi
148. responsibility or liability for actual use based on the illustrative uses and applications No patent liability is assumed by Allen Bradley Company Inc with respect to use of information circuits or equipment described in this text Reproduction of the content of this manual in whole or in part without written permission of the Allen Bradley Company Inc is prohibited The information in this manual is organized in numbered chapters Read each chapter in sequence and perform procedures when you are instructed to do so Do not proceed to the next chapter until you have completed all procedures Throughout this manual attention statements make you aware of safety considerations 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 e Avoid the hazard e Recognize the consequences Important Identifies information that is especially important for successful application and understanding of this product SMC Dialog Plus SMB SCANport and Accu Stop are trademarks of Rockwell Automation DeviceNet is a trademark of the Open DeviceNet Vendors Association O D V A For Bulletin 150 SMC Smart Motor Controller technical support on start up or existin installations contact your Allen Bradley representative In the United States and Canada you can also call 1 800 765 SMCS 765 7627 for assista
149. ring Diagram for the Preset Slow Speed Option 1 15 Typical Retrofit Wiring Diagram 1 16 Typical Wiring Diagram for Applications Requiring an Isolation Contactor 1 17 Typical Wiring Diagram for Applications Requiring a Bypass Contactor 7 18 Typical Wiring Diagram for Hand Off Auto SCANport Control 7 19 Preset Slow Speed Option Sequence of Operation 7 20 Accu Stop Option Sequence of Operation 7 21 Typical Wiring Diagram for the Slow Speed with Braking Option 7 22 Typical Retrofit Wiring Diagram for the Slow Speed with Braking Option 7 23 Typical Wiring Diagram for the Slow Speed with Braking Option with an Isolation Contactor 7 24 Typical Wiring Diagram for the Slow Speed with Braking Option with a Bypass Contactor 7 25 Slow Speed with Braking Option Sequence of Operation 7 26 Fault Display 9 1 Troubleshooting Flowchart 10 2 Removal of Control Module 24 1354 10 7 Removal of Control Module 180 360A 10 9 Removal of Protective Cover 500 1000A 10 12 Removal of Control Module 500 1000A 10 10 MOV Fuse Replacement 10 13 Pin Locations for Power Module Resistance Check 10 22 Pin Locations for Power Pole Resistance Check 180 1000A
150. ring and absent correct if necessary e Failed control module e Replace control module e Pilot devices e Check wiring SMC Enable input is e Check wiring open at terminal 13 e Terminall5isopenon Check wiring Soft Stop Pump Control and SMB e Start Stop control has not been enabled for the human interface module Control voltage Failed control module Follow the instructions on pages 2 13 and 2 14 to enable control capability Check control voltage Replace control module Starting Table 10 C Motor Ro Display Fault displayed Two or three power phases are missing Check power system tates but does not accelerate to full speed Possible Cause Possible Solutions See Table 10 A addressing fault conditions See fault description Starting Table 10 D Motor Stops While Running Display Fault displayed Mechanical problems Check for binding or external loading and correct Check motor Adjust the Current Limit Level to a higher setting Replace control module Inadequate Current Limit setting e Failed control module Possible Cause Possible Solutions Display is blank See fault description See Table 10 A addressing fault conditions e Control voltage is e Check control wiring and absent correct if necessary e Replace control module e Failed control module Stopped 0 0 Amps e Pilot devices Check control wiring and correct if necess
151. rrent Description Check all power and control wiring connections to the controller and motor Apply a start command to the controller and check for motor rotation to full speed Action Display AT SPEED HHE AMPS Using the clamp on ammeter measure the three phase motor currents Place the ammeter around the phase with the largest current draw AT SPEED Ht AMPS In the Calibrate group scroll to the Calibration parameter CALIBRATION OFF Monitor the clamp on ammeter and verify that the motor current is stable Press the Select key Toggle the Up Down keys to the Activate setting Press the Enter key to accept Monitor the ammeter display for the next 2 seconds and record the average value During this time period the SMC Dialog Plus controller samples motor response data SEL CALIBRATION ACTIVATE Access the next parameter using the Up key fi ae aN ENTER CALIB AMPS 0 0 AMPS Press the Select key Enter the clamp on meter value monitored in step 4 Press the Enter key to accept The SMC Dialog Plus controller is now calibrated EEG ENTER CALIB AMPS HHHH AMPS The currents should measure a minimum of 70 of the motor s full load current rating in order to achieve the best results in accuracy 5 4 Calibration Calibration Procedure cont Description You can scroll to the next parameter to view the current measurement in phase A Action
152. s Control Terminals T Internal Auxiliary Contacts 2080 2 23 a 2s ae ay 28 29 30 T Q Refer to the controller nameplate to verify the rating of the control power input voltage Customer supplied Notes 1 Programmable controller interfacing in this diagram refers to hard wiring between the PLC s output contacts and the SMC Dialog Plus controller s control terminals For a wiring diagram related to programmable controller interfacing via the SMC Dialog Plus controllers SCANport refer to Figure 3 14 2 TheOFF state leakage current for a solid state device must be less than 6 mA Wiring 3 9 Figure 3 13 Typical Wiring Diagram for Dual Ramp Applications e L1 1 T1 2 3 Phase L2 3 72 4 Input Power L3 5 13 6 Fast acting Branch A s SMC Dialog Plus Protection optiona Controller D AT 533 Stop D Q O Ramp 1 Ramp 2 Start O O ua rO T us d 32 i Mey H5 IG ay 3S 39 20 SMC Dialog Plus Control Terminals TM Internal Auxiliary Contacts 2L 22 29 28 25 ae 2m 28 29 30 T Refer to the controller nameplate to verify the rating of the control power input voltage
153. ses the MO and M1 file areas for data transfer Words 224 through 256 must be used to execute the Explicit Message Request and Response functions The minimum data size for an Explicit Message Request is 6 words and the maximum is 32 words Following is the data format to follow for a scattered parameter value read Get Attribute Multiple as used in this example Explicit Message Request Get Attribute Multiple 15 0 TXID COMMAND word 0 PORT SIZE SERVICE MAC ID CLASS INSTANCE ATTRIBUTE PARAMETER DATA PLACE HOLDER word 31 8 30 Serial Communications Explicit Message Response Get Attribute Multiple 15 0 TXID STATUS word 0 PORT SIZE SERVICE MAC ID PARAMETER DATA word 31 Transmission ID TXID The scanner uses this value to track the transaction to completion and returns the value with the response that matches the request downloaded by the SLC 500 processor The TXID data size is one byte Command This code instructs the scanner how to administer the request A listing of these codes can be found in the 1747 SDN Use Manual Publication 1747 5 8 The Command data size is one byte Status The Status code provides the communication module s status and its response Port The physical channel of the scanner where the transaction is to be routed The port setting can be zero channel A or one channel B The Port data size is one byte Size
154. sions 180 through 360 Amp Controllers A C N mrp P maj Qo 281 7 1 Dia al 6 Mtg Holes h 281 7 1 4 ad 2 Key Holes 8E Terminal Detail 8r J 136 3 5 Dia a B 8 32 UNC 2B a 413 10 5 Dia H 8 4 1 02 g 3 984 eum 25 m T S T G F i h i i E 1161 J el J ol Je E Les MU a ea Q 57 180 240 and Ground Nut 360 Amp Dbl Lug Mtg 1 4 20 L A B c Approx Unit Width Height Depth D E F G H J K L M N P Q R s Ship igoa mm 273 580 294 2 245 5 81 221 361 453 56 251 167 35 193 84 28 47 25 kg cont in 10 750 22 063 11583 9 647 207 3195 8695 14195 17 817 2213 9 880 6562 1375 76 250 11 187 55 lbs 240 mm 273 580 294 2 245 5 81 221 361 453 56 251 167 35 193 84 28 47 30kg 360A Con jn 10 750 22 063 11583 9 647 207 3195 8 605 14195 17 817 2213 9 880 6562 1375 76 250 11 187 65lbs All dimensions are approximate and are not intended for manufacturing purposes Refer to the nearest Allen Bradley sales office for com
155. sistance values directly at the gate lead connectors as shown in Figure 10 9 Based on the results one of the following actions will be required 1 Allresistance values are valid Replace interface board 2 Resistance s measure greater than 1009 Replace correspond ing power pole s Thermistor Resistance 1 Measure resistance between e pins J6 and J24 for phase L1 T1 e pins J8 and J23 for phase L2 T2 e pins J7 and J22 for phase L3 T3 The resistance should be less than 5009 If any of the resistances measure greater than 500Q recheck th resistance values directly at the thermistor lead connectors as shown in Figure 10 9 Based on the results one of the following actions will be required e fall resistance values are valid replace interface board e fresistance s measure greater than 500 replace the corresponding power pole s Figure 10 9 Gate and Thermistor Lead Identification 180 1000A Gate lead phase L2 T2 dete OQ GO Sofe S o e S Gate lead phase L1 T1 Gate lead phase L3 T3 Thermistor lead phase L1 T1 Gate lead phase L3 T3 Gate lead phase L1 T1 Thermistor lead Gate lead phase L3 T3 Thermistor lead hace L2 T2 p phase L2 T2 Specifications Electrical Ratings Power Circuit UL CSA NEMA IEC Method of Connection Motor in delta or star S
156. t Fan Power Connections Power Wiring 24 54A The power modules for controllers rated 24A 54A have internal mechanical type lugs to accept line and load cables Table 3 A and Table 3 B provide the lug wire capacity and tightening torque requirements Table 3 A Lug Wire Capacity Metric AWG 2 5 25 mm 14 4 Table 3 B Tightening Torque Tightening Torque f ds 2 5 6 mm 10 mm 16 25 mm W dos 14 10 AWG 8 AWG 6 4 AWG m 2 80 N m 3 4 N m 3 95 N m q 25 Lb in 30 Lb in 35 Lb in 97 1000A Power lugs are available as optional kits Each kit contains three lugs The number of terminal lug kits required is listed in the table below Table 3 C also provides the lug wire capacity and the tightening torque requirements 3 4 Wiring Terminal Locations cont Control Power Table 3 C Lug Wire Capacity and Tightening Torque Maxno Tightening Torque SMC Lug Kit Conductor Lugs Pole Rating Cat No Range Line Load Wire Lug Side Side Lug Busbar 97 16 120m 31N m 31N m 135A RAS 6 4 0 AWG 2 275 Ib in 275 Ib in 180 16 120m 31 N m 31 N m 360a Ieee et 6 4 0 AWG 275 Ib in 275 Ib in 25 240 m 42 N m 45 N m A 199 LG1 PODA 199461 M Sawe grsibin 400 bain 650 50 240 m 2 42 N m 45 N m 199 LG1 7A 16b iaio sooawce G75lb in 400 Ib in 850 99 11 50 240 m 6
157. t require an extended coast to rest The voltage ramp down time is user adjustable from 0 to 60 seconds and is adjusted independently from the starting time The load will stop when the output voltage drops to a point where the load torque is greater than the developed motor torque Figure 1 12 Soft Stop Option Percent Voltage 100 Kickstart f Initial Torgue Start gt lt Run gt Soft Stop gt Time seconds ATTENTION Soft Stop is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements Product Overview 1 13 Pump Control Option This option reduces surges during the starting and stopping of centrifugal pump by smoothly accelerating and decelerating th motor The microprocessor analyzes the motor variables and generates commands that control the motor and reduce the possibility of surges occurring in the system The starting time is programmable from 0 30 seconds and the stopping time is programmable from 0 120 seconds Figure 1 13 Pump Control Option 10 Motor Speed Pump Start gt lt Run Pump Stop gt Time seconds ATTENTION Pump stopping is not intended to be used as an emergency stop Refer to the applicable standard for emergency stop requirements ATTENTION Pump stopping may cause moto heating depending on the mechanical dynamics of th pumping system Therefore s
158. t six inches 15 cm above and below the controller This area allows air to flow through the heatsink Ventilation openings are required above and below this air space The ventilation outlet should be placed at least six inches 15 cm above the controller with the ventilation inlet placed near the bottom of the enclosure A filter is required to prevent contaminants from entering the enclosure Use the table below to determine the minimum ventilation openings and fan blower requirements Table2 B Minimum Ventilation Openings SMC Rating Top Cutout DO Bottom Cutout DO Fan Size 24 54A 65 cm 65 cm 110 CFM 10 in 10 in 97 and 135A 233 cm 233 cm 110 CFM 36 in 36 in 180A is 100 CFM 240A AA 250 CFM 360A m n amp 2 250 CFM 500A ie o 275 CFM 650A 2 a A 2 3 240 CFM 720A j i x I 3 240 CFM 850A 2 E a A 3 240 CFM 1000A 2 Fs 3 3 240 CFM Cutout size assumes 50 blockage filters louvers etc Cutout size is the same as required for the particular fan or blower being used Dimensions are in centimeters inches in parentheses Non ventilated Enclosures For Type 12 IP54 or non ventilated enclosures it is recommended that a bypass contactor be used This will allow the SMC Dialog Plus controller to bring the motor up to speed After the controller is up to full voltage it is bypassed Note that the Energy Saver Phase Rebalance some metering
159. terface board pins are not bent To install a control module reverse the order of the removal procedure 650 1000 Amp Figure 10 5 Removal of Protective Cover 500 1000A MOV Fuse Replacement Power Module and Interface Board Resistance Check Troubleshooting 10 11 500 1000 Amp ATTENTION To avoid shock hazard disconnect mainpower before working on the controller motor or control devices such as Start Stop push buttons ATTENTION Replacementof the fuse with anything other than the recommended part number may cause physical damage to the controller 1 Remove the fuse from the fuse holder with a fuse puller Figure 10 6 2 Push the replacement fuse into the fuse holder Figure 10 6 MOV Fuse Replacement MOV Fuses If a power module needs to be checked use the applicable procedur ATTENTION To avoid shock hazard disconnect main power before working on the controller motor or control devices such as Start Stop push buttons ATTENTION Make sure that wires are properly marked and pr
160. ters PLC Se Programmable Controller Port Power Factor Preset Speed Programmable Controll r Protocol Remote 1 0 RS 232 C RS 422 RS 485 Scrolling Serial Service Factor S F Silicon Controlled Rectifier SLC Controller Glossary 3 On acommunication link the logic circuitry or software at a station that determines its communication parameters for a particular communication channel A measurement of the time phase difference between the voltage and current in an AC circuit It is represented by the cosine of the angle of this phase difference Power factor is the ratio of Real Power kW to total kVA or the ratio of actual power W to apparent power volt amperes Preset speed refers to one or more fixed speeds at which the drive will operate A solid state system that has a user programmable memory for storage of instruc tions to implement specific functions such as I O control logic timing counting report generation communication arithmetic and data file manipulation A con troller consists of a central processor input output interface and memory A con troller is designed as an industrial control system A set of conventions governing the format and timing of data between communi cation devices T O connected to a processor across a serial link With a serial link remote I O can be located long distances from the processor An EIA standard that specifies electrical mechanical and
161. the Metering group Refer to page 1 10 for details on the metering functions 6 2 Metering Viewing Metering Data cont Description Scroll through the Metering parameters with the Up Dow keys to access the desired information Action B u VOLTS PHASE A B VOLTS PHASE B C VOLTS PHASEC A CURRENT PHASE A CURRENT PHASE B aN CURRENT PHASE C Tia ea KILO WATT HOURS AA MTR THERM USAGE Display HHFVOLTS li HHFVOLTS HHFVOLTS 3HHE E AMPS 3HHE AMPS 3HHE AMPS WATTMETER HHHHE KW ii HHHHE KWH ELAPSED TIME 3HHHHE HOURS POWER FACTOR JHE L4 3H 96 n Overview Human Interface Module Chapter 7 Options The SMC Dialog Plus controller offers a variety of unique control options that provide enhanced motor starting and stopping capabilities See pages 1 12 through 1 15 for brief descriptions of each option Note Only one option can reside in a controller The control buttons available with the Bulletin 1201 human interface modules are compatible with the SMC Dialog Plus controller s control options The following table details the functionality of each button with regards to each option Notes 1 Control logic must be enabled prior to initiating control commands to the SMC Dialog Plus controller Refer to pages 2 14 and 2 15 for instructions 2 The control terminals must be w
162. the SMC Dialog Plus controller Figure 3 11 Typical Wiring Diagram for Standard Controller e L1 1 T1 2 EE 3 Phase e L2 3 T2 4 Input Power 13 5 T36 Fast acting Branch SCR Fuses SMC Dialog Plus Protection optional Controller AA rrr Stop e Q O Start m e ESO O Q iil a2 is p 3 5 16 17 18 19 20 el SMC Dialog Plus Control Terminals ass Internal Auxiliary Contacts Hil 22 23 24 25 26 27 28 29 30 Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage 3 8 Wiring Standard Controller Figure 3 12 Typical Wiring Diagram for Two Wire Control or Programmabl Wiring Diagrams cont Control Interfacing e L1 1 T1 2 3 Phase L2 3 T2 4 Input Power 13 5 T36 Fast acting Branch A ie SMC Dialog Plus Protection optional Controller Pias MA Two wire Device i ae 359 ud p 5 NG 3 aks 38 20 A H SMC Dialog Plu
163. tions requiring extended acceleration times or high duty cycles may experience nuisance tripping of the coordinated fast acting current limiting fuses This type of fuse has a limited thermal capacity that is less than that of the SCRs they are designed to protect This makes them susceptible to thermal fatigue Protective Modules Motor Overload Protection Installation 2 11 Protective modules containing metal oxide varistors MOVs and capacitors can be installed on controllers rated 24A to 360A to protect the power components from electrical transients and or high electrical noise The protective modules clip voltage transients generated on the lines to prevent such surges from damaging the SCRs The capacitors in the protective modules are used to shunt noise energy away from the controller electronics Surge protection is provided as standard for controllers rated 500 1000A 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 though it must be programmed with the SMC Dialog Plus controller If th 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 Three sp
164. to their respective job assignments ATTENTION Hazardous voltage is present in the motorcircuiteven when the SMC Dialog Plus controlle is off To avoid shock hazard disconnect main powe before working on the controller motor or control devices such as Start Stop push buttons Procedures that require parts of the equipment to be energized during troubleshooting testing etc must be performed by properly qualified personnel using appropriate local safety work practices and precautionary measures ATTENTION Disconnect the controller from the motor before measuring insulation resistance IR of th motor windings Voltages used for insulation resistance testing can cause SCR failure Do not make any measurements on the controller with an IR teste megger Note The time it takes for the motor to come up to speed may be more or less than the time programmed depending on th frictional and inertial characteristics of the connected load Note Depending on the application the SMB Smart Motor Braking Accu Stop and Slow Speed with Braking options may cause some vibration or noise during the stopping cycle This may be minimized by lowering the braking current adjustment If this is a concern in your application pleas consult the factory before implementing these options 10 2 Troubleshooting The following flowchart is provided to aid in guick troubleshooting Figure 10 1 Troubleshooting Flowchart YES KA NO
165. top Options Preset Slow Speed and Accu Stop options Figure 7 10 Typical Wiring Diagram for the Preset Slow Speed Option lt Control Power Stop e OE Option Command Start O Q m rO O iW 32 i2 p d s p 3 16 17 18 19 20 SMC Dialog Plus Control Terminals Internal Auxiliar Contacts A 22 23 2722 102528 ae 2 28 29 30 Customer supplied T Q Refer to the controller nameplate to verify the rating of the control power input voltage amp Slow Speed or Accu Stop Note Refer to Chapter 3 for typical power circuits Figure 7 11 Typical Retrofit Wiring Diagram Options e r Control Power gt OL O 9 e Stop D e Q Option Command 0 Start e O O sujas E rO O ii 32 iS 34 35 Ne xy xe ag 20 Auxiliary contacts se for Norma e SMC Dialog Plus Nk Control Terminals Ml 22 2 24 25 26 27 28 29 30 e Customer supplied Overload protection should be disabled in the SMC Dialog Plus controller Refer to the controller nameplate to verify the rating of the control power input voltage Slow Speed or Accu Stop Note Refer to Chapter 3 for typical power circuits T Internal Au
166. topYoo Option 1 15 Slow Speed with Braking Option 1 15 RECENO S ee 44 02 iat Gin 408 edie yh ak ook A eae ah UE 2 1 UA iii 2 1 INSPecting anananannans 2 1 SONDO KITINI ISHA RARA ITO TDI 2 1 General Precautions s 2 2 Heat Dissipation nuuanu naa 2 2 ENCIOSUTES 25 Saji 86 S56 tied NASAHA EA 2 2 Ventilated Enclosures 2 3 Non ventilated Enclosures 2 3 MoUntllig oa Bee EL REGE WI REESE RE ER 2 4 toc iv Table of Contents Chapter 3 Wiring Chapter 4 Programming DIMensioNsS 1 428 oan coin bac caun ceca cnen cana cued 2 4 Power Factor Correction Capacitors 2 9 Fast Acting Current limiting Fuses 2 10 Protective Modules 2 11 Motor Overload Protection 2 11 nya TC eee CeCe CCC Te CCST CT Se OF Ee ee oe ee 2 11 Two speed Motors an 2 11 Multi motor Protection 2 11 Human Interface Module 2 12 Connecting the Human Interface Module to the Controller 2 13 Control Enable 2 13 Communication Modules 2 16 Converter Modules 2 16 Electromagnetic Compatibility EMC
167. un Brake gt ATTENTION The user is responsible for determining which stopping mode is best suited to th application and will meet applicable standards for operator safety on a particular machine Overview Logic Control Data depge 8 Serial Communications The SMC Dialog Plus controller can be started and stopped through programmable logic controllers using an optional communication module Additionally parameter data can be read to the logic controller through data transfer The amount of information that can be transferred from the SMC Dialog Plus controller is determined by the DIP switch settings on the communication module Note Parameter values modified while the motor is operating are not valid until the next start sequence begins The information in Table 8 A provides the logic control information that can be sent to the SMC Dialog Plus controller through the logic controller s output image table Table8 A Logic Control Data Logic Bits 0 Description Definition 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 Stop X Sp 0 Not Stopped 1 Start 2 state 0 Not Start X Option 1 Option Init Comman 0 Not Option Init 1 Clear Faults 5 Clear Fault o 0 Not Clear Faults 8 Control Wiring Only one bit may be asserted at any give The stop bit will take priority in operation n time A0 to 1 transition is required for a valid command
168. up parameters 1 11 Please note that the data shown is in a hexadecimal format The first three words are shown segmented into two bytes corresponding to the upper and lower bytes shown in the Explicit Message Request table TXID Command Port Size Service MAC ID Class Instance Attribute vv 7Y File 0 1 2 3 4 5 6 7 8 9 N11 0 01 01 00 2E 32 0D 0093 0000 0000 0001 0001 0002 0001 Parameter Number il Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number 4 v Data Place Holder File 0 1 2 3 4 5 6 7 8 9 N11 10 0003 0001 0004 0001 0005 0001 0006 0001 0007 0001 Parameter Number T li Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder I Parameter Number y M Data Place Holder File 0 1 2 3 4 5 6 7 8 9 N11 20 0008 0001 0009 000A 000B 0001 Serial Communications 8 33 Note There is no reguired value for the words identified as Data Place Holder Example Ladder Logic Program Rung 0 The 1747 SDN scanner module will map output data from its scanner output table MO and discrete outputs to eachnode only when it s in the run mode This is accomplished by setting bit
169. urrent reaches the user defined trip level which is based on a percentage of the programmed motor full load current rating Overload Protection Overload protection is enabled in the Calibration group by programming the e Overload class e Overload reset e Motor FLC e Service factor Refer to Chapter 5 for more information on calibration Underload Underload protection is available for undercurrent monitoring The controller will shut down when the motor current drops below the trip level This trip level a percentage of the motor s full load current rating can be programmed Voltage unbalance protection is disabled during braking operation Jam detection and underload protection are disabled during slow speed and braking operation Diagnostics 9 5 Open Gate Open gate indicates that an abnormal condition that causes faulty firing i e open SCR gate has been sensed during the start sequence The SMC Dialog Plus controller will attempt to start the motor a total of three times before the controller shuts down Excess Starts Hour Excess starts hour is displayed when the number of starts in a one hour period exceeds the value programmed Controller Temp Controller temp is an indication that a powerpole s maximum rated temperature has been reached The controller s microprocessor monitors the temperature of the SCRs by using internal thermistors When the controller detects an overtemperature condition
170. ut data is mapped to words 7 and 8 By clicking the radio button next to Output the output data mapping can be seen the following screen will appear 1747 SDN Datatable Map x e TEN ch ee ai ao eA EOD pS a e e ao EEE 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 Display Mode Data Entry Browse Double click on word to display bit mapping Device Select 13 Unknown product Unknown catalog number Appl Seament Map Segment AA AY Oe BORE Delete Segment Map Data To Poll Message Bytejo Bifo oaf Bf Nabis Print to File Map Data From C Close Help This indicates that the SLC 500 s output data associated with the SMC Dialog Plus controller is mapped to words 7 and 8 Given this data table mapping following are the individual logic command and status bit addresses for the SMC Dialog Plus controller SMC Dialog Plus Controller Logic Command Addresses Bit Description Address Stop 0 1 7 00 Start 0 1 7 01 Option Command 0 1 7 02 Clear Fault 0 1 7 03 amp Refer To Table 8 A Serial Communications 8 29 SMC Dialog Plus Controller Status Addresseso Bit Description Address Enabled 1 7 00 Running 1 7 01 Starting 1 7 04 Stopping 1 7 05 Fault 1 7 07 At Speed 1 7 08 Q Refer To Table 8 B Explicit Messaging The 1747 SDN scanner module u
171. xiliar Contacts Options Figure 7 12 Typical Wiring Diagram for Applications Reguiring an Isolation Contactor e lt Control Power gt Stop e Option Command atO e O O ee mE ro OF d 12 15 x4 35 IG xy 39 39 2 Auxiliary contacts se L for Norma Yi SMC Dialog Plus Control Terminals Internal Auxiliar Contacts ZL a2 2k 2b 9250 2 C ay 208 2 30 Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage amp Slow Speed or Accu Stop Note Refer to Chapter 3 for typical power circuits Options 7 17 Figure 7 13 Typical Wiring Diagram for Applications Requiring a Bypass Contactor r Control Power e co KI Stop bd Q LO Option Command Start En E roO O i 32 J 39 NS i5 1G ay ws ag 20 Auxiliary contacts se for Up to speed SMC Dialog Plus Control Terminals z Bulletin 82 Fanning Strip ternal Converter Pese Mehle Contacts 2 ae 29 2 25 ai 28 29 30 m Customer supplied Refer to the controller nameplate to verify the
172. xplicit Messaging 8 24 1203 GK5 Communication Module Switch Settings 8 24 Example Information 8 25 Switeh Settings ce ee Ee SERE he Be VR eR kakaa 8 25 IO Mapping oonan 8 25 SMC Dialog Plus Controller Logic Command Addresses 8 29 Explicit MeSSaging awanan 8 29 Explicit Message Request Get Attribute Multiple 8 29 Explicit Message Response Get Attribute Multiple 8 29 Examples RR RTT E T TET RT T 8 30 Sequence of EVents 8 31 Setting up the Data File 8 31 Example Ladder Logic Program 8 32 DIBIVIEN cose SE TER arier erepta a La aN r 4 Y3d3 3x3 9 1 Protection Programming 9 1 Fault Display onnaa nuaa a 9 1 Clear 1 PMRPRPRIIMIT o EnEn 9 1 Fault Buffer 9 2 Fault Codes 9 2 Fault Auxiliary Contact 9 2 Fault Definitions 9 3 au gc eraann atc aa 9 3 KUN aa 9 3 Phase Reversal asaaaanaan 9 3 Overvoltage and Undervoltage Protection 9 3 Voltage Unbalance 9 4 Stall PFOIBEUDTI 2254344144405 aiaitindsiaenisiaaias 9 4 Jam Detection 9 4 Overload Protection 9
173. y Use 6 Current Phase C 50 Factory Use 7 Wattmeter 51 Stopping Current 8 Kilowatt Hours 52 Undervolt Level 9 Elapsed Time 53 Undervolt Delay 10 Power Facto 54 Overvolt Level 11 Mtr Therm Usage 55 Overvolt Delay 12 Factory Use 56 Jam Level 13 Factory Use 57 J am Delay 14 SMC Option 58 Unbalance Level 15 ETM Reset 59 Rebalance 16 Factory Use 60 Underload Level 17 Parameter Mgmt 61 Underload Delay 18 Clear Fault 62 Phase Reversal 19 Fault Buffer 1 63 Starts per Hour 20 Fault Buffer 2 64 Restart Attempts 21 Fault Buffer 3 65 Restart Delay 22 Fault Buffer 4 66 Factory Use 23 Fault Buffer 5 67 Factory Use 24 Factory Use 68 Factory Use 25 Factory Use 69 Line Voltage 26 Factory Use 70 Motor FLC 27 Factory Use 71 Factory Use 28 Starting Mode 72 Mtr Code Letter 29 Dual Ramp 73 Factory Use 30 Ramp Time 1 74 Converter Rating 31 Initial Torgue 1 75 CT Ratio 32 Ramp Time 2 76 Calibration 33 Initial Torgue 2 77 Enter Calib Amps 34 Curr Limit Level 78 Language Select 35 Kickstart Time 79 Motor HP Rating 36 Overload Class 80 Motor kW Rating 37 Stall Delay 81 LRC Ratio 38 Energy Save 82 Factory Use 39 Aux Contacts 1 amp 2 83 Factory Use 40 Aux Contact 3 84 Service Factor 41 Contact 3 Config 85 Logic Mask 42 Stop Time 86 Unbalance Delay 43 Factory Use 87 S W Version 44 Slow Speed Sel 88 Overload Reset Passwor Search Programming 4 5 The SMC Dialog Plus controller allows the user to limit access to th programming system
174. y of the braking current applied to the motor 0 400 of full load current All braking stopping current settings in the range of 1 100 will provide 100 braking current to the motor Options 7 5 Control Wiring for Refer to Figure 3 14 on page 3 10 for the applicable wiring diagram SCANport Control to achieve start stop control via the SCANport Soft Stop Pump Control and Figure 7 1 through Figure 7 6 show the different wiring for the Soft SMB Smart Motor Braking Options Stop Pump Control and SMB Smart Motor Braking options Figure 7 1 Typical Wiring Diagram lt Control Power gt Stop e Q LO Option Stop 0 l aolo stato 11 12 i5 p mAb pom Xo yg 3s 39 20 SMC Dialog Plus Control Terminals Internal Auxiliar Contacts 2L a2 29 25 25 ae 27 28 29 30 T Customer supplied Q SoftStop Pump Stop or Brake amp Refer to the controller nameplate to verify the rating of the control power input voltage Note Refer to Chapter 3 for typical power circuits 7 6 Options Figure 7 2 Typical Retrofit Wiring Diagram e r Control Power gt OL e Stop e Option Stop amp O O Start rO O i a2 is w aS 16 17 18 19 20 Auxi

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