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150-AT002_-EN-P - Rockwell Automation

1. tt 12 13 14 15 16 17 18 19 20 21 22 T I Opt Stop nput 1 Input J H Opt Start nput 2 Inpu Aux 1 SMC Flex Control Terminals 23 24 25 26 27 28 29 30 31 32 33 34 et Wee Gag SE a PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Rockwell Automation Publication 150 AT002C EN P March 2013 Overview AirFilter Chapter 2 Application Profiles for the SMC Flex Controller In this chapter a few of the many possible applications for the SMC Flex controller are described The basis for selecting a particular control method is also detailed Illustrations are included to help identify the application Motor ratings are specified but the ratings may vary in other typical applications For example a tumbler drum is described as requiring the Soft Start feature The application is examined further to determine how the SMC Flex controller options can be used to improve the tumbler drum performance and productivity Figure 41 Compressor with Soft Start 208 480 Volts InletValve 50 250Hp gt 50 60 Hz TurnValve Ports Problem A compressor OEM shipped its equipment into overseas markets where wye delta motors are co
2. Discharge Problem Because of the remote location of a rock quarry the power company required a reduced voltage start on all motors over 150 Hp The starting current on these large motors strained the capacity of the power system causing severe voltage dips When the rock crusher became overloaded the current draw by the Wye Delta motor increased Therefore current monitoring capabilities within the soft starter were required Because the conveyor feeding the rock crusher was controlled by a PLC communications between the soft starter and a PLC was necessary When the rock crusher ran occasionally a stall or jam would occur Solution The SMC Flex controller was installed meeting the power company requirements The motor was wired inside the delta which saves valuable panel space The metering capabilities of the SMC Flex controller allowed the current drawn by the motor to be monitored With the built in communications capabilities the motor current was communicated to the PLC When the motor current reached a specified limit the conveyor feeding the rock crusher could be slowed By slowing the conveyor a jam condition in the rock crusher was avoided The stall and jam detection capabilities of the SMC Flex controller would shut off the motor when a stall or jam condition occurred Rockwell Automation Publication 150 AT002C EN P March 2013 51 Chapter 2 52 Hammer er Feed Figure 46 Hamm
3. Pump Start gt lt Run gt lt Pump Stop gt Time in Seconds Push Buttons Start Closed Open Stop Closed Open Pump Stop Stop Option Closed Open Auxillary Contacts If the Pump Stop is Selected Normal Closed Open Up to Speed Closed Open If the Coast to Rest is Selected Rockwell Automation Publication 150 AT002C EN P March 2013 29 Chapter 1 Overview Figure 25 Pump Control Option Wiring Diagram me Control Power gt aa Stop Pump Stop Start O 11 12 13 14 15 16 17 18 19 20 21 22 SMC Flex Control Terminals Aux 1 Normal Up to Speed es B uxilary ie Contacts 23 24 25 26 27 28 29 30 31 32 33 34 Ga ua eee PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input rating Braking Control SMB Smart Motor Braking Option The SMB Smart Motor Braking option provides motor braking for applications which require the motor to stop quickly It is a microprocessor based braking system which applies braking current to a motor The strength of the braking current is adjustable from 0 4
4. Figure 20 Soft Stop Coast to rest Soft Stop Soft Stop Start Run Time seconds The basic parameter setup for Soft Stop follows Table 7 Soft Stop Parameters Parameter Adjustments SMC Option Standard Braking Pump Stop Mode Soft Stop Stop Time 0 120 seconds Figure 21 Soft Stop Sequence of Operation 100 Coast to rest Soft Stop Motor Speed Start Run Soft Stop Time seconds Push Buttons Start Closed Open Stop Closed i i Open i Le Soft Stop Closed 7 Open t Auxiliary Contacts J If Soft Stop Selected Normal Closed Open z N If Coast to rest Selected Up to speed Closed Open 26 Rockwell Automation Publication 150 AT002C EN P March 2013 Pump Control Overview Chapter 1 Figure 22 Soft Stop Wiring Diagram Control Power Soft Sto p olo TE T a 11 12 13 15 16 17 18 19 20 21 22 SMC Flex q J Control Terminals Aux 1 Normal Up to Speed msy nal Bypass Auxilary Contacts 23 24 25 26 27 28 29 30 31 32 33 34 Co a Mod v yE PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied
5. Time seconds Rockwell Automation Publication 150 AT002C EN P March 2013 67 Chapter 3 Special Application Considerations Rockwell Automation Publication 150 AT002C EN P March 2013 Mining and Metals Applications Roller Mills SMC Flex X Product Line Applications Matrix Description Chapter 4 Use this chapter to identify possible SMC Flex controller applications This chapter contains an application matrix which will identify starting characteristics as well as typical stopping features that may be used in various applications Soft Start Current Limit Smart Pump Accu St Motor Kickstart Soft Stop Control op Brak rake Preset Slow Speed Slow Speed with Brake Linear Speed Acceleration Hammermills gt lt Roller Conveyors Centrifugal Pumps Fans Tumbler Rock Crusher Dust Collector Chillers Compressor gt lt x XxX XxX x x x OK x x lt gt lt x Xx x x x x lt Wire Draw Machine gt x lt gt x lt Belt Conveyors Shredder Grinder Slicer x x x Xx Overload Conveyor x x x x Xx Rockwell Automation Publication 150 AT002C EN P March 2013 69 Chapter 4 Product Line Applications Matrix Food Processing SMC Flex X ao Slow Aplications so
6. By using the controller as shown in Figure 58 the motor accelerates under a controlled start mode in either forward or reverse Note Minimum transition time for reversing is second Phase Reversal must be OFF Figure 58 Typical Application with a Single Speed Reversing Starter LW T2 Y gt SY N 3 Phase en L2 3 T24 M Input Power X 2 AN a e L3 5 T3 6 e Branch SMC Flex Protection Controller Customer Supplied Overload protection is included as a standard feature of the SMC Flex controller Reversing Contactors 64 Rockwell Automation Publication 150 AT002C EN P March 2013 Special Application Considerations Chapter 3 SMC Flex Controller as a By using the controller as shown in Figure 59 a soft start characteristic can be Byp ass to an AC Drive provided in the event that an AC drive is non operational Note A controlled acceleration can be achieved with this scheme but speed control is not available in the bypass mode Figure 59 Typical Application Diagram of a Bypass Contactor for an AC Drive AF AF OL 3 Phase j y b VFD Pa M Input Power N F e __ o Xo x VED Branch Protecti i lon X K Lit T1 2 L2 3 T2 4 L3 5 T3 6 IC IC SMC Flex Mechan
7. Refer to the controller nameplate to verify the rating of the control power input rating Pump Control Option with Selectable Kickstart The SMC Flex controller s unique interactive Pump Control is designed to reduce fluid surges in pumping systems It provides closed loop acceleration and deceleration control of centrifugal pump motors without the need for feedback devices The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started It is intended to provide a current pulse with user adjustable locked rotor torque from 0 90 and kickstart time from 0 0 to 2 0 seconds Rockwell Automation Publication 150 AT002C EN P March 2013 27 Chapter 1 Overview Figure 23 Pump Control Option with Selectable Kickstart 100 Motor Speed lt M Pump Start P4 Run _H _ Pump Stop gt Ramp Time n Stop Time Time in Seconds The basic parameter setup for Pump Control follows Table 8 Pump Control Option Parameters Parameter Adjustments SMC Option Pump Starting Mode Pump Start Start Time 0 30 s Initial Torque 0 90 LRT Kickstart Time 0 0 2 0s Kickstart Level 0 90 LRT Stop Time 0 120s Anti Backspin Timer 0 999 s 28 Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 24 Pump Control Option Sequence of Operation Motor Speed 100 Coast to Rest
8. Ambient insensitivity is inherent in the electronic design of the overload Motors can experience locked rotor currents and develop high torque levels in the event ofa stall or a jam These conditions can result in winding insulation breakdown or mechanical damage to the connected load The SMC Flex controller provides both stall and jam detection for enhanced motor and system protection Stall protection allows the user to program a maximum stall protection delay time from 0 to 10 seconds The stall protection delay time is in addition to the programmed start time and begins only after the start time has timed out Jam detection allows the user to determine the motor jam detection level as a percentage of the motor s full load current rating To prevent nuisance tripping a jam detection delay time from 0 99 seconds can be programmed This allows the user to select the time delay required before the SMC Flex controller will trip ona motor jam condition The motor current must remain above the jam detection level during the delay time Jam detection is active only after the motor has reached full speed A serial interface port is furnished as standard on the SMC Flex controller The connections allows a Bulletin 20 COMM to be installed Using the built in communication capabilities the user can remotely access parameter settings fault diagnostics and metering Remote start stop control can also be performed When used with the Bulle
9. E N AN Be Slow Start Run is Stop Speed Time seconds The basic parameter setup for Slow Speed with Braking follows Figure 33 Slow Speed with Braking Parameters Parameter Adjustments SMC Option Braking Option 2 Input Preset SS Slow Speed Sel SS Low SS High Slow Speed Dir SS Forward SS Reverse Slow Accel Cur 0 450 FLC Slow Running Cur 0 450 FLC Stop Mode SMB Braking Current 0 400 FLC Rockwell Automation Publication 150 AT002C EN P March 2013 37 Chapter 1 38 Overview Figure 34 Slow Speed with Braking Sequence of Operation 100 i Coast to Stop x ra Motor N Speed N a Si Braking N is Ty Slow Speed Start Run Brake Time seconds i Push Buttons i Start i Closed Open Stop Closed t i t Open Eom Slow Speed H Closed Open Brake Closed Open i H Brake Auxiliary Contacts i Pa Normal Closed j t f j Open Penno ooo Up to speed Closed If Coast to rest select d Open r Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Features Figure 35 Slow Speed with Braking Wiring Diagram t Control Power ow Speed 11 12 13 14 15 16 17 18 19 20 21 22 SMC Flex J Co
10. control a single motor or an integrated automation system our range of controllers meet your required needs This document discusses the SMC Flex Some of the key features are listed below SMC Flex Features e Soft Start with Selectable Kickstart e Current Limit Start with Selectable Kickstart e Dual Ramp with Selectable Kickstart e Full Voltage e Linear Speed Acceleration with Selectable Kickstart e Preset Slow Speed e Soft Stop e Pump Control with Selectable Kickstart e SMB Smart Motor Braking e Accu Stop e Slow Speed with Braking e Built in Bypass e Inside the Delta e Electronic Motor Overload Protection e Stall and Jam Detection e Ground Fault Protection Thermistor Input PTC e Metering e Fault Indication e Parameter Programming e Communication Capabilities Rockwell Automation Publication 150 AT002C EN P March 2013 5 Chapter 1 Description Overview When the Smart Motor Controller SMC was first introduced in 1986 its modular design digital setup and microprocessor control set the standard for soft starters Since its launch in 1996 the SMC Dialog Plus controller has been in a class by itself providing unmatched performance with innovative starting and stopping options Now the SMC Flex controller achieves a higher level of sophistication with greatly enhanced protection expanded diagnostics ability to log the motor s operation A kW and power facto
11. current and torque fora NEMA Design B motor Table 13 Typical Voltage Current and Torque Characteristics for NEMA Design B Motors lt i ptor Starting Current as a Line Current as a of Motor Starting Torque as a of Starting Method a Voltage at or otor Terminals Locked Rotor Full Load Locked Rotor Full Load Locked Rotor Full Load Current Current Current Current Torque Torque Full Voltage 100 100 600 100 600 100 180 Autotrans 80 tap 80 80 480 64 384 64 115 65 tap 65 65 390 42 252 42 76 50 tap 50 50 300 25 150 25 45 Part Winding 100 65 390 65 390 50 90 Wye Delta 100 33 198 33 198 33 60 Solid state 0 100 0 100 0 100 0 100 0 100 0 100 0 100 76 With the wide range of torque characteristics for the various starting methods selecting an electromechanical reduced voltage starter becomes more application dependent In many instances available torque becomes the factor in the selection processes Rockwell Automation Publication 150 AT002C EN P March 2013 Reduced Voltage Starting Chapter 6 Limiting line current has been a prime reason in the past for using electromechanical reduced voltage starting Utility current restrictions as well as in plant bus capacity may require motors above a certain horsepower to be started with reduced voltage Some countries require that any motor above 7 Hp be started with reduced voltage Using reduced volta
12. 0 K 8 0 9 0 L 9 0 10 0 M 10 0 11 2 N 9 222425 P 12 5 14 0 R 14 0 16 0 S 16 0 18 0 T 18 0 20 0 U 20 0 22 4 V 22 4 and up By manipulating the preceding equation for KVA Hp for three phase motors the following equation can be used for calculating locked rotor current 1000 x Hp x KVA Hp 1 73 x Volts LRA This equation can then be used to determine the approximate starting current of any particular motor For instance the approximate starting current for 7 Hp 230V motor with a locked rotor KVA code letter of G would be 1000 x 7 5 x 6 0 Operating a motor in a locked rotor condition for an extended period of time will result in insulation failure because of the excessive heat generated in the stator The following graph illustrates the maximum time a motor may be Rockwell Automation Publication 150 AT002C EN P March 2013 87 Chapter 8 operated at locked rotor without incurring damage caused by heating This graph assumes a NEMA Design B motor with Class B temperature rise Figure 78 Motor Safe Time vs Line Current Standard Induction Motors From Operating Temperature 8 From Ambient 6 Motor Line 4 Amps Motor Stalled Per et 1 15 Serv Factor Motor 2 Motor Running 1 1 0 Serv Factor Motor 0 f a 10 15 20 1000 2000 7000 Time in Seconds Motor protection either inherent or in the motor control should be selected to limit the stall time of the motor 88 Rockwell Aut
13. 230 for higher resistance to malfunction in a noisy environment An optional MOV module is available to protect SCRs from voltage transients Solid state controller ratings must ensure reliability under the wide range of current levels and starting times needed in various applications SCR packaging keeps junction temperatures below 125 C 257 F when running at full rated current to reduce thermal stress and provide longer more reliable operation The thermal capacity of the SMC Flex controllers meet NEMA standards MG 1 and IEC34 S1 Solid state controllers must withstand the shock and vibration generated by the machinery that they control Rockwell Automation Publication 150 AT002C EN P March 2013 73 Chapter 5 Design Philosophy Noise and RF Immunity Altitude Pollution Setup 74 SMC Flex controllers meet the same shock and vibration specifications as electromechanical starters They can withstand a 5 G shock for 11 ms in any plane and one hour of vibration of 1 0 G without malfunction This product meets Class A requirements for EMC emission levels Altitudes up to 2000 meters 6560 ft are permitted without de rating The products allowable ambient temperature must be de rated for altitudes in excess of 2000 meters 6560 ft The allowable ambient temperature must be de rated by 3 C 27 F per 1000 meters 3280 ft up to a maximum of 7000 meters 23000 ft Current ratings of the devices do not change
14. Running Cur 0 450 FLC Rockwell Automation Publication 150 AT002C EN P March 2013 Figure 15 Preset Slow Speed Sequence of Operation 100 Motor Speed Push Buttons Start Stop Slow Speed Auxiliary Contacts Normal Up to speed Rockwell Automation Publication 150 AT002C EN P March 2013 Closed Open Closed Open Closed Open Closed Open Closed Open Overview Chapter 1 Coast to rest my Soft Stop OA we 7 or 15 so N J i Slow Speed Start Run Dja Coast gt y Time seconds 21 Chapter 1 Overview Figure 16 Preset Slow Speed Wiring Diagram Control Power H Stop j QO O Slow Speed Start aee O SMC Flex Control Terminals Aux 1 Normal Up to Speed Imemal Bypass Auxilary Contacts 23 24 25 26 27 28 29 30 31 32 33 34 Cie Ry A PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input rating Linear Speed Acceleration with Selectable Kickstart This method starts the motor following a linear speed ramp The ramp time de
15. changes or routinely to change the saw blade This application required 25 minutes to coast to stop and braking devices were unacceptable due to their high complexity and panel space requirements After a blade was replaced it was dangerous to bring the saw up to full speed because of alignment problems Metering the application for jam conditions was a necessity In addition single phasing of the motor was a problem because of distribution limitations Solution The SMC Flex controller was installed to provide a reduced voltage start This minimized the starting torque shock to the system With the braking option configured as Slow Speed with Braking it provided a preset slow speed allowing the saw blade tracking to be inspected before the motor was brought to full speed The current monitoring and jam detection features of the SMC Flex controller were implemented saving valuable panel space and the cost of purchasing dedicated monitoring devices The controller s built in programmable overload protection was used The SMC Flex controller s diagnostic capabilities would detect single phasing and shut the motor off accordingly Starting and stopping control was furnished in a single modular unit providing ease of installation 50 Rockwell Automation Publication 150 AT002C EN P March 2013 Chapter 2 Figure 45 Rock Crusher with Soft Start 250 HP 480 Volts Starts Unloaded JETE S A Gearbox rN Motor
16. for altitudes that require a lower maximum ambient temperature This product is intended for a Pollution Degree 2 environment Simple easily understood settings provide identifiable consistent results For ease of installation the controllers include compact design and feed through wiring SMC Flex controllers are global products rated at 50 60 Hz All parameter adjustments are programmed into the controller through the built in keypad A full line of enclosures is available Rockwell Automation Publication 150 AT002C EN P March 2013 Introduction to Reduced Voltage Starting Chapter 6 Reduced Voltage Starting There are two primary reasons for using reduced voltage when starting a motor e Limit line disturbances e Reduce excessive torque to the driven equipment The reasons for avoiding these problems will not be described However different methods of reduced voltage starting of motors will be explored When starting a motor at full voltage the current drawn from the power line is typically 600 of normal full load current This high current flows until the motor is almost up to speed and then decreases as shown in Figure 63 This could cause line voltage dips and brown outs Figure 63 Full Load Current vs Speed 600 500 400 Full Load 300 Current 200 100 0 Speed 100 In addition to high starting currents the motor also produces starting torques that are higher th
17. for ease of programming and fast access to parameters The displayed language can also be changed to meet global customer needs Parameter Programming Programming of parameters is accomplished through a five button keypad on the front of the SMC Flex controller The five buttons include up and down arrows an Enter button a Select button and an Escape button The user needs only to enter the correct sequence of keystrokes for programming the SMC Flex controller Figure 36 LCD Display with Keypad Li Keypad E 50000 Electronic Overload The SMC Flex controller meets applicable requirements as a motor overload protective device Overload protection is accomplished electronically through current sensors and an Ft algorithm The overload trip class is selectable for OFF 10 15 20 or 30 protection The trip current is set by entering the motor s full load current rating and the service factor Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Thermal memory is included to model motor operating and cooling temperatures Ambient insensitivity is inherent in the electronic design of the overload Stall Protection and Jam Detection Motors can experience locked rotor currents and develop maximum torque in the event of a stall during start or a jam after full speed is reached These conditions can result in winding insulation breakdown or mechanical damage to the connected
18. its rated horsepower at full load speed In foot lbs it is equal to the rated horsepower multiplied by 5250 divided by the full load speed in RPM Locked Rotor Torque LRT Locked rotor torque is the torque which the motor will develop at rest for all angular positions of the rotor with rated voltage at rated frequency applied It is sometimes known as starting torque and is usually measured as a percentage of full load torque Pull Up Torque PUT Pull up torque of an induction motor is the minimum torque developed during the period of acceleration from locked rotor to the speed at which breakdown torque occurs For motors that do not have definite breakdown torque such as NEMA Design D pull up torque is the minimum torque developed up to rated full load speed and is usually expressed as a percentage of full load torque Rockwell Automation Publication 150 AT002C EN P March 2013 85 Chapter 8 86 Breakdown Torque BT The breakdown torque of an induction motor is the maximum torque the motor will develop with rated voltage applied at rated frequency without an abrupt drop in speed Breakdown torque is usually expressed as a percentage of full load torque In addition to the relationship between speed and torque the relationship of current draw to these two values is an important application consideration The speed torque curve is repeated below with the current curve added to demonstrate a typical relations
19. motor The SMC Flex controller incorporates a microprocessor to control the firing of the SCRs Six SCRs are used in the power section to provide full cycle control of the voltage and current The voltage and current can be slowly and steplessly increased to the motor Figure 72 Silicon Controlled Rectifier SCR Gate fi Pi P SCR Figure 73 Typical Wiring Diagram for SCRs Power Input 3 Phase SMC Flex Controller Power Section Rockwell Automation Publication 150 AT002C EN P March 2013 81 Chapter7 Solid State Starters Using SCRs Figure 74 Different Firing Angles Single Phase Simplification Mgr q g Supply Voltage x Firing for Approx 50 RMS Voltage Firing for 25 RMS Voltage a S Firing for N X 100 RMS Voltage 82 Rockwell Automation Publication 150 AT002C EN P March 2013 Motor Output Speed Torque Horsepower Torque and Horsepower Chapter 8 Reference Certain mechanical parameters must be taken into consideration when applying motor controllers The following section explains these parameters and how to calculate or measure them The speed at which an induction motor operates depends on the input power frequency and the number of poles for which the motor is wound The higher the frequency the faster the motor runs The more poles the motor has the slower it runs To determine the synchronous speed of an induction motor use the
20. pee Time seconds Push Buttons Start Closed Open Stop Closed Open Accu Stop Closed Open Slow Speed Auxiliary Contacts 2 Braking Normal Closed I If Coast to rest Pa Open Up to speed Closed Selected Open Rockwell Automation Publication 150 AT002C EN P March 2013 35 Chapter 1 Overview Figure 31 Accu Stop Wiring Diagram Control Power Accu Stop 11 12 13 14 15 16 17 18 19 20 21 22 SMC Flex l i Control Terminals Aux 1 Normal Up to Speed Internal Bypass Auxilary Contacts 23 24 25 26 27 28 29 30 31 32 33 34 eS oea Se v wW ka PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input rating Slow Speed with Braking The Slow Speed with Braking option combines the benefits of the SMB Smart Motor Braking and Preset Slow Speed options for applications that require slow setup speeds and braking to a stop 36 Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 32 Slow Speed with Braking 100 f ENAN Braking Motor y Speed Coast to rest 7 or 15 va N l N
21. the controller could be configured to simulate a full voltage start allowing the conveyor to accelerate when fully loaded The OEM liked the SMC Flex controller because of its ability to control three motors as if they were a single motor eliminating the need for multiple soft starters Figure 50 Ball Mill with Current Limit Start 480 Volts Loading 150 Hp Port Drum eae ns Ss Gearbox Motor Substance id e o Kapa aan ve Ball Shot Rockwell Automation Publication 150 AT002C EN P March 2013 55 Chapter 2 56 Problem An across the line starter was used to start the motor in a ball mill application The uncontrolled start was causing damage to the gearbox resulting in maintenance downtime as well as the potential for the loss of the product paint being mixed Line failures were a frequent problem The application required prestart and running protection as well as an elapsed time meter to monitor the process time Communication capability was desired and panel space was limited Solution The SMC Flex controller was installed It was programmed for a 26 second current limit start thereby reducing the starting torque and the damage to the gearbox The metering feature of the SMC Flex controller contained an elapsed time meter which could monitor the process time of the ball mill The communications capabilities of the controller allowed the process time
22. the motor s full voltage starting torque capability After an adjustable time interval the motor is automatically connected in delta To apply an SMC Flex controller to a wye delta motor the power wiring from the SMC Flex controller is simply wired in an inside the delta configuration to the motor This connects all six motor connections back to the SMC Flex Because the SMC Flex controller applies a reduced voltage start electronically the transition connection is no longer necessary Additionally the starting torque can be adjusted with parameter programming Note Increased Hp ratings are achieved with the SMC Flex being connected to wye delta motors Figure 55 Inside the Delta Wiring dL 3 L2 5 L3 12 T6 2 71 8 T4 4 T2 10 T5 6 T3 3 Sef NF Rockwell Automation Publication 150 AT002C EN P March 2013 61 Chapter3 Special Application Considerations Altitude De rating Part Winding Part winding motors incorporate two separate parallel windings in their design With the traditional part winding starter one set of windings is given full line voltage and the motor draws about 400 of the motor s full load current rating Additionally about 45 of locked rotor torque is generated After a preset interval the second winding is brought online in parallel with the first and the motor develops normal torque The part winding motor may be wired to an SMC Flex controller by connecting both windings in paralle
23. 0 me Start ia Run j Soft Stop Time seconds Push Buttons Start Closed Open Stop Closed Open Soft Stop Closed Open Auxiliary Contacts J If Soft Stop Selected Normal Closed Open Wek Rs ee EE If Coast to rest Selected Up to speed Closed f Open Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 7 Current Limit Wiring Diagram Control Power SMC Flex Control Terminals Aux 1 Normal Up to Speed Internal Bypass Auxilary Contacts PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input rating Dual Ramp Start with Selectable Kickstart This starting method is useful on applications with varying loads starting torque and start time requirements Dual Ramp Start offers the user the ability to select between two separate Start profiles with separately adjustable ramp times and initial torque settings The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started It is intended to provide a current pulse user adjustable 0 90 locked rotor torque for a selected period of time from 0 0 to 2 0 seconds Rockwell Automation Publication 150 AT002C EN P March 2013 13 Chapter 1 14 Overview Figure 8 D
24. 00 of full load current 30 Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 26 Smart Motor Braking Smart Motor Braking Coast to Rest Automatic Zero Speed Shut Off Motor Speed lt Start P lt Run _ gt 4t Brake gt Time in Seconds The basic parameter setup for Smart Motor Braking follows Table 9 Smart Motor Braking Parameters Parameter Adjustments SMC Option Braking Stop Mode SMB Braking Current 0 400 FLC Rockwell Automation Publication 150 AT002C EN P March 2013 31 Chapter 1 Overview 32 Figure 27 Smart Motor Braking Sequence of Operation Motor Speed 100 S Smart Motor Braking ss S Coast to Rest N My Automatic Zero s Speed Shut Off Run gt lt Brake Time in Seconds Push Buttons Start Closed Open Stop Closed Open Smart Motor Braking Stop Option Closed Open Auxillary Contacts If Brake Selected Normal Closed Open Up to Speed If Coast to Rest Closed Selected Open Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 28 Smart Motor Braking Wiring Diagram Control Power 3 11 12 13 15 16 17 18 19 20 21 22 SMC Flex 7 J Control Terminals Aux 1 Normal Up to Speed Internal Bypass Auxila
25. 2013 Overview Chapter 1 Table 11 Control Terminal Designation Terminal Number 11 Description Control Power Input 12 Control Power Common 13 Controller Enable Input 14 Ground 15 Option Input 2 16 Option Input 1 17 Start Input 18 Stop Input 19 N O Aux Contact 1 Normal Up to Speed External Bypass 20 N O Aux Contact 1 Normal Up to Speed External Bypass 21 Not Used 22 Not Used 23 PTC Input 24 PTC Input 25 Tach Input 26 Tach Input 27 Ground Fault Transformer Input 28 Ground Fault Transformer Input 29 Fault Contact N 0 N C 30 Fault Contact N 0 N C 31 Alarm Contact N 0 N C 32 Alarm Contact N O N C 33 Aux Contact 2 Normal N 0 N C 34 Aux Contact 2 Normal N 0 N C Do not connect any additional loads to these terminals These parasitic loads may cause problems with operation which may result in false starting and stopping External Bypass operates an external contactor and overload once the meter reaches full speed The SMC Flex overload functionality is disabled when the external bypass is activated Proper sizing of the contactor and overload is required Rockwell Automation Publication 150 AT002C EN P March 2013 45 46 Chapter 1 Overview Figure 40 SMC Flex Controller Control Terminals
26. Application Techniques Allen Bradley SMC Flex Solid State Smart Motor Controller Bulletin 150 A w REE A WCQ_EC SSN KCS oree Rockwell Allen Bradley gt Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respec
27. Supplied Overload protection is included as a standard feature of the SMC Flex controller Multi motor App lications The SMC Flex controller will operate with more than one motor connected to it To size the controller add the total nameplate amperes of all of the connected loads The stall and jam features should be turned off Separate overloads are still required to meet the National Electric Code NEC requirements Note The SMC Flex controller s built multi motor applications Figure 54 Multi Motor Application in overload protection cannot be used in L1 1 T1 2 XG onn 3 Phase a aa L2 3 T2 4 DE COR Input Power No 1 iN AN S L3 5 T3 6 X 2 Sa Overload Branch SMC Flex Relay O L Protection ae Controller _ 7 INA S N y Motor Customer Supplied WN No 2 aw ae ee Overload D Relay O L 60 Rockwell Automation Publication 150 AT002C EN P March 2013 Special Motors Special Application Considerations Chapter 3 The SMC Flex controller may be applied or retrofitted to special motors wye delta part winding synchronous and wound rotor as described below Wye Delta Wye Delta is a traditional electro mechanical method of reduced voltage starting It requires a delta wound motor with all its leads brought out to facilitate a wye connection At the start command approximately 58 of full line voltage is applied generating about 33 of
28. an full load torque The magnitude of the starting torque depends on the motor design NEMA publishes standards for torques and currents for motor manufacturers to follow Typically a NEMA Design B motor will have a locked rotor or starting torque in the area of 180 of full load torque In many applications this starting torque can cause excessive mechanical damage such as belt chain or coupling breakage Rockwell Automation Publication 150 AT002C EN P March 2013 75 Chapter 6 Reduced Voltage Starting Reduced Voltage Figure 64 Bulletin 570 Autotransformer The most widely used method of electromechanical reduced voltage starting is the autotransformer Wye Delta Y D also referred to as Star Delta is the next most popular method All forms of reduced voltage starting affect the motor current and torque characteristics When a reduced voltage is applied to a motor at rest the current drawn by the motor is reduced In addition the torque produced by the motor is a factor of approximately the square of the percentage of voltage applied For example if 50 voltage is applied to the motor a starting torque of approximately 25 of the normal starting torque would be produced In the previous full voltage example the NEMA Design B motor had a starting torque of 180 of full load torque With only 50 voltage applied this would equate to approximately 45 of full load torque Table 13 shows the typical relationship of voltage
29. bleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact Canada your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwe
30. ch typically starts at less than 300 current Current limit starting is typically used on low inertia loads such as compressors Figure 71 Current Limit Start 600 Stes 450 i Full Load Current 100 0 Speed 100 Other features available with solid state controllers include additional protection to the motor and controller and diagnostics to aid in setup and troubleshooting Protection typically provided includes shorted SCR phase loss open load lead SCR overtemperature and stalled motor Appropriate fault messages are Rockwell Automation Publication 150 AT002C EN P March 2013 79 Chapter 6 Reduced Voltage Starting displayed to aid in troubleshooting when one of these faults trip out the solid state reduced voltage controller Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter Solid State Starters Using SCRs In solid state starters silicon controlled rectifiers SCRs see Figure 72 are used to control the voltage output to the motor An SCR allows current to flow in one direction only The amount of conduction of an SCR is controlled by the pulses received at the gate of the SCR When two SCRs are connected back to back see Figure 73 the AC power toa load can be controlled by changing the firing angle of the line voltage see Figure 74 during each half cycle By changing the angle it is possible to increase or decrease the voltage and current to the
31. controlling several other processes in the facility communication capabilities were desired Solution The SMC Flex controller with the braking option configured as Accu Stop was installed on the process The Soft Start provided a smooth acceleration of the drive chain which reduced downtime The controlled acceleration made positioning for loading unloading easier The drum was positioned for loading using the Preset Slow Speed For unloading the drum was rotated at Preset Slow Speed and then accurately stopped This increased the productivity of the loading unloading cycle Further the Accu Stop option did not require additional panel space or wiring The SMC Flex controller s built in overload eliminated the need to mount an external overload relay in the enclosure The built in SCR Bypass eliminated the need for an external bypass contact in the enclosure Both features saved further panel space The communication feature of the SMC Flex controller allowed remote starting and stopping of the process from a PLC 48 Rockwell Automation Publication 150 AT002C EN P March 2013 Chapter 2 Figure 43 Pump with Soft Start 480V Ground Level 150 Hp Check Valve Pump Motor ra Problem A municipal water company was experiencing problems with pump impellers being damaged The damage occurred during frequent motor starting while the load below the check valve was draining from the system A timing relay was insta
32. d j Start a Run Soft Stop Time seconds Push Buttons Start Closed Open Stop Closed l Open 1 Soft Stop or Linear Speed inear Speer cisi Open Auxiliary Contacts Fi If Soft Stop Selected Normal Closed Open H N If Coast to rest Selected i Up to speed Closed Open Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 19 Linear Speed Acceleration Wiring Diagram Control Power Linear Stop T a 11 12 13 15 16 17 18 19 20 21 22 SMC Flex 7 J Control Terminals Aux 1 Normal Up to Speed Internal Bypass Auxilary Contacts 23 24 25 26 27 28 29 30 31 32 33 34 Co a AU v yE PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input rating Soft Stop The Soft Stop option can be used in applications requiring an extended coast to rest The voltage ramp down time is user adjustable from 0 120 seconds The Soft Stop time is adjusted independently from the start time The load will stop when the voltage drops to a point where the load torque is greater than the motor torque Rockwell Automation Publication 150 AT002C EN P March 2013 25 Chapter 1 Overview
33. d see Figure 61 These torque characteristics will also vary depending on the speed selected Refer to Table 12 for the approximate maximum available starting and running full load torque at maximum current settings On adjustment Slow Speed Current will control the starting and running torque values 66 Rockwell Automation Publication 150 AT002C EN P March 2013 Special Application Considerations Chapter 3 Figure 61 Starting and Running Torque 100 _ Motor Speed 7 or 15 Starting torque Time seconds Running torque Table 12 Maximum Torque at Maximum Current Settings Present Slow Maximum Running Torque as a Speed Percentage of Full Load Torque Percentage of Full Load Torque iE T10 120 15 100 Accu Stop Two levels of braking torque are applied with the Accu Stop option There is the braking portion that brakes to slow speed and the slow speed braking coast see Figure 3 12 The level of these braking currents are adjusted using one rotary digital switch The maximum braking torque available from braking to slow speed and from slow speed to stop is approximately 80 100 of full load torque of the motor Using the slow speed starting portion of the Accu Stop option will result in the same starting and running torque characteristics as described in the Preset Slow Speed option Figure 62 Accu Stop Option 100 Braking A Slow Speed Braking Coast Motor Speed Slow Speed B
34. e 0 e sissehd00 Wacadeie eetedeed behets 72 Lumber and Wood Products 44 lt os Ps acute node ieaswan eka e wes 72 Water Wastewater Treatment and Municipalities 72 Chapter 5 Piitlosophyci sus sores chee Malden chu gem eas peered 73 Line Voltage Conditions sc5 4 lt seoeds evant ona s wa suidn das porate 73 Current and Thermal Ratings 0hi6 sce stark nguenetens eeaee pawiens 73 Mechanical Shock and Vibration 00 ce cece cence nee ee eens 73 Noise and RF Immunity 21200 eis as Baden el aee eee 74 Alude Ahana ede wien ded haeok a ites Sooke tan oa 74 DG a A Bio secesnn a nd eh ea hh Sop oS rasa sh bd atte edd Morente sracien asia Sek 74 n E e seis van T E ve Sows ata cad sacar aoe Sees Sus eax ows 74 Rockwell Automation Publication 150 ATO02C EN P March 2013 Reduced Voltage Starting Solid State Starters Using SCRs Table of Contents Chapter 6 Introduction to Reduced Voltage Starting 0 0 cece eee ee 75 Red c d Voltages onin nda ncaa eienenn reie a acne aa 76 SMC Flex Solid State c cigs wok aways bdbiaididto te eased 78 Chapter 7 OVERVIEW Si nce ta tinea Maseeatce ndahhe spokes eae ae peg aaa 81 Chapter 8 Motor Output Speed Torque Horsepower ee eee eee eee 83 Torque and Horsepower vie tse seed 22 eed eee ERS 83 Pullcboad Torque FLT sctenci re raae n 85 Locked Rotor Porque LRT ic 22533 onde ssncawedecvent oteteaees 85 Pull Up Torque PU Liu cecequt escameunsiwe
35. e than the present 15 minute coast to rest was desired The long stop time caused delays in the production process A Wye Delta starter with a mechanical brake was currently in use A zero speed switch was used to release the brake The mechanical brake required frequent maintenance and replacement which was costly and time consuming Both the mechanical brake and zero speed switches were worn out and required replacement Solution The SMC Flex controller with the braking option configured as SMB Smart Motor Braking was installed and wired inside the delta to the wye delta motor The controller was set for a 28 second 340 current limit start meeting the power company requirements and reducing the starting torque stress to the gearbox SMB Smart Motor Braking allowed the centrifuge to stop in approximately 1 minute The SMC Flex controller with SMB Smart Motor Braking did not require additional mounting space or panel wiring The controller was mounted in a panel that was considerably smaller than the previous controller Additionally the controller did not require frequent maintenance and could sense zero speed without a feedback device Rockwell Automation Publication 150 AT002C EN P March 2013 53 Chapter 2 Figure 48 Wire Draw Steel Mill Machine with Soft Start 575 Volts 35 Hp Unwind Spool Take Up Spool Pa Chain Sx Wire Ee w Motor Problem An across the line starter was u
36. ee s 39 LCD Displays te acti ecteoredieih et bila EE hehe 40 Parameter Programming acts ty taneemen ase h hs aak eee eseet 40 Electronic Overload i c3s fas e e ease ee ph eas 40 Stall Protection and Jam Detection n n n 00 0 cece cece eee nee 41 Ground Fault Protection 6056 59 sho ou Vax ceaad oa ea ee ee 42 Thermistor Input dees dyciais epee eae tase eters per awaoers 42 Metering aaia a mbes ta Ra ates beter agitate Gone eg etd a 42 Fault Indication e ee no a a NE oe aowenenediws 42 Parameter Programming cs4 seein cawige ws odage boonies cane ness 43 Communication Capabilities s 0 55 caneiecs se dcedasy god ee Reeeers 43 Auxiliary Contacts arrer ie enna ager use ues ER eames 43 Modular Desin hci ieee ane ames meat ene esas be ualhs 44 Control Terminal Descriptiony 33 42s es034 eves eee eis is os 44 Chapter 2 Overview eee ra rae gE CTR CROP er rer ere NT ree rR noire aerate 47 Rockwell Automation Publication 150 AT002C EN P March 2013 1 Table of Contents Special Application Considerations Product Line Applications Matrix Design Philosophy Chapter 3 SMC Flex Controllers in Drive Applications 0 008 57 Use of Protective Modules cccccuccccccceveceeenvns 57 Motor Overload Protection cccceccecececcecueccceeesens 58 Stall Protection and Jam etertionys i lt a oowi su cddasabein ans ess 58 Built in Communication 2 a5 o556 cau eee gadaedica eel aor awe 58 Power Factor Ca
37. ermill with Current Limit Start and SMB Smart Motor Braking 480 Volts 350 Hp Belts Basn Motor Problem A hammermill required a reduced voltage start because of power company restrictions A stopping time less than the present 5 minute coast to rest was desired To save panel space the customer wanted to incorporate both starting and stopping control in the same device Solution The SMC Flex controller with the braking option configured as SMB Smart Motor Braking was installed A 23 second 450 current limit acceleration was programmed meeting the power company requirements and reducing the mechanical stress on the belts during start up The braking function was accomplished without additional power wiring panel space or contactors Zero speed was detected without additional sensors or timers The current limit start braking and overload protection were accomplished within the same modular package Rockwell Automation Publication 150 AT002C EN P March 2013 Chapter 2 Figure 47 Centrifuge with Current Limit Start and SMB Smart Motor Braking 480 Volts 400 Hp Centrifuge Motor Gearbox Problem A centrifuge required a reduced voltage start because of power company restrictions The high torque during starting was causing damage to the gearbox A shorter stopping tim
38. erview Chapter 1 Figure 11 Full Voltage Start 100 Percent Voltage Time in Seconds The basic parameter setup for Full Voltage Start follows Table 4 Full Voltage Start Parameters Parameter Adjustments SMC Option Standard Braking Pump Starting Mode Full Voltage Stop Mode Disable Stop Time Os Rockwell Automation Publication 150 AT002C EN P March 2013 17 Chapter 1 18 Overview Figure 12 Full Voltage Start Sequence of Operation 100 Percent Voltage Push Buttons Start Stop Soft Stop Auxiliary Contacts Normal Up to speed Rockwell Automation Publication 150 AT002C EN P March 2013 Closed Open Closed Open Closed Open Closed Open Closed Open Coast to rest Soft Stop a Soft Stop Start Run Time seconds Z If Soft Stop Selected If Coast to rest Selected N Figure 13 Full Voltage Start Wiring Diagram Control Power 11 12 13 14 15 16 17 18 19 20 21 22 SMC Flex J Control Terminals Aux 1 Normal Up to Speed Bypass 23 24 25 26 27 28 29 30 31 32 33 34 eae eee E v yE PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Co
39. ew Table of Contents Important User Information 25 24 20 43 c esses ek eled ae 2 Chapter 1 Introductions isis a NE ate A E E ie needed 5 SMC Flex Feat iesn sir en r ra dh Ea A A AT AE 5 D siripti ny eiea d saon Eaa E E EEE o EINE Sab A N a aa 6 Modes 6f Op r tioneren rrena re E ER RE ote 7 Gratien neari ea a batalla tte a AANS 7 Pup Opto ss sees ee oane cy AAAS NE AE A A TANS 7 Biaking Peon sassarese pnd cde aeaaee e a enian eh 7 Standard meren aera N a E eS ec 7 Soft Start with Selectable Kickstart ts lt s 03 2 26q00 54a van camraeuas out 7 Current Limit Start with Selectable Kickstart 004 10 Dual Ramp Start with Selectable Kickstart 000 13 Pull Voltage St rt i oi aarti Masry yaetalie a e e Eaa 16 Preset Slow Speed is rera soseri teste ea eee ie 19 Linear Speed Acceleration with Selectable Kickstart 22 Sofe Stoph lice cie intel eee ee 25 Pump Control c 0ca sats ets ad ase eos ea V aa RGS 27 Pump Control Option with Selectable Kickstart 27 Braking Conttol vier ir evecmainie ewe dhe eae eran nals 30 SMB Smart Motor Braking Option 0 0 0 se ee eee 30 JNA NIO E E oy aaa ha utara ay Ge Me eee cms 33 Slow Speed with Braking scsticcsmes adn tcxupningeke rats wom nenens 36 Beatties eit seve deh Ghee aaa ee lek eee hee a aeels 39 SCR Bypass sdstscuiwa sk uses sane ama E EEEN EE EATER EE PENA 39 Standard or Wye Delta Wiring vein iad cisceareteatcnee cd gocmit
40. f a rotating member that was calculated by assuming the weight of the object was concentrated at some smaller radius K termed the radius of gyration To determine the WK ofa part the weight is normally required e g cylinder pulley gear Hp x 5250 is N Where e Hp Horsepower T Torque ft lb e N Speed of motor at rated load RPM T FxR Where T Torque ft lb e F Force lb e R Radius ft Rockwell Automation Publication 150 AT002C EN P March 2013 Chapter 8 WK x ARPM T Accelerating 308 xt Where T Torque ft lb e WK Inertia reflected to the motor shaft ft lb e ARPM Change in speed e t Time to accelerate s Note To change in lb sec to ft Ib 2 multiply by 2 68 To change ft Ib to in Ib sec divide by 2 68 AC Motor Formulas Frequency x 120 Synchronous Speed Number of Poles Where e Synchronous Speed Synchronous Speed RPM e Frequency Frequency Hz Synchronous Speed Full Load Speed Synchronous Speed jae Percent Slip Where Full Load Speed Full Load Speed RPM e Synchronous Speed Synchronous Speed RPM WK of Load Reflected WK _ _ Reduction Rate Where WK Inertia ft 1b Torque Characteristics on This chart offers a quick guideline on the torque required to breakaway start and Common Applications ema than a Rockwell Automation Publication 150 AT002C EN P Marc
41. fines the time the motor will ramp from zero speed to full speed This ramp time is user adjustable from 0 30 seconds Linear Speed requires a tachometer input 0 5V DC 4 5 V 100 speed The current limit is active during the starting ramp The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started It is intended to provide a current pulse user adjustable 0 90 locked rotor torque for a selected period of time 0 0 2 0 seconds Note that speed ramp begins once the kickstart is completed Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 17 Linear Speed Acceleration 100 ale aa Start Run Stop Time seconds The basic parameter set for Linear Speed follows Table 6 Linear Speed Acceleration Parameters Parameter Adjustments SMC Option Standard Starting Mode Linear Speed Ramp Time 0 0 30 0 s Current Limit Level 0 600 FLC Full Load Current Kickstart Time 0 0 2 0s Kickstart Level 0 90 LRT Option 2 Disable Stop Mode Linear Speed Stop time 0 0 120 0 s Rockwell Automation Publication 150 AT002C EN P March 2013 23 Chapter 1 24 Overview Figure 18 Linear Speed Acceleration Sequence of Operation 100 Coast to rest x Soft Stop or Linear Speed Motor Spee
42. following equation 60 x 2 x Frequency Synchronous Speed Number of Poles Actual full load speed the speed at which the motor will operate at nameplate rated load will be less than synchronous speed This difference between synchronous speed and full load speed is called slip Percent slip is defined as follows Synchronous Speed Full Load Speed Synchronous Speed x100 Percent Slip Induction motors are built with slip ranging from less than 5 to as much as 20 A motor with a slip of less than 5 is called a normal slip motor Motors with a slip of 5 or more are used for applications requiring high starting torque Torque and horsepower two important motor characteristics determine the size of the motor required for a given application The difference between the two can be explained using a simple illustration of a shaft and wrench Rockwell Automation Publication 150 AT002C EN P March 2013 83 Chapter 8 84 Figure 75 Shaft and Wrench N L One Pound Pitt Se eR One Foot NSS Ce Torque is merely a turning effort In the previous illustration it takes one pound at the end of the one foot wrench to turn the shaft at a steady rate Therefore the torque required is one pound x one foot or one foot lb If the wrench were turned twice as fast the torque required would remain the same provided it is turned at a steady rate Horsepower on the other hand takes into account
43. ft start Gurrent Kickstart sot stop Pump Accu St Motor Slow SReed Speed Brake Speed Brake Acceleration Centrifugal Pumps X X X Pallitizers X X Mixers X X X X Agitators X Centrifuges X X X Conveyors X X X X Fans X X Bottle Washers X X Compressors X X Hammermill X X Separators X X Dryers X X Slicers X X X Pulp and Paper SMC Flex X AE Slow Applications Sett Start Current Kickstart Soft top Pump Accu St iMotor sow 824 Speed Brake Speed Brake Acceleration Compressors X X Conveyors X X X X X X Trolleys X X X X Dryers X X Agitators X X Centrifugal Pumps X X X Mixers X X Fans X X Re Pulper X X X Shredder X X 70 Rockwell Automation Publication 150 AT002C EN P March 2013 Product Line Applications Matrix Chapter 4 Petrochemical SMC Flex X de Linear with Speed Speed Brake Acceleration Smart Preset Accu St Motor Slow Control op Brake Applications Soft Start aha Kickstart Soft Stop Pump Centrifugal Pumps Extruders Screw Conveyors Mixers Agitators Compressors Fans Ball Mills Centrifuge gt lt XxX x XxX x x x x Xx x x x x x x x x Xx Transportation and Machine Tool SMC Flex X Smart Preset Slow Current Pump Accu Sto Speed Linear Speed Soft Start Limit Kickstart Soft Stop Control p aar Sheed with Accelerat
44. ge motor starting also enables torque control High inertia loads are a good example of an application in which electromechanical reduced voltage starting has been used to control the acceleration of the motor and load Electromechanical reduced voltage starters must make a transition from reduced voltage to full voltage at some point in the starting cycle At this point there is normally a line current surge The amount of surge depends upon the type of transition being used and the speed of the motor at the transition point There are two methods of transition Open Circuit Transition and Closed Circuit Transition Open circuit transition means that the motor is actually disconnected from the line for a brief period of time when the transition takes place With closed transition the motor remains connected to the line during transition Open circuit transition will produce a higher surge of current because the motor is momentarily disconnected from the line Examples of open and closed circuit transition currents are shown in Figure 65 and Figure 66 Figure 65 Open Circuit Transition Figure 66 Closed Circuit Transition 600 600 i 500 500 ek ws SS Fee iin 400 wh Full gom aN N q Load N Load ayy au N current Current Ns 200 aaa 100 100 0 Speed 100 0 Speed 100 The motor speed can determine the amount of current surge that occurs at transit
45. ger pumps conveyors and compressors Speed Figure 82 Typical NEMA Design D Speed Torque Curve Starting Current Normal Starting Torque High Breakdown Torque None Full load Slip High 5 13 Torque k Applications The combination of high starting torque and high slip make NEMA Design D motors ideal for use on very high inertia loads and or in applications where a considerable variation in load exists These motors are commonly used on punch presses shears cranes hoists and elevators Speed Table 14 Motor Output Comparison of NEMA Polyphase Designs Locked NEMA Starting Breakdown re Rotor Slip Applications Design Torque Torque Torque A High High High lt 5 Broad applications including fans blowers pumps and machine tools Normal starting torque for fans blowers rotary pumps unloaded B Normal Normal Normal lt 5 compressors conveyors metal cutting machine tools miscellaneous machinery High inertia starts such as large centrifugal blowers fly wheels and C Low High Low Low crusher drums Loaded starts such as piston pumps compressors and conveyors Hiah Very high inertia and loaded starts Choice of slip range to match g application D Normal High None 5 8 Punch press sheers and forming machine tools 8 13 Cranes hoists elevators and oil well pumping jacks 90 Rockwell Automation Publication 150 AT002C EN P March 2013 Calculating Torque Acceleration T
46. h 2013 93 Chapter 8 Table 15 Torque Characteristics on Common Applications ar Load Torque as Percent of Full Load Drive Torque Application Breakaway Accelerating Peak Running Agitators Liquid 100 100 00 Slurry 150 100 00 Blowers centrifugal Valve closed 30 50 40 Valve open 40 110 00 Blowers positive displacement rotary bypassed 40 40 00 Card machines textile 100 110 00 Centrifuges extractors 40 60 25 Chippers wood starting empty 50 40 200 Compressors axial vane loaded 40 100 00 Compressors reciprocating start unloaded 100 50 00 Conveyors belt loaded 150 130 00 Conveyors drag or apron 175 150 00 Conveyors screw loaded 175 100 00 Conveyors shaker type vibrating 150 150 75 Draw presses flywheel 50 50 200 Drill presses 25 50 50 Escalators stairways starting unloaded 50 75 00 Fans centrifugal ambient Valve closed 25 60 50 Valve open 25 110 00 Fans centrifugal hot Valve closed 25 60 00 Valve open 25 200 75 Fans propeller axial flow 40 110 00 Feeders belt loaded 100 120 00 Feeders distributing oscillating drive 150 150 00 Feeders screw compacting rolls 150 100 00 Feeders screw filter cake 150 100 00 Feeders screw dry 175 100 00 Feeders vibrating motor driven 150 150 00 Frames spinning text
47. her Formulas Chapter 8 Calculating Motor Amperes Motor Amperes UPX746___ E x 1 732 x Eff x PF Motor Amperes KVA x 1 000 1 73 x E Motor Amperes Nx 1 000_ 1 73 xE x PF Where HP Horsepower E EMF or Voltage Volts Eff Efficiency of Motor 100 KVA Kilovolt Amperes kW Kilowatts PF Power Factor Calculating Accelerating Force for Linear Motion F Acceleration Wx AV x AV 1 933 x t Where F Force Ib W Weight Ib AV Change in Velocity FPM t Time to accelerate weight seconds HP x ELE ce x 1 000 HP E x 1 73 LRA Where LRA Locked Rotor Amperes HP Horsepower kVA Kilovolt Amperes E EMF or Voltage Volts 60 Hz LRA 60 y Freq X Where 60 Hz LRA Locked Rotor Amperes Freq X Desired frequency Hz LRA Freq X Rockwell Automation Publication 150 AT002C EN P March 2013 97 Chapter 8 98 Rockwell Automation Publication 150 AT002C EN P March 2013 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and trou
48. hip Figure 77 Speed Torque Curve with Current Curve Locked Rotor Synchronous Speed Current Breakdown Torque BT a a AQ aX Locked Rotor NOY N Torque LRT PS Slip gt lt _ _ A of Pull Up Torque PUT oN i Full Se Load Torque N Full Speed a Full load Current Two important points on this current curve require explanation Full load Current The full load current of an induction motor is the steady state current taken from the power line when the motor is operating at full load torque with rated voltage and rated frequency applied Locked rotor Current Locked rotor current is the steady state current of a motor with the rotor locked and with rated voltage applied at rated frequency NEMA has designed a set of code letters to define locked rotor Kilovolt amperes per horsepower kVA Hp This code letter appears on the nameplate of all AC squirrel cage induction motors Rockwell Automation Publication 150 AT002C EN P March 2013 Chapter 8 KVA per Hp is calculated as follows For three phase motors _ 1 73 x Current in Amperes x Volts KVA HP 000x Hp For single phase motors Current in Amperes x Volts kVA Hp 1000 x Hp Letter Designation kVA per Hp A 0 3 15 B 3 15 3 55 C 3 55 4 0 D 4 0 4 5 E 4 5 5 0 F 5 0 5 6 G 5 6 6 3 H 6 3 7 1 J 7 1 8
49. how fast the shaft is turned Turning the shaft rapidly requires more horsepower than turning it slowly Thus horsepower is a measure of the rate at which work is done By definition the relationship between torque and horsepower is as follows 1 Horsepower 33 000 ft Ib minute In the above example the one pound of force moves a distance of 2 ft xXx 1 Ib 6 28 ft lb To produce one horsepower the shaft would have to be turned at rate of 1 Hp x 33 000 ft Ib minute 6 28 ft Ib revolution 5250 RPM For this relationship an equation can be derived for determining horsepower output from speed and torque _ RPM x Torque X 2 R RPM x Torque 30 000 5250 For this relationship full load torque is Hp x 5250 Full Load Torque in ft Ib Ful load RPM Rockwell Automation Publication 150 AT002C EN P March 2013 Chapter 8 Figure 76 illustrates a typical speed torque curve for a NEMA Design B induction motor An understanding of several points on this curve will aid in properly applying motors Figure 76 Speed Torque Curve Synchronous Speed Breakdown Torque BT 1 i Bes I T Locked Rotor Torque LT ei va amp Pa a oP XE cobs l ie Slip of 4 fu Pull Up Torque PUT Load Torque l l l l I Full Load Torque FLT K E A E ad TA Full Speed Full load Torque FLT The full load torque of a motor is the torque necessary to produce
50. ical interlock required Controller Customer supplied Many VF drives are rated 150 FLA Because the SMC Flex controller can be used for 600 FLA starting separate branch circuit protection may be required Overload protection is included as a standard feature of the SMC Flex controller Rockwell Automation Publication 150 AT002C EN P March 2013 65 Chapter3 Special Application Considerations SMC Flex Controller with a Bulletin 1410 Motor Winding Heater Figure 60 Typical Application Diagram of SMC Flex Controller with a Bulletin 1410 Motor Winding Heater IC OL 3 Phase Input Power Li T1 2 rY ws T4 H L3 5 T3 6 ae SMC Flex Controller Customer supplied ne Bulletin 1410 MWH Overload protection is included as a standard feature of the SMC Flex controller Motor Torque Capabilities with SMC Flex Controller Options SMB Smart Motor Braking The stopping torque output of the SMC Flex controller will vary depending on the braking current setting and motor characteristics Typically the maximum stopping torque will be between 80 100 of the full load torque of the motor when set at 400 braking current Preset Slow Speed Two torque characteristics of the Preset Slow Speed option must be considered The first is the starting torque The second is the available running torque at low spee
51. ile 50 125 00 Grinders metal 25 50 00 lroners laundry mangles 50 50 25 Jointers woodworking 50 125 25 Machines bottling 150 50 00 Machines buffing automatic 50 75 00 Machines cinder block vibrating 150 150 70 Machines keyseating 25 50 00 Machines polishing 50 75 00 Mills flour grinding 50 750 00 Mills saw band 50 75 200 Mixers chemical 175 75 00 Mixers concrete 40 50 00 Mixers dough 175 125 00 Mixers liquid 100 100 00 Mixers sand centrifugal 50 100 00 Mixers sand screw 175 100 00 Mixers slurry 150 125 00 94 Rockwell Automation Publication 150 AT002C EN P March 2013 Chapter 8 ere Load Torque as Percent of Full Load Drive Torque Application i Breakaway Accelerating Peak Running Mixers solids 75 125 175 Planers woodworking 50 125 150 Presses pellet flywheel 50 75 150 Presses punch flywheel 50 75 100 Pumps adjustable blade vertical 50 40 125 Pumps centrifugal discharge open 40 100 100 Pumps oil field flywheel 50 200 200 Pumps oil lubricating 40 150 150 Pumps oil fuel 40 150 150 Pumps propeller 40 100 100 Pumps reciprocating positive displacement 175 30 175 Pumps screw type primed discharge open 150 100 100 Pumps Slurry handling discharge open 150 100 100 Pumps turbine centrifugal deep well 50 100 100 Pumps vacuum paper mill service 60 100 150 Pumps vacuum other applications 40 60 100 Pumps va
52. ing can also cause spikes 2 The second situation arises when the SMC Flex controller is installed on a system that has fast rising wavefronts present although not necessarily high peak voltages Lightning strikes can cause this type of response Additionally if the SMC Flex controller is on the same bus as other SCR devices AC DC drives induction heating equipment or welding equipment the firing of the SCRs in those devices can cause noise Rockwell Automation Publication 150 AT002C EN P March 2013 57 Chapter3 Special Application Considerations Motor Overload Protection Stall Protection and Jam Detection Built in Communication 58 When coordinated with the proper short circuit protection overload protection is intended to protect the motor motor controller and power wiring against overheating caused by excessive overcurrent The SMC Flex controller meets applicable requirements as motor overload protective device The SMC Flex controller incorporates as standard electronic motor overload protection This overload protection is accomplished electronically with circuits and an Ft algorithm The controller s overload protection is programmable providing the user with flexibility The overload trip class can be selected for class OFF 10 15 20 or 30 protection The trip current can be programmed to the motor full load current rating Thermal memory is included to model motor operating and cooling temperatures
53. ion Brake Applications Material Handling Conveyors Ball Mills Grinders gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt x lt Centrifugal Pumps Trolleys Presses Fans Palletizers Compressors Roller Mill Die Charger gt lt x x x Xx gt lt gt lt gt lt gt lt gt lt x XxX x x x x x x OK Rotary Table Rockwell Automation Publication 150 AT002C EN P March 2013 71 Chapter 4 Product Line Applications Matrix OEM Specialty Machine SMC Flex X Slow 5 Applications Smart Preset Linear FE Soft Start rte nt Kickstart Soft Stop Pamp Ain St Motor Slow Stee Speed P Brake Speed Brake Acceleration Centrifugal Pumps X X X Washers X X Conveyors X X X Power Walks X X Fans X X Twisting Spinning i X X Machine Lumber and Wood Products SMC Flex X Slow i Applications Smart Preset Linear ER Soft Start rane nt Kickstart Soft Stop Hla aaa Motor Slow opang Speed P Brake Speed Brake Acceleration Chipper X X X Circular Saw X X X Bandsaw X X X X Edger X X Conveyors X X X X X X Centrifugal Pumps X X X Compressors X X Fans X X Planers X X Sander X X X X Debarker X X Water Wastewater Treatment and Municipalities SMC Flex X Slow Applications y Smart Preset Li
54. ion Transfer from reduced voltage to full voltage should occur at as close to full speed as possible This also minimizes the amount of surge on the line Figure 67 and Figure 68 illustrate transition at low motor speed and near full speed The transition at low speed shows the current surge as transition occurs at 550 which is greater than the starting current of 400 The transition near full speed shows that the current surge is 300 which is below the starting current Rockwell Automation Publication 150 AT002C EN P March 2013 71 Chapter6 Reduced Voltage Starting Figure 67 Transition at Low Speed 600 500 D Full 0a e Load i Current ane 200 100 Figure 68 Transition near Full Speed 0 Speed SMC Flex Solid State 5 85A 78 108 600 500 NN S Sa DS ee SS Full 400 Se o N Xe Load 300 NN x Current 200 a 100 l 100 0 Speed 100 The main function of solid state controllers is their ability to provide a soft start or stepless reduced voltage start of AC motors The same principles of current and torque apply to both electromechanical reduced voltage starters and solid state controllers Many solid state controllers offer the choice of four starting modes soft start current limi
55. l Again the starting torque can be adjusted to match the load with parameter programming Wound Rotor Wound rotor motors require careful consideration when implementing SMC Flex controllers A wound rotor motor depends on external resistors to develop high starting torque It may be possible to develop enough starting torque using the SMC Flex controller and a single step of resistors The resistors are placed in the rotor circuit until the motor reaches approximately 70 of synchronous speed At this point the resistors are removed from the secondary by a shorting contactor Resistor sizing will depend on the characteristics of the motor used Please note that it is not recommended to short the rotor slip rings during start up as starting torque will be greatly reduced even with full voltage applied to the motor The starting torque will be even further reduced with the SMC Flex controller since the output voltage to the motor is reduced on startup Synchronous Synchronous brush type motors differ from standard squirrel cage motors in the construction of the rotor The rotor of a synchronous motor is comprised of two separate windings a starting winding and a DC magnetic field winding The starting winding is used to accelerate the motor to about 95 of synchronous speed Once there the DC magnetic field winding is energized to pull the motor up to synchronous speed The SMC Flex controller can be retrofitted to a synchronous contr
56. lance e Loss of Communication e Power Loss e Excessive Starts Hour e Ground Fault e Motor Lead Loss e Line Fault e Communication Fault Any fault condition will cause the auxiliary contacts to change state and the hold in circuit to release Communication Capabilities A serial interface port is furnished as standard with the SMC Flex controller This communication port allows connection to a Bulletin 20 Human Interface Module and a variety of 20 COMM modules These include Allen Bradley Remote I O DeviceNet ControlNet Ethernet ProfiBUS Interbus and RS485 Auxiliary Contacts Four hard contacts are provided as standard with the SMC Flex controller The first contact is programmable for Normal Up to speed Bypass The second third and fourth contact are configured to N O N C Rockwell Automation Publication 150 AT002C EN P March 2013 43 Chapter 1 Overview Modular Design The SMC Flex controller packaging is designed for industrial environments The modularity of control and power modules feature plug in functionality There are no gate wires to remove and no soldering is required Common control modules reduce inventory requirements Figure 39 Exploded View Control Terminal Description The SMC Flex controller contains 24 control terminals on the front of the controller These control terminals are described below See Figure 40 44 Rockwell Automation Publication 150 AT002C EN P March
57. llautomation com literature www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Rockwell Automation Publication 150 ATO02C EN P March 2013 Supercedes 150 AT002B EN P June 2004 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in the U S A
58. lled to prevent restart underload but need to be adjusted frequently The pumping station motor was over 100 feet below ground making repair costly For maintenance scheduling purposes an elapsed time meter measuring motor running time had to be installed in the enclosure Solution The SMC Flex controller with Pump control was installed providing a controlled acceleration of the motor By decreasing the torque during start up the shock to the impeller was reduced The SMC Flex Anti backspin timer feature was implemented to prevent the motor from starting while turning in a reverse direction Panel space was saved by employing the built in elapsed time meter The SMC Flex controller s line diagnostics detected the pre start and running single phase condition and shut off the motor protecting against motor damage Rockwell Automation Publication 150 AT002C EN P March 2013 49 Chapter 2 Figure 44 Bandsaw with Soft Start and Slow Speed with Braking 480 Volts 300 Hp Saw Blade A by yi a Log J Carriage High Inertia Problem Because of the remote location of the facility and power distribution limitations a reduced voltage starter was needed on a bandsaw application When the saw blade became dull the current drawn by the motor increased Therefore an ammeter was required The saw was turned off only during shift
59. load The SMC Flex controller provides both stall and jam detection for enhanced motor and system protection Stall protection allows the user to program a maximum stall time of up to 10 seconds Jam detection allows the user to determine the jam level as a percentage of the motor s full load current rating and a trip delay time of up to 99 seconds The stall trip delay time is in addition to the programmed start time Figure 37 Stall Protection Sequence of Operation 600 Percent Full Load Current Programmed Start Time Stall gt Time seconds Figure 38 Jam Detection Sequence of Operation Percent Full Load User Programmed Trip Level Current j 100 i lt Running gt lt Jam gt Time seconds Rockwell Automation Publication 150 AT002C EN P March 2013 41 Chapter 1 42 Overview Ground Fault Protection The SMC Flex Controller can sense ground faults before they become short circuits Ground faults generally start at low levels amps but can rapidly increase to hundreds or thousands of amperes This feature is not intended as a ground fault circuit interrupter for personnel protection The Ground Fault protection settings are user adjustable A separate Cat No 825 CBCT core balance current transformer is required for setup of this feature Thermistor Input The SMC Flex controller offers enhanced motor protection with additional circuitr
60. mmon There were many different voltage and frequency requirements to meet because of the compressor s final destination Due to power company requirements and mechanical stress on the compressor a reduced voltage starter was required This made ordering and stocking spare parts difficult Solution The SMC Flex controller was installed and wired to a wye delta motor The unit was set for an 18 second Soft Start which reduced the voltage to the motor during starting and met the power company requirements By reducing the voltage the starting torque was also reduced minimizing the shock to the compressor Panel space was saved because the SMC Flex controller has a built in overload and SCR bypass feature Rockwell Automation Publication 150 AT002C EN P March 2013 41 Chapter 2 Figure 42 Tumbler with Soft Start and Accu Stop 480 Volts 50 Hp Loading Door Bal Drive Chain Tumbler Drum i YW Motor Ld Problem A tumbler drum used in the de burring process was breaking the drive chain because of the uncontrolled acceleration from the across the line starter To increase production on the drum the coasting time on stop had to be reduced Previous solutions were a separate soft start package plus a motor brake which required additional panel space and power wiring A small enclosure size and simplified power wiring were needed to reduce the cost of the controls Because a PLC was
61. mp Starting Mode Soft Start Ramp Time 0 30s Initial Torque 0 90 LRT Kickstart Time 0 0 2 0s Kickstart Level 0 90 LRT Option 2 Input Disable Stop Mode Disable Stop Time Os Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 3 Soft Start Sequence of Operation Selectable Kickstart 100 E r55 l Coast to rest l l gt I Percent l Soft Stop Voltage h Start Run Soft Stop Time seconds Push Buttons Start Closed Open Stop Closed i Open Lt Soft Stop Closed Open Auxiliary Contacts ri If Soft Stop Selected Normal Closed Open Ft te fo N If Coast to rest Selected Up to speed Closed Open Rockwell Automation Publication 150 AT002C EN P March 2013 Chapter 1 Overview Figure 4 Soft Start Wiring Diagram Control Power I Sto Po O_ O Start a O Oo SMC Flex Control Terminals Aux 1 Normal Up to Speed pean B uxilary ee Contacts 23 24 25 26 27 28 29 30 31 32 33 34 Ww Ys PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power inp
62. ne type positive displacement 150 150 175 Rolls crushing sugar cane 30 50 100 Rolls flaking 30 50 100 Sanders woodworking disk or belt 30 50 100 Saws band metalworking 30 50 100 Saws circular metal cut off 25 50 150 Saws circular wood production 50 30 150 Saws edger see edgers Saws gang 60 30 150 Screens centrifugal centrifuges 40 60 125 Screens vibrating 50 150 70 Separators air fan type 40 100 100 Shears flywheel type 50 50 120 Textile machinery 150 100 90 Walkways mechanized 50 50 100 Washers laundry 25 75 100 Electrical Formulas Ohm s Law p E R Es IxR R Where Current Amperes E EMF or Voltage Volts R Resistance Ohms Rockwell Automation Publication 150 AT002C EN P March 2013 95 Chapter 8 Power in DC Circuits P IxXE HP kW Ix E kWH LXE x Hour 1 00 1 000 Where P Power Watts Current Amperes E EMF or Voltage Volts kW Kilowatts kWH Kilowatt Hours _ IxXEx1 73 IxE KVA 3 phase KVA phase Ag 1 000 Where KVA Kilovolt Amperes Current Amperes E EMF or Voltage Volts Ix Ex PF KW 1 phase LEX PF I ophase 00 kW 2 phase bolt an kW 3 phase PSR AHAB x Ax ue W kW PF xi VA Where kW Kilowatts Current Amperes E EMF or Voltage Volts PF Power Factor W Watts V Volts kVA Kilovolt Amperes 96 Rockwell Automation Publication 150 AT002C EN P March 2013 Ot
63. near PE Soft Start rune nt Kickstart Soft Stop am Wi St Motor Slow Spoon Speed P Brake Speed Brake Acceleration Centrifugal Pumps X X X Centrifuge X X X X Fans X X Compressors X X 72 Rockwell Automation Publication 150 AT002C EN P March 2013 Philosophy Line Voltage Conditions Current and Thermal Ratings Mechanical Shock and Vibration Chapter 5 Design Philosophy Allen Bradley SMC controllers are designed to operate in today s industrial environments Our controllers are manufactured to provide consistent and reliable operation Rockwell Automation has more than just an adequate solution to meet your needs we have the right solution With a broad offering of power device products and application services Rockwell Automation can effectively address the productivity issues most important to you Voltage transients disturbances harmonics and noise exist in any industrial supply A solid state controller must be able to withstand these noises and should not be an unnecessary source of generating noise back into the line Ease of selection for the required line voltage is achieved with a design that provides operation over a wide voltage range at 50 60 Hz within a given controller rating The controller can withstand 3000V surges at a rate of 100 bursts per second for 10 seconds IEEE Std 472 Further the controller can withstand the showering arc test of 350 1500V NEMA Std ICS2
64. nse eewaaansas 85 Breakdown Torque Bl iit eigen aceguie ts eaelin gee eancanes 86 Bull load Current sses ite A ead a i Reet 86 Locked rotor Current 68s tee acc bow test hla tah tila ato 86 Motor Output for NEMA Design Designations Polyphase 2500 Apis sceavaawetadess dubogeseeee ee aa Seagate 89 Calculating Torque Acceleration Torque Required for Rotating Motion 91 Tine ti aseisohirn ck aa weeks eA ola OWS ba ONES ela eg destics 92 Torque Formulas 2 24420 242k ai cs wey sede ees ag ee 92 AC Motor Formulas 2 ox deraawd dawstieedonsen 4 opera etenrenS Oe ac osew ease 93 Torque Characteristics on Common Applications 4 93 El cttical Formulasi eane Say os Sie a sata Linon e Sat wea eee 95 Ohms Lawra ass aene sod whet setr orp heaca iid a aided onions 95 Power in DC Circuits svcd ool Ba A oc N 96 Other Fornatlas cricdett Bold katy ey ne di eed Ae teas ark es 97 Calculating Accelerating Force for Linear Motion 97 Rockwell Automation Publication 150 AT002C EN P March 2013 3 Table of Contents 4 Rockwell Automation Publication 150 AT002C EN P March 2013 Introduction Chapter 1 Overview The Allen Bradley SMC Controller lines offer a broad range of products for starting or stopping AC induction motors from Hp to 6000 Hp The innovative features compact design and available enclosed controllers meet world wide industry requirements for controlling motors Whether you need to
65. ntact Normal Customer supplied Overview Chapter 1 Internal Auxilary Contacts Refer to the controller nameplate to verify the rating of the contro power input rating Preset Slow Speed This method can be used on applications that require a slow speed for positioning material The Preset Slow Speed can be set for either Low 7 of base speed or High 15 of base speed Reversing is also possible through programming Speeds provided during reverse operation are Low 10 of base speed or High 20 of base speed Rockwell Automation Publication 150 AT002C EN P March 2013 19 Chapter 1 20 Overview Figure 14 Preset Slow Speed 100 E Motor Speed Forward 77n 15 High Z 7 Low Time seconds n Start PRR Run 10 Low x ye 20 High Reverse The basic parameter setup for Soft Start selection with Preset Slow Speed Option follows Table 5 Preset Slow Speed Parameters Parameter Adjustments SMC Option Standard Braking Starting Mode Full Voltage Current Limit Soft Start Linear Speed Ramp Time 0 30s Initial Torque 0 90 LRT Current Limit Level 50 600 FLC Torque Limit 0 100 LRT Kickstart Time 0 0 2 0s Kickstart Level 0 90 LRT Option 2 Input Preset SS Stop Mode Disable Stop Time Os Slow Speed Sel SS Low SS High Slow Speed Dir SS Forward SS Reverse Slow Accel Cur 0 450 FLC Slow
66. ntrol Terminals Aux 1 Normal Up to Speed Internal B Auxilary ypass Contacts 23 24 25 26 ar 28 29 30 31 32 33 34 PFET CT Ge Ge Gd v v PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input rating SCR Bypass The SMC Flex has a built in bypass contactor that is automatically pulled in when the motor reaches full speed An external bypass contactor may be used When an external bypass contactor is enabled by setting the parameter Aux1 Config to Bypass the internal bypass contactor will not be used and a separate overload is required Standard or Wye Delta Wiring The SMC Flex can operate either a standard squirrel cage induction motor or a wye delta motor The user must program the selected configuration into the unit using the Motor Connection parameter The wye delta motor is connected in an inside the delta wiring configuration and the Motor Connection is det to Delta Rockwell Automation Publication 150 AT002C EN P March 2013 39 Chapter 1 LCD Display 40 Overview LCD Display A graphical backlit LCD display provides parameter definition with straightforward text so that controller setup may be accomplished without a reference manual Parameters are arranged in an organized three level menu structure
67. o not include any allowance for machine friction winding or other factors that must be considered when selecting a device for a machine application After the machine torque is determined the required horsepower is calculated using the formula TXN Hp 5950 Where Hp Horsepower T Torque ft lb e N Speed of motor at rated load RPM Rockwell Automation Publication 150 AT002C EN P March 2013 91 Chapter 8 Inertia Torque Formulas 92 If the calculated horsepower falls between standard available motor ratings select the higher available horsepower rating It is good practice to allow some margin when selecting the motor horsepower Inertia is a measure of the body s resistance to changes in velocity whether the body is at rest or moving at a constant velocity The velocity can be either linear or rotational The moment of inertia WK7 is the product of the weight W of an object and the square of the radius of gyration K The radius of gyration is a measure of how the mass of the object is distributed about the axis of rotation Because of this distribution of mass a small diameter cylindrical part has a much lower inertia than a large diameter part WK or WR2 Where e WR refers to the inertia of a rotating member that was calculated by assuming the weight of the object was concentrated around its rim at a distance R radius from the center e g flywheel WK refers to the inertia o
68. oller by replacing the stator contactor with the SMC Flex controller and maintaining the DC field application package Because of the decreased efficiency of fans and heatsinks it is necessary to de rate the SMC Flex controller above 6 500 feet approximately 2 000 meters When 62 Rockwell Automation Publication 150 AT002C EN P March 2013 Isolation Contactor Special Application Considerations Chapter 3 using the controller above 6 500 feet use the next size device to guard against potential overtemperature trips Note The motor FLA Rating must remain in the range of the SMC Flex Amp rating When installed with branch circuit protection and an overcurrent device SMC Flex controllers are compatible with the National Electrical Code NEC When an isolation contactor is not used hazardous voltages are present at the load terminals of the power module even when the controller is turned off Warning labels must be attached to the motor terminal box the controller enclosure and the control station to indicate this hazard The isolation contactor is used to provide automatic electrical isolation of the controller and motor circuit when the controller is shut down Shut down can occur in either of two ways either manually by pressing the stop button or automatically by the presence of abnormal conditions such as a motor overload relay trip Under normal conditions the isolation contactor carries only the load current During s
69. omation Publication 150 AT002C EN P March 2013 Chapter 8 Motor Outp ut for N EM A NEMA has designated several specific types of motors each having unique D e sign D e sign ati ons speed torque relationships These designs along with some typical applications for each type are described below Following these descriptions are summaries of Polyphase 1 500 Hp performance characteristics Figure 79 Typical NEMA Design A Speed Torque Curve e Starting Current High e Starting Torque High 7 a e Breakdown Torque High oo Full load Slip Low Applications Fans blowers pumps machine tools or other Torque applications with high starting torque requirements and an essentially constant load Speed Figure 80 Typical NEMA Design B Speed Torque Curve e Starting Current Normal ae e Starting Torque Normal o oo i e Breakdown Torque Normal a e Full load Slip Normal Applications Fans blowers pumps machine tools or other Torque applications with normal starting torque requirements and an essentially constant load Speed Rockwell Automation Publication 150 AT002C EN P March 2013 89 Chapter 8 Figure 81 Typical NEMA Design C Speed Torque Curve Starting Current Low i N Starting Torque High Breakdown Torque Low Full load Slip Low Torque Applications The higher starting torque of NEMA Design C motors makes them advantageous for use on hard to start loads such as plun
70. orque Required for Rotating Motion Chapter 8 Some machines must be accelerated to a given speed in a certain period of time The torque rating of the drive may have to be increased to accomplish this objective The following equation may be used to calculate the average torque required to accelerate a known inertia WK2 This torque must be added to all the other torque requirements of the machine when determining the drive and motor s required peak torque output WK x AN 308 xt Where T Acceleration Torque ft lb e WK total system inertia ft Ib that the motor must accelerate This value includes motor armature reducer and load e AN Change in speed required RPM e t time to accelerate total system load seconds Note The number substituted for WK in this equation must be in units of ft Ib 2 Consult the conversion tables for the proper conversion factor The same formula can be used to determine the minimum acceleration time of a given drive or it can be used to establish whether a drive can accomplish the desired change in speed within the required time period Transposed formula WK x AN 308 xt General Rule If the running torque is greater than the accelerating torque use the running torque as the full load torque required to determine the motor horsepower Note The following equations for calculating horsepower are meant to be used for estimating purposes only These equations d
71. p Closed l i Open laal Soft Stop Closed Open Auxiliary Contacts L If Soft Stop Selected Normal Closed T Open ee pn N If Coast to rest Selected Up to speed Closed i Open 1_ Rockwell Automation Publication 150 AT002C EN P March 2013 15 Chapter 1 Overview Figure 10 Dual Ramp Start Wiring Diagram t Control Power I Stop D O O D Start Ramp 1 Ramp 2 O O O O 11 12 13 14 15 16 17 18 19 20 21 22 SMC Flex Control Terminals Aux 1 Normal Up to Speed Internal Bypass Auxilary Contacts 23 24 25 26 27 28 29 30 31 32 33 34 ee ka a PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input rating Full Voltage Start This method is used in applications requiring across the line starting The SMC Flex controller performs like a solid state contactor Full inrush current and locked rotor torque are realized The SMC Flex may be programmed to provide full voltage start in which the output voltage to the motor reaches full voltage in second 16 Rockwell Automation Publication 150 AT002C EN P March 2013 Ov
72. pacitors scscsoveesses st ahve dddeetaeecaserneawes 59 Multi motor Applications s s sssssesesueeeeererrerrerrrrreen 60 Special Motors errana nua LEET EE PA E EE EE LEEA 61 WyeDelta ssacttica Sank outa cure oot RT aaah inne eae ete toes 61 Part Windmee seule be a CLA kai ae Ae tale 62 Wound Rotor isre Gdns tia ticecatesd ot Geb Gaba na eae 62 SAIC OR OUIS onn Seen a arent a i tid earn rade are rae oar pE E iatras 62 Altitude De rating iis tides vos te nears her deeaw eee eye aeead nad s 62 Isolation Contactori 146 ia tosis h exten oe cide eee ck Uae ee each 63 SMC Flex Controller with Bypass Contactor BC 006 63 SMC Flex Controller with Reversing Contactor 0 0055 64 SMC Flex Controller as a Bypass to an AC Drive 04 65 SMC Flex Controller with a Bulletin 1410 Motor Winding Heater 66 Motor Torque Capabilities with SMC Flex Controller Options 66 SMB Smart Motor Braking s005 cs20s idea veweseeetererd abeees 66 Preset Slow Speed s naneo ree aana pa totals ann eager 66 NCO SOD 52 ira Eno Bes pie oe Renee cheese EEE 67 Chapter 4 Description popsi BU ti e a Nae ees regia te BG Om oh ee weed stand 69 Mining and Metals sx scxcincledaacaseranctneeencs ddan des EE 69 Food PROCESSING s npara E anaE EAE EE O O OE EE 70 P lpand Papere riene eea ETa a E T AE ta we Malet eh all 70 JERKO Aae T E EEEE SEEE EE EES 71 Transportation and Machine Tool s sussssreererrrrrrrrere 71 OEM Specialty Machin
73. peed e Linear Speed Acceleration with Selectable Kickstart e Soft Stop Pump Option e Pump Control with Selectable Kickstart Braking Option e Smart Motor Braking e Accu Stop e Slow Speed with Braking Soft Start with Selectable Kickstart This method covers the most general applications The motor is given an initial torque setting which is user adjustable from 0 to 90 of locked rotor torque From the initial torque level the output voltage to the motor is steplessly increased during the acceleration ramp time which is user adjustable from 0 to 30 seconds If during the voltage ramp operation the SMC Flex controller senses that the motor has reached an up to speed condition the output voltage will automatically switch to full voltage and transition over the SCR Bypass contactors The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started It is intended to provide a current pulse user adjustable 0 90 locked rotor torque for a selected period of time from 0 0 to 2 0 seconds Chapter 1 Overview Figure 2 Soft Start Current Limit 10 jal ue Ramp Time ee stat t uuu Run _ gt Time in Seconds Following are the parameters that are specifically used to provide and adjust the voltage ramp supplied to the motor Table 1 Soft Start Parameters Parameter Adjustment SMC Option Standard Braking Pu
74. r and flexibility to communicate with various network protocols The SMC Flex can also be wired in a standard wiring configuration or inside the delta This allows the product to operate wye delta motors with a much smaller device than before Figure 1 SMC Flex Controller The SMC Flex controller is a compact modular multi functional solid state controller used in both starting three phase squirrel cage induction motors or wye delta motors and controlling resistive loads The SMC Flex contains as standard a built in SCR bypass and a built in overload The SMC Flex product line includes current ratings 5 to 480 A 200 to 600V 50 60Hz This covers squirrel cage induction motor applications up to 400 Hp wye delta motors up to 650 Hp The SMC Flex controller meets applicable standards and requirements While the SMC Flex controller incorporates many new features into its design it remains easy to set up and operate You can make use of as few or as many of the features as your application requires Rockwell Automation Publication 150 AT002C EN P March 2013 Modes of Operation Standard Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 The following modes of operation are standard within a single controller Standard e Soft Start with Selectable Kickstart e Current Limit with Selectable Kickstart Dual Ramp Start with Selectable Kickstart e Full Voltage Start e Preset Slow S
75. ry Contacts 23 24 25 26 27 28 29 30 31 32 33 34 coe eee a v yE PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input rating Accu Stop The Accu Stop option provides rapid braking to a slow speed and then braking to stop facilitating cost effective general positioning control Rockwell Automation Publication 150 AT002C EN P March 2013 33 Chapter 1 34 Overview Figure 29 Accu Stop 100 Motor Speed Braking 7 or 15 Slow Speed Braking Coast to rest f NN a Slow Speed K Slow a Start Run Brake Speed Time seconds The basic parameter setup for Accu Stop follows Table 10 Accu Stop Parameters Parameter Adjustments SMC Option Braking Stop Mode Accu Stop Slow Speed Sel SS Low SS High Slow Accel Cur 0 450 FLC Slow Running Cur 0 450 FLC Braking Current 0 400 FLC Stopping Current 0 400 FLC Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 30 Accu Stop Sequence of Operation 100 Braking Motor Speed Slow Speed Braking Coast to rest L S s s Slow Speed mia Start Run Acou Stop p Slow Speed
76. sed on a wire draw machine to pull wire This rapid cycling application caused mechanical wear on both the chain and the electromechanical starter Other soft starts had been experimented with but not enough torque was developed to pull the wire through the die Solution The SMC Flex controller was installed to accelerate the motor smoothly The kickstart feature was adjusted to provide enough torque to pull the wire through the die After the initial kickstart the controller went back to the soft start acceleration mode reducing the amount of starting torque on the chain and helping to lower maintenance inspection and repair time The controller was set for a 9 second ramp time 54 Rockwell Automation Publication 150 AT002C EN P March 2013 Chapter 2 Figure 49 Overload conveyor with Linear Speed and Tack Feedback 240 Vol 1 5 Hp Chain Conveyor Problem A overload gravel conveyor had three motors to drive the conveying system Across the line starts caused damage to the conveyor and spilled gravel on the conveyor Occasionally the conveyor would stop fully loaded An across the line start would then be needed to provide enough torque to accelerate the load Solution The conveyor OEM installed a single SMC Flex controller with linear speed and tach feedback to provide a smooth acceleration to all three motors reducing the starting torque of the motors and the mechanical shock to the conveyor and load In addition
77. should be sized to carry the steady state current that will flow through the capacitor bank during normal operations The coils should be mounted on insulated supports away from metal parts This will minimize the possibility of producing heating effects Do not mount the coils to be stacked directly on top of each other This will increase the chances of cancelling the effectiveness of the inductors Ifan isolation contactor is used it is preferable that the power factor capacitors be installed ahead of the isolation contactor if at all possible see Figure 53 In some installations this may not be physically possible and the capacitor bank will have to be connected to the downstream terminals of the contactor In this case the installer must exercise caution and ensure that the air core inductance is sufficient to prevent oscillating voltages from interfering with the proper performance of the SMC Flex controller It may be necessary to add more loops to the coil Rockwell Automation Publication 150 AT002C EN P March 2013 59 Chapter3 Special Application Considerations Figure 53 Power Factor Capacitors with Isolation Contactor L1 1 T 4 AA 3 Phase T gt L2 3 72 4 M i Input Power E L3 5 13 6 dD LO Branch 5 Pa Isolation ER i lin Sa Contactor Flex eon Ay IC Controller Power Factor Correction Capacitors Customer
78. t start dual ramp start or full voltage start in the same device Figure 69 SMC Flex Solid State Controllers 251 A 317 480 A In addition to selecting the starting modes the solid state controller allows adjustment of the time for the soft start ramp or the current limit maximum value which enables selection of the starting characteristic to meet the Rockwell Automation Publication 150 AT002C EN P March 2013 Reduced Voltage Starting Chapter 6 application The most widely used version is the soft start This method provides a smooth start for most applications The major advantages of solid state controllers are the elimination of the current transition point and the capability of adjusting the time to reach full voltage The result is no large current surge when the solid state controller is set up and correctly matched to the load as illustrated in Figure 70 Figure 70 Soft Start Percent Voltage Kickstart 100 Initial lt Torque Start Run Time seconds Current limit starting can be used in situations in which power line limitations or restrictions require a specific current load Figure 71 shows a 450 current limit curve Other values may be selected such as 200 300 or 400 depending on the particular application Current limit starting is also used in applications where higher starting torque is required compared to a soft start whi
79. t to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures gt e eD IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies 2 Rockwell Automation Publication 150 AT002C EN P March 2013 Overvi
80. tart the isolation contactor is energized before the SCRs are gated on While stopping the SCRs are gated off before the isolation contactor is de energized The isolation contactor is not making or breaking the load current Figure 56 Typical Connection Diagram with Isolation Contactor L1 1 T1 2 SoS 3 Phase X x l L2 3 T2 4 M Input Power s D J Isolation Branch Protection Contactor SMC Flex IC Controller Customer Supplied SMC Flex Controller with Bypass Contactor BC Controlled start and stop are provided by wiring the controller as shown in Figure 57 When the motor is up to speed the external bypass contactor is pulled in for run The bypass mode must have a separate overload as the SMC Flex overload is not active in this configuration Rockwell Automation Publication 150 AT002C EN P March 2013 63 Chapter3 Special Application Considerations Figure 57 Typical Application Diagram of a Bypass Contactor 3 Phase L1 1 T1 2 e oan Input Power Branch Protection Customer Supplied o L2 3 T2 4 M SMC Flex Controller NA AS a ae i y A j tt External BC Overload protection is included as a standard feature of the SMC Flex controller SMC Flex Controller with Reversing Contactor note Aux Contact 1 must be set to Bypass
81. tin 20 COMM communication modules the SMC Flex controller offers true networking capabilities with several network protocols including Allen Bradley Remote I O DeviceNet network RS 485 ControlNet EtherNet ProfiBUS and Interbus Rockwell Automation Publication 150 AT002C EN P March 2013 Power Factor Capacitors 3 Phase Input Power Branch Protection Special Application Considerations Chapter 3 The controller may be installed on a system with power factor correction capacitors These capacitors must be installed on the line side to prevent damage to the SCRs in the SMC Flex controller See Figure 52 Figure 52 Power Factor Capacitors Li 1 L2 3 T2 4 L3 5 T36 l Q es o u ee eee l SMC Flex Controller Customer Supplied Overload protection is included as a standard feature of the SMC Flex controller Power Factor Correction Capacitors High values of inrush current and oscillating voltages are common when capacitors are switched Therefore additional impedance should be connected in series with the capacitor bank to limit the inrush current and dampen oscillations The preferred practice is to insert air core inductors as shown in Figure 53 The inductors can be simply constructed e for volts greater than or equal to 460V use a six inch diameter coil with eight loops e for volts less than 460V use a six inch diameter coil with six loops The wire
82. to be communicated to the PLC which could remotely stop the ball mill The line diagnostics required in the application are standard in the SMC Flex controller and the built in overload protection and SCR Bypass saved panel space Rockwell Automation Publication 150 AT002C EN P March 2013 SMC Flex Controllers in Drive Applications Chapter 3 Special Application Considerations The SMC Flex controller can be installed in starting and stopping control applications A variable frequency drive must be installed when speed variation is required during run Use of Protective Modules A protective module see Figure 51 containing metal oxide varistors MOVs can be installed to protect the power components from electrical transients and or electrical noise The protective modules clip transients generated on the lines and prevent such surges from damaging the SCRs Figure 51 Protective Module There are two general situations that may occur which would indicate the need for using the protective modules 1 Transient spikes may occur on the lines feeding the SMC Flex controller or feeding the load from the SMC Flex controller Spikes are created on the line when devices are attached with current carrying inductances that are open circuited The energy stored in the magnetic field is released when the contacts open the circuit Examples of these are lightly loaded motors transformers solenoids and electromechanical brakes Lightn
83. ual Ramp Start _Current Limit 2 Current Limit 1 100 Initial jue 2 Initial jue 1 Astar H _ gt d _ Pun 1 _ gt __ Start 2 _ _ _ _ gt q _ Pu 2 gt Time in Seconds To obtain Dual Ramp Start control the following parameters are available when you select Dual Ramp in the Option 2 Input parameter Table 3 Dual Ramp Start Parameters Parameter Adjustments SMC Option Standard Starting Mode Full Voltage Current Limit Soft Start Linear Speed Ramp Time 0 30s Initial Torque 0 90 LRT Current Limit Level 50 600 FLC Torque Limit 0 100 LRT Kickstart Time 0 0 2 0s Kickstart Level 0 90 LRT Option 2 Input Dual Ramp Starting Mode 2 Full Voltage Current Limit Soft Start Linear Speed Start Time 2 0 30s Initial Torque 2 0 90 LRT Current Limit Level 2 50 600 FLC Torque Limit 2 0 100 LRT Kickstart Time 2 0 0 2 0s Kickstart Level 2 0 90 LRT Stop Mode Disable Stop Time Os Rockwell Automation Publication 150 AT002C EN P March 2013 Figure 9 Dual Ramp Start Sequence of Operation Overview 100 Percent Ramp 1 Voltage Coast to rest Soft Stop Chapter 1 Start 1 Run 1 Soft Stop Start 2 a Run 2 Tim seconds Push Buttons Start Closed Open Sto
84. ut rating Current Limit Start with Selectable Kickstart This method provides a current limit start and is used when it is necessary to limit the maximum starting current The starting current is user adjustable from 50 to 600 of full load amperes The current limit ramp time is user adjustable from 0 to 30 seconds The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started It is intended to provide a current pulse user adjustable 0 90 locked rotor torque for a selected period of time from 0 0 to 2 0 seconds 10 Rockwell Automation Publication 150 AT002C EN P March 2013 Overview Chapter 1 Figure 5 Current Limit Start 600 Percent Full Load Current Start _ Time seconds To apply a current limit output to the motor the following parameters are provided for user adjustment Table 2 Current Limit Start Parameters Parameter Adjustments SMC Option Standard Braking Pump Starting Mode Current Limit Ramp Time 0 30s Current Limit Level 50 600 FLC Kickstart Time 0 0 2 0s Kickstart Level 0 90 LRT Option 2 Input Disable Stop Mode Disable Stop Time Os Rockwell Automation Publication 150 AT002C EN P March 2013 11 Chapter 1 12 Overview Figure 6 Current Limit Sequence of Operation 600 Percent Full Load Current Soft Stop 100 t Coast to rest 5
85. y to monitor motor stator embedded positive temperature coefficient PTC thermistors The PTC acts as a thermally sensitive resistor It exhibits a large sudden increase in resistance at its activation temperature rating Excessive motor heating can still occur without the motor being overloaded Such over heating can result from blocked motor ventilation or high ambient temperatures and the PTC will help identify this The thermistor input settings are user adjustable See the User Manual for more details Metering The SMC Flex controller contains several power monitoring parameters as standard These parameters include e Three phase current e Three phase voltage Power in kW e Power usage in KWH e Power factor e Elapsed time e Motor thermal capacity usage Fault Indication The SMC Flex controller monitors both the pre start and running modes If the controller senses a fault the SMC Flex controller shuts down the motor and displays the appropriate fault condition in the LCD display The controller monitors the following conditions e Line Loss e Shorted SCR e Open SCR Gate e Thermistor PTC Rockwell Automation Publication 150 AT002C EN P March 2013 Parameter Programming Overview Chapter 1 e Overtemperature Power Pole SCR Motor e Bypass Failure e No Load e Overvoltage e Undervoltage Overload e Underload e Jam e Stall e Phase Reversal e Phase Unbalance e Current Unbalance e Voltage Unba

150-AT002_-EN-P - Rockwell Automation

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