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SMC-Flex™ - Columbia Electric Supply Pasco

1. Grou Parameter Parameter Units Min Default User P Description Number Max Settings Settings Metering Volts Phase A B 1 Metering Volts Phase B C 2 Metering Volts Phase C A 3 Metering Current Phase A 4 A Metering Current Phase B 5 A Metering Current Phase C 6 A Metering Watt Meter 7 KW MW Metering Kilowatt Hours 8 KWH MWH Metering Elapsed Time 9 Hours Metering Meter Reset 10 Ready Ready ETM Reset KWH Reset Metering Power Factor 11 0 00 0 99 Metering Mtr Therm Usage 12 0 100 Metering Motor Speed 13 0 100 Basic Set Up SMC Option 14 Standard Brake Pump Control Basic Set Up Motor Connection 15 Line Delta Line Basic Set Up Line Voltage 16 0 10000 480 Basic Set Up Starting Mode 17 Full Voltage Soft Start Current Limit Soft Start Linear Speed Pump Start Basic Set Up Ramp Time 18 SEC 0 30 10 Basic Set Up Initial Torque 19 LRT 0 90 70 Basic Set Up Cur Limit Level 20 FLC 50 600 350 Basic Set Up Torque Limit 21 LRT 0 100 90 Basic Set Up Kickstart Time 22 SEC 0 0 2 0 0 0 Basic Set Up Kickstart Level 23 LRT 0 90 0 Basic Set Up Option 2 Input 24 Disable Disable Dual Ramp Preset SS Dual Ramp Starting Mode 2 25 Full Voltage Soft Start Current Limit Soft Start Linear Speed Dual Ramp Ramp Time 2 26 SEC 0 30 10 Dual Ramp Initial Torque 2 27 LRT 0 90 70 Dual Ramp Cur Limit Level 2 28 FLC 50 600 350 Dual Ramp Torque Limit 2 29 LRT 0 100 9
2. Fault Contact Alarm Contact Aux 2 Normal Customer supplied Wiring 3 25 Preset Slow Speed Figure 3 24 and Figure 3 25 show the different wiring for the Preset Slow Speed Figure 3 24 Typical Wiring Diagram for the Preset Slow Speed Control Power Option Command O SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass rud 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 voltage Slow Speed Note Refer to Chapter 3 for typical power circuits 3 26 Wiring Figure 3 25 Typical Slow Speed Wiring Diagram for Hand Off Auto DPI Control L1 1 T1 2 3 Phase BERN 1 2 3 2 4 i Input Power L3 5 T3 6 SMC Flex rotection Controller 8 T Hand Start s io O oO Option Command _ 00 O O EN TT TeTe Te Te elo T Te Te SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass SM PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Slow Speed Refer to the controller nameplate to verify the rating of the cont
3. Metering Overview While the SMC Flex controller operates your motor it also monitors several different parameters providing a full function meteringo package Viewing Metering Data To access the metering information follow the procedure below Description Action Display EE Aas Voit Pt Main Menu 1 Press any of the following keys to Memory Storage access the Main Menu e 2 Scroll with the Up Down keys until e the Parameter option is shown Memory Storage 3 Press the Enter key to select the Parameter option e 4 Scroll with the Up Down keys until A e GP File the Monitoring option is displayed Set Up 5 Pressthe Enter key to access the Monitoring group e 6 the Enter key to access the e FOP Group Metering group Refer to Metering on page 1 19 or Figure 4 2 on page 4 3 for details on the metering functions Metering Description Scroll through the Metering parameters with the Up Down keys to access the desired information Press the Enter key to view that parameter Action Display 1 Volts Phase HHH Volt F Gig P 2 Volts Phase B C HHH Volt F Gig P 3 Volts Phase C A HHH Volt F Gig P 4 Current Phase A Amps F Gig P 5 Current Phase B Amps F Gig P 6 Current Phase C Amps 7 Watt Mete
4. 25 406 16 229 9 43 406 16 229 9 60 406 16 229 9 85 406 16 229 9 108 610 24 305 12 135 610 24 305 12 201 762 30 356 14 251 762 30 356 14 317 965 38 356 14 361 965 38 356 14 480 965 38 356 14 889 35 20 Usethis row for 460V 58 and 575V 59 this row for 460V 59 and 575V 60 and 61 2 4 Mounting Dimensions Installation All units are fan cooled It is important to locate the controller in a position that allows air to flow vertically through the power module The controller must be mounted in a vertical plane and have a minimum of 15 cm 6 in free space above and below the controller Figure 2 1 shows the SMC Flex product dimensions for the 5 85 A devices Figure 2 2 shows the dimensions for 108 251 A devices Figure 2 3 shows the dimensions for 317 480 A devices Installation 2 5 Figure 2 1 Dimensions 5 85 A Controllers C 4 12 46 1201 1164 F
5. 1 19 Accu Stop Option seen 1 20 Slow Speed with Braking Option 1 20 Dimensions 5 85 A Controllers 2 5 Dimensions 108 251 A Controllers 2 6 Dimensions 317 480 A Controllers 2 7 Typical Wiring Diagram for Power Factor Correction 2 8 Typical Wiring Diagram for Power Factor Correction Capacitors and 2 8 Wiring Terminal Locations 5 85 A 3 1 Wiring Terminal Locations 108 480 A 3 2 Line Power Wiring diagram 3 3 Delta Power Wiring diagram 3 4 5 480 A Fan Terminations 3 6 SMC Flex Controller Control Terminals 3 7 Typical Wiring Diagram for Standard Controller 3 8 Typical Wiring Diagram for Two Wire Control with No Stopping Control No DPI Control 3 9 Typical Wiring Diagram for Two Wire Control with Stopping Control 3 10 Bulletin 150 SMC Flex Figure 3 10 Typical Wiring Diagram for Dual Ramp Applicatioris 3 11 Figure 3 11 Typical Wiring Diagram for Start Stop Control via DPI Communications eeeeeeeeenennnnnnnnnn 3 12 Fi
6. 2 2 Enclosures tco RR ERR eke 2 3 imn ge 2 4 ae se peer ere eve ees 2 4 Power Factor Correction Capacitors 2 8 Protective Modules esses eene 2 9 Motor Overload Protection 2 9 Two speed Motors ccccsceseescsssssssesssescsessesseseseesesaessseeserss 2 9 Multi motor Protection eene 2 9 Electromagnetic Compatibility 2 10 Ho 2 10 inp 2 10 Recommendations 2 10 Terminal Locations 3 1 POWER SITUCIUFG nete reet teda 3 2 Power WINO 2 22 22 einer rere dete esee ee 3 3 Control iet o ic etri 3 4 Control Voltage 3 4 Control Wiring isisisi teisiniai iiciin eiaeia 3 5 Fan POWOM ER 3 5 Fan Terminations essen 3 5 Control Terminal Designations 3 6 Wiring Diagrams essere nnn 3 7 Standard Controller sess 3 7 Soft Stop Pump Control and SMB Smart
7. ccccecsssssessecsessseseeseeseeseecseceeseeseecenseneseeesees 8 6 Loss of Communication and Network Faults 8 6 SMC Flex Specific Information seeeeeesess 8 6 Default Input Output Configuration sees 8 7 Variable Input Output Configuration 8 7 SMC Flex Bit Identification 55555555555 8 8 Reference Feedback 8 9 Parameter Information ccccscccscssssssssesssssssssssessessseeseesaesaseeseres 8 9 Scale Factors for PLC Communication 8 9 Read Example cccccscsssscsssssssssscsessesssssssessessesessesesateaseesers 8 9 Write Exam ples ssc seas utet Dec erecto tace 8 9 Display Text Unit Equivalent 8 9 Configuring DataLinkS esee 8 9 Rules for Using DataLinks eene 8 10 Updating Firmware esee 8 10 VeIVIOW oat rette eite et Po b de 9 1 Protection Programming sese 9 1 Display i e i Re Recreo kr dae dee 9 1 dci METTRE 9 2 Fault Buffer essent nnns 9 2 Fault CodeS PEE 9 3 Fault and Alarm Auxiliary Contact esee 9 3 Fault Definitions
8. dm H a4 2 20 4 112 561 2 PLACES er nm 40 31 13541 ist fl m il R IT EH a Lii L2 3 us cL ooo DH S 2 PLACES D 250 16 35 4 PLACES wr BO NET 09 14 87 311 8 19 12 64 321 1 2425575523229 TROWESUEED2 fo 0 295 17 5 E 2 PLACES em Tee T540 q a m 2144 35 41 LH dis 2 50 E E s diis 295 E __ 105 91 2 LACES ni i x E 1168 190 1188 61 NOTE DIMENSIONS IN INCHES MILLIMETERS 2 DIMENSIONS ARE NOT INTENDED TO BE USED FOR MANUFACTURING PURPOSES B H Approx i Ship Wt 5 85 mm 150 1 307 203 1 120 291 119 8 14 1 5 7 kg Controler i 5 91 1209 800 472 1146 472 056 126b All dimensions are approximate and are not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings 2 6 Installation Figure 2 2 Dimensions 108 251 A Controllers 508 2 0 24 9 5 980 531 tA e 7 ls 984 1 890 7 ne 8 32 UNC 2B DETAIL AA SCALE 1 000 m C
9. 38 at tt Pree tint vey a Prt torque A 3 Pere tite 9 kta Tine 8 8 gt Programming Password The SMC Flex controller allows the user to limit access to the programming system through password protection This feature is disabled with a factory set default of 0 To modify the password or login after a password is programmed complete the procedure below Description Action Display m os E vo MTU 1 Press the ESC key to go from the Main Menu status display to the Main menu Parameter 2 Scroll with the Up Down keys until the Vg e Main Menu Preferences option is highlighted 3 Press the Enter key to access the e Preferences Change Password Preferences menu User Dspy lines 4 Scroll with the Up Down keys until the Preferences Change Password option is e User Dspy lines highlighted 5 Press the Enter key e 6 Press the Up Down keys to enter the Prefs Password desired number If you are modifying e s the password make a note of it as displayed Use the Sel key to highlight a single digit 7 Verification of the new password is required Press the Enter key 8 Press the Enter key
10. Motor Monitoring 4 Set Up Protection Communications 4 Utility lt gt Linear List A A A A A i i ma ii Metering Basic Overload Jam Comm Masks Language Linear List Volts Phase A B Motor Connection Overload Class Jam F Lvl Logic Mask Language All parameters Volts Phase B C Line Voltage Service Factor Jam F Dly Parameter Mgt Parameter Mgt Parameter Mgt Volts Phase C A Starting Mode Motor FLC Jam A Lvl Current Phase A Ramp Time Overload Reset Jam A Dly Current Phase Initial Torque Overload A Lvl Parameter Mgt Pee Dee Current Phase Cur Limit Lvl Parameter Mgt Data In A1 MotorFLC Watt Meter Kickstart Time Stall Data In A2 Motor ID Kilowatt Hours Kickstart Lvl Underload Data In B1 Parameter Mgt Elapsed Time Option 2 Input Stall Dly Data In B2 Meter Reset Stop Mode Underload F Lvl Parameter Mgt Data In C1 Power Factor Stop Time Underload F Dly Data In C2 Mtr Therm Usage Braking Current Underload A Lvl Ground Fauli Data In D1 Overload Class Underload A Dly Data In D2 Service Factor Parameter Mgt Gnd Fit Enable Data Out A1 Motor FLC Gnd Fit Lvl Data Out A2 Overload Reset Gnd FIt Dly Data Out B1 Aux1 Config Gnd Fit Inh Time Data Out B2 Fault Contact Undervolt F Lvl Gnd Fit A Enable Data Out C1 Alarm Contact Undervolt F Dly Gnd FIt A Lvl Data Out C2 Aux2 Config Undervolt A Lvl Gnd Fit A Dly Data Out D1 Parameter Mgt Undervolt A Dly Data Out D2
11. Description Action Display 2 m m EY Amps voi 1 Press the ESC key to go from the status display to the Main menu 2 Scroll with the Up Down keys MAM MENU until the Parameter option is O highlighted Memory Storage 3 Pressthe Enter key to access the e c s PEEL Parameter menu Set Up 4 Scroll with the Up Down keys GP File until the option you want to use O MOT Protection Monitoring Motor Protection etc is highlighted For this example Set Up will be used 5 Press Enter to select the Set Up group e i G 6 miley Basic Set Up and press e e ere roup 7 Scroll to the Starting Mode parameter by using the Up Down O 62 e XS keys and press Enter 8 Press Enter to select the option F Gl PH 17 Scroll to the option of your O e e GIS choice by using the Up Down keys For this example we will choose Current Limit 9 Press the Enter key to accept the new setting e 10 Scroll to the next parameter by F Gig PH 18 using the Down key Continue amp Em o the process until all desired settings are entered 11 To save modifications to 115 memory scroll to Parameter e e irc P Mgmt press Enter twice and scroll to User Store Press the Enter key again to save the new settings to EEPROM The SMC Option advises the user if any control option i e Pump Control is resident This parameter is factory set and cannot be modified by the u
12. mi Start Run Brake Automatic Zero Speed Time seconds Shut off Closed Open Closed Open Closed Open If Brake Selected Closed Open Closed x If Coast to rest Selected Open vilis IB The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine 3 32 Wiring Figure 3 31 Accu Stop Sequence of Operation 100 Braking Motor Speed Slow Speed Braking Coast to rest M M b Slow Speed Slow Stat Run n Accu Stop e Speed Time seconds Push Buttons Start Closed Open Stop Closed Open D Accu Stop Closed Open Slow Speed Braking Auxiliary Contacts Normal 1 If Coast to rest Up to speed Selected When Accu Stop push button is closed start stop function is disabled viis iil The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine 100 Motor Speed Push Buttons Start Stop Slow Speed Brake Auxiliary Contacts Normal Up to speed Closed Open Closed Open Closed Open Closed Open Closed Open
13. Closed Open Wiring 3 33 Figure 3 32 Slow Speed with Braking Sequence of Operation Coast to Stop M ow N N Braking Slow Speed i Start a Run Brake Time seconds Brake If Coast to rest select d es Co viuis IU B The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine 3 34 Wiring Notes Chapter 4 Programming Overview This chapter provides a basic understanding of the programming keypad built into the SMC Flex controller This chapter also describes programming the controller by modifying the parameters Keypad Description The keys found on the front of the SMC Flex controller are described below Escape Exit a menu cancel a change to a parameter value or acknowledge a fault alarm Lang Select Select a digit select a bit or enter edit mode in a parameter screen Will get to menu to change the language being displayed Up Down Scroll through options increase decrease a value or O e Arrows toggle a bit Enter Enter a menu enter edit mode in a parameter screen or e save a change to a parameter value Note For ease of programming values after using the Enter key to edit use the Sel key to jump to the digit that needs to be modified then u
14. state of the second auxiliary contact This contact is located at terminals 33 and 34 Parameter Mgmt 9 The newly programmed parameters values can be saved to memory or the factory default parameter values can be recalled Ready User Store User Recall Load Default Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter Q Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter Thenew programmed parameter values will not be stored to the EEPROM without the user s direction in Parameter Management User Store 4 16 Programming Motor Protection While the Basic Set Up group allows the user to get started with a minimum number of parameters to modify the Motor Protection group allows full access to the SMC Flex controller s powerful parameter set Following is a listing of the additional setup parameters provided Note Parameter Overload Allows the user to select the operation of the overload Underload Determines the trip level as a percentage of the motor s FLA and the delay period Undervoltage Determines the trip level as a percentage of the line voltage and the delay period Overvoltage Determines the trip level as a percentage of line voltage and delay period Unbalance Allows the user to set the current unbalance trip level and delay period Jam 2 Determines the trip
15. 1 10 Product Overview Accu Stop Option This option combines the benefits of the SMB Smart Motor Braking and Preset Slow Speed options For general purpose positioning the Accu Stop option provides a brake from full speed to the preset slow speed setting then brakes to stop Figure 1 11 Accu Stop Option 100 Braking Motor Speed 7 or 15 Slow Speed Braking Coast to rest LMS Slow Speed x Slow Start Run Brake Speed Time seconds viis ill Accu Stop and Slow Speed with Braking not intended to be used as an emergency stop Refer to applicable standards for emergency stop requirements Slow Speed with Braking Option The Slow Speed with Braking option provides a jog speed for process set up and braking to stop at the end of the cycle Figure 1 12 Slow Speed with Braking Option 100 AN Braking Motor Speed N Coast to rest 7 or 15 F a N Slow Start Run Stop Speed Time seconds Product Overview 1 11 Protection and Diagnostics The SMC Flex controller provides the protective and diagnostic features described below Overload The SMC Flex controller meets applicable requirements as a motor overload protective device Thermal memory provides added protection and is maintained even when control power is removed The built in overload controls the value stored in Parame
16. E SEE DETAIL BB e i mo fl D B _ 3 15 5 O E to eoooco fol f Alen Bradey SMC Fiex 76 12 T4 8 T540 s s 177 938 R 7 01 1 EN H Y TAA THe L 13 022 51 D 40 9 1 6 317 480A mm 290 600 276 5 200 539 18 182 25 104 5 55 5 103 5 45 8 kg Controller All dimensions are approximate and are not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings 2 8 Installation Power Factor Correction Capacitors The controller can be installed on a system with power factor correction PFC capacitors The capacitors must be located on the line side of the controller This must be done to prevent damage to the SCRs in the SMC Flex controller When discharged a capacitor essentially has zero impedance For switching sufficient impedance should be connected in series with the capacitor bank to limit the inrush current One method for limiting the surge current is to add inductance in the capacitor s conductors This can be accomplished by creating turns or coils in the power connections to the capacitors e 250V 15 cm 6 in diameter coil 6 loops e 480 600V 15 cm 6 in diameter coil 8 loops Take care in mounting the coils so that they are not stacked directly on top of each other stacking will cause a ca
17. cccccsccsecsecsscsscesecseceecssecsecsecseessccsecseeseesaeeas 9 4 Introduction 10 1 Power Module Check 10 6 Bulletin 150 SMC Flex Appendix A Functional Design Specifications A 1 Specifications Wiring Diagram A 2 Electrical Ratings A 2 Environmental c cccccsccsscssssscsscssessessecseeseessecsesseeseessecseeeeeeees A 4 Mechanical cccccesecsccsscsscesecsecseeseessecsecsesssscaecsessessaseeeseesaseaaee A 5 5 Approximate Dimensions and Shipping Weights A 6 Open Type Controllers A 6 Enclosed Type Line Connected Controllers A 6 Enclosed Type Delta Connected Controllers A 7 Appendix B Parameter Information Appendix C Renewal Parts Appendix D Accessories Appendix E Renewal Part Cross Reference Bulletin 150 SMC Flex List of Figures Chapter 1 Figure 1 1 Product Overview Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Figure 1 11 Figure 1 12 Figure 1 13 Figure 1 14 Figure 1
18. 150 F60NCR 150 F85NCR 150 FS1FX 150 FPP25B 150 FS1FX 150 FPP43B 150 FS1FX 150 FPP60B 150 FS1FX 150 FPP85B 150 FS1FX 150 FPP5C 150 FS1FX 150 FPP25C 150 FS1FX 150 FPP43C 150 FS1FX 150 FPP60C 150 FS1FX 150 FPP85C 150 FS2FX 150 FPP5B 150 FS2FX 150 FPP25B 150 FS2FX 150 FPP43B 150 FS2FX 150 FPP60B 150 FS2FX 150 FPP85B 150 FS2FX 150 FPP5C 150 FS2FX 150 FPP25C 150 FS2FX 150 FPP43C 150 FS2FX 150 FPP60C 150 FS2FX 150 FPP85C m gt D D D D D D D D D D D D D D D D D gt These are not orderable cat nos If a control module needs to be ordered reference the control module renewal part no found in Appendix C E 2 Renewal Part Cross Reference Originally Ordered Internal Control Orderable Power Control Type Control Voltage Line Voltage Amperes AB Cat No Module Label Poles Pump Control 100 240V 200 480V AC 5 150 F5NBDB 150 FBIFX 150 FPP5B 25 150 F25NBDB 150 150 FPP25B 43 150 F43NBDB 150 FB1FX 150 FPP43B 60 150 F60NBDB 150 FB1FX 150 FPP60B 85 150 F85NBDB 150 FB1FX 150 FPP85B 600V AC 5 150 F5NCDB 150 FB1FX 150 FPP5C 25 150 F25NCDB 150 FB1FX 150 FPP25C 43 150 F43NCDB 150 FB1FX 150 FPP43C 60 150 150 150 FPP60C 85 150 F85NCDB 150 FB1FX 150 FPP85C 24V AC DC 480V AC 5 150 F5NBRB 150 FB2FX 150 FPP5B 25 150 F25NBRB 150 FB2FX 150 FPP25B
19. 20 HIM A3 20 HIM A4 20 HIM A5 Door Mounted 20 HIM C3 20 HIM C3S 20 HIM C5 20 HIM C5S Extension Cables 1202 H03 1202 H10 1202 H30 1202 H90 Splitter Cable 1203 803 Communication DeviceNet 20 COMM D Modules ControlNet 20 COMM C Remote 1 0 20 COMM R Profibus 20 COMM P RS 485 20 COMM S InterBus 20 COMM I EtherNet 20 COMM E Requires a 20 HIM H10 cable Appendix E Renewal Part Cross Reference Line Input Orderable Control Module Description Voltage Volta Allen Bradley Internal Cat No 9 9 Renewal Part No Label Standard 100 240V 41391 454 01 S1FX 150 FS1FX 24N 41391 454 02 S2FX 150 FS2FX Pump Control 100 240V 41391 454 01 B1FX 150 FB1FX 24N 41391 454 02 B2FX 150 FB2FX Control Brake Control us 100 240V 41391 454 01 D1AX 150 FD1AX Module s 24V 41391 454 02 D2AX 150 FD2AX 100 240V 41391 454 01 D1BX 150 FD1BX 24N 41391 454 02 D2BX 150 FD2BX 100 240V 41391 454 01 D1CX 150 FD1CX 24V 41391 454 02 D2CX 150 FD2CX Originally Ordered Internal Control Orderable Power Control Type Control Voltage Line Voltage AB Cat No Sones Module Label Poles Standard 100 240V 200 480V AC 150 F5NBD 150 FS1FX 150 FPP5B 150 F25NBD 150 F43NBD 150 F60NBD 150 F85NBD 200 600V AC 150 F5NCD 150 F25NCD 150 F43NCD 150 F60NCD 150 F85NCD 24V AC DC 200 480V AC 150 F5NBR 150 F25NBR 150 F43NBR 150 F60NBR 150 F85NBR 200 600V AC 150 F5NCR 150 F25NCR 150 F43NCR
20. 43 150 F43NBRB 150 FB2FX 150 FPP43B 60 150 F60NBRB 150 FB2FX 150 FPP60B 85 150 F85NBRB 150 FB2FX 150 FPP85B 600V AC 5 150 F5NCRB 150 FB2FX 150 FPP5C 25 150 F25NCRB 150 FB2FX 150 FPP25C 43 150 F43NCRB 150 FB2FX 150 FPP43C 60 150 F60NCRB 150 FB2FX 150 FPP60C 85 150 F85NCRB 150 FB2FX 150 FPP85C Braking 100 240V 480V AC 5 150 F5NBDD 150 FD1AX 150 FPP5B Control 25 150 F25NBDD 150 FD1AX 150 FPP25B 43 150 F43NBDD 150 FD1AX 150 FPP43B 60 150 F60NBDD 150 FD1AX 150 FPP60B 85 150 F85NBDD 150 FD1AX 150 FPP85B 600V AC 5 150 F5NCDD 150 FD1AX 150 FPP5C 25 150 F25NCDD 150 FD1AX 150 FPP25C 43 150 F43NCDD 150 FD1AX 150 FPP43C 60 150 F60NCDD 150 FD1AX 150 FPP60C 85 150 F85NCDD 150 FD1AX 150 FPP85C 24V AC DC 480V AC 5 150 F5NBRD 150 FD2AX 150 FPP5B 25 150 F25NBRD 150 FD2AX 150 FPP25B 43 150 F43NBRD 150 FD2AX 150 FPP43B 60 150 F60NBRD 150 FD2AX 150 FPP60B 85 150 F85NBRD 150 FD2AX 150 FPP85B 600V AC 5 150 F5NCRD 150 FD2AX 150 FPP5C 25 150 F25NCRD 150 FD2AX 150 FPP25C 43 150 F43NCRD 150 FD2AX 150 FPP43C SSS D D D D D D D D D D D D D D D D D D D gt D D D D D D D D D D D D D D D D 60 150 F60NCRD 150 FD2AX 150 FPP60C 85 150 F85NCRD gt 150 FD2AX 150 FPP85C These are not orderable cat nos If a control module needs to be ordered reference the control module renewal part no found in Appendix C
21. All 24V AC DC Pump Control All Braking Control Description Power Poles 5 85A 108 251A 317 480A 41391 454 02 S2FX 41391 454 02 B2FX 41391 454 02 D2AX 41391 454 02 D2BX 41391 454 02 D2CX Part No 150 FPP5B 29 150 FPP25B 9 150 FPP43B 9 150 FPP60B 9 150 FPP85B 9 41391 800 01 amp 41391 800 03 amp 41391 800 05 amp 41391 800 07 amp 41391 800 09 41391 800 11 41391 800 13 150 FPP5C 29 150 FPP25C 29 150 FPP43C 150 FPP60C 150 FPP85C 29 41391 800 02 amp 41391 800 04 amp 41391 800 06 amp 41391 800 08 amp 41391 800 10 amp 41391 800 12 41391 800 14 Heatsink Fans 41391 801 03 41391 801 01 41391 801 02 Base Plate 41391 803 01 e One piece provided per part number 5 85 A power pole structure does not include heatsink fan Three phase power pole structure provided per part no One phase power pole provided per part no 41391 803 02 Appendix D Accessories Description Description Used With Cat No Protective Modules 5 85 A 480V 150 F84 108 480 A 480V 150 F84L 5 85 A 600V 150 F86 108 480 A 600V 150 F86L Terminal Lugs 108 251A 199 LF1 317 480A 199 LG1 IEC Terminal Covers 108 251A 150 TC2 317 480A 150 TC3 HIM Hand Held 20 HIM A2
22. If a human interface module is disconnected from the SMC Flex controller while the Logic Mask is set to 1 a Coms Loss will occur For ease of programming values after using the Enter key to edit use the Sel key to jump to the digit that needs to be modified then use the arrow keys to scroll through the digits The Bulletin 20 HIM LCD interface modules may be used to program and control the SMC Flex controller The human interface modules have two sections a display panel and a control panel The display panel duplicates the 3 line 16 character backlit LCD display and programming keypad found on front of the SMC Flex controller Refer to Chapter 4 for a description of the programming keys refer to Appendix D for a listing of human interface module catalog numbers that are compatible with the controller Note Note Note Bulletin 20 HIM Rev3 002 or later must be utilized with the SMC Flex Extension cables are available up to a maximum of 10 m in total length A maximum of two HIM modules can be installed Communications 8 3 The control panel provides the operator interface to the controller Start The green start button when pressed will begin motor operation Proper setup of the HIM port is required Stop The red stop button when pressed will halt motor operation and or reset a fault Jog e The jog button is active only when a control option is present Pressing the jog button will initiate the o
23. Profibus 20 COMM P 20COMM UM0060 EN P RS 485 20 COMM S 20COMM UM0050 EN P InterBus 20 COMM I 20COMM UM0070 EN P EtherNet IP 20 COMM E 20COMM UM0100 EN P Denotes revision level of user manual Example Publication 20COMM UM002C EN P is at revision C The SMC supports three DPI ports for communication Ports 2 and 3 are supported through the serial connection on the side of the device and are typically used to interface with a Human Interface Module HIM Port 2 is the default connection with port 3 available by installing a splitter on port 2 Port 5 is supported by connecting one of the modules listed above to the internal DPI comm card connection The SMC FLEX controller can be programmed with the built in keypad and LCD display or with the optional Bulletin 20 HIM LCD human interface modules Parameters are organized in a three level menu structure and divided into programming groups 8 2 Communications Keypad Description The functions of each programming key are described below Table 8 B Keypad Descriptions Escape Exit a menu cancel a change to a parameter value or acknowledge a fault alarm Select Select a digit select a bit or enter edit mode in a ce parameter screen Up Down Scroll through options increase decrease a value or Arrows toggle a bit Enter Enter a menu enter edit mode in a parameter screen e or save a change to a parameter value Note Note
24. 15 Figure 1 16 Figure 1 17 Figure 1 18 Figure 1 19 Figure 1 20 Figure 1 21 Chapter 2 Figure 2 1 Installation Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Chapter 3 Figure 3 1 Wiring Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 vi SOM Start icri 1 2 Selectable Kickstart 1 3 Current Limit 1 1 3 Dual Ramp Start sese 1 4 Full Voltage Start sss 1 4 Preset Slow Speed 1 5 Linear Speed Acceleration 1 6 50 STOP ethene hie el eed ered 1 7 Overload Trip Curves 1 9 Restart Trip Curves after Auto Reset 1 9 Stall Protection sse 1 11 Jam Detection 1 11 Overload Trip 1 12 PTC Sensor Characteristics per IEC 34 11 2 1 14 DPI LOCA iiti redes i Dr Ere ras 1 16 Built in Keypad and LCD 1 17 Control Terminals 1 17 Pump Control Option 1 18 SMB Smart Motor Braking Option
25. 197 115 459 i i T oq 64 NO 8 250 py 275 M 1 083 o e o 6 164 126 6 46 A Do M 245 689 L23 138 SEE DETAIL AA 5 e E B e PE e B 80 E 5 5 El d a e Te 5 0 3 Cc c L1 o 152 749 7 6 01 tL 108 251A mm 225 560 253 8 150 5041 15725 91189 44 311 79 811 30 4kg Controller in 8858 22047 9 992 5 906 19 847 6 2 3 59 1 74 3 14 67 Ib All dimensions are approximate and are not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings Installation 2 7 Figure 2 3 Dimensions 317 480 A Controllers 635 2 50 3274 17 48 1 28 S 68 Lj ra a 48 2 T 1 89 V X Las ail L 22 5 Le C 3 DETAIL 88 MI2x 1 75 SCALE 1 000 48 82 UNC 2B 30 1 20 a F a 12 522 49 1 i 106 35 m 25 2 ON E I 25 m aan 1 08 ES i O IUD 178 938 2605 Q e Qe Qe 7 04 CP 10 26
26. 30 seconds If the SMC Flex controller senses that the motor has reached the up to speed condition during the current limit starting mode the internal bypass contactor will be pulled in Figure 1 3 Current Limit Start 600 Percent Full Load Current 50 Start Time seconds Kickstart is also available with Current Limit Start 1 4 Product Overview Dual Ramp Start This starting mode is useful on applications that have varying loads and therefore varying starting torque requirements Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings Figure 1 4 Dual Ramp Start Percent Voltage Ramp 2 100 i Initial Torque 2 Initial Torque 1 Start 1 1 Start 2 _ Run 2 Time seconds Dual Ramp Start is available only with the standard controller Full Voltage Start This starting mode is used for applications requiring across the line starting The output voltage to the motor will reach full voltage within 1 4 second Figure 1 5 Full Voltage Start 100 Percent Voltage Time seconds Product Overview 1 5 Preset Slow Speed This option can be used in applications that require a slow speed jog for general purpose positioning Preset Slow Speed provides either 7 of base speed low or 15 of base speed h
27. AB Allen Bradley SMC Flex Bulletin 150 User Manual ee a LM Automation l Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or part without written permission of Rockwell Automation is prohibited Throughout this manual we use notes to ma
28. Figure 3 16 Typical Wiring Diagram for Two speed Applications Two Speed Motor Starter 1 3 Phase 12 8 T2 4 Input Power SMC Flex rotection Controller SMC Flex Aux 1 Control Terminals Normal Up to Speed Bypass 23 24 25 26 27 28 29 30 31 32 33 34 TACH PTC Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied consequent pole installations Refer to the controller nameplate to verify the rating of the control power input voltage Overload must be disabled 3 18 Wiring 3 Phase Input Power Figure 3 17 Typical Wiring Diagram for SMC Off Bypass Control Branch Protection L1 1 T1 2 L2 3 T2 4 M 13 5 T3 6 SMC Flex Controller _ _ Start D 16 17 18 19 20 21 22 T SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass 23 25 27 28 29 31 34 om Diss be Ground Fault Alarm Na i Fault Contact Contact Customer supplied mud d Bypass Connector BC Refer to the controller nameplate to verify the rating of the control power input voltage Wiring 3 19 F
29. Flex controller Important An overload fault cannot be reset until the Motor Thermal Usage parameter 12 value is below 75 See Protection and Diagnostics on page 1 11 for further details The SMC Flex controller stores in memory the five most recent faults Display the fault buffer by selecting the View Faults Queue and scrolling through the fault buffer parameters The information is stored as fault codes and fault descriptions A fault code cross reference is provided in Table 9 A Diagnostics 9 3 Fault and Alarm Auxiliary Contact Fault Codes Table 9 A provides a complete cross reference of the available fault codes and corresponding fault descriptions Table 9 A Fault Code Cross reference Fault Code Fault Code Line Loss A 1 Jam 24 Line Loss B 2 Stall 25 Line Loss C 3 Phase Reversal 26 Shorted SCR A 4 Coms Loss P2 27 Shorted SCR B 5 Coms Loss P3 28 Shorted SCR C 6 Coms Loss P5 29 Open Gate A 7 Network P2 30 Open Gate B 8 Network P3 31 Open Gate C 9 Network P5 32 PTC Pwr Pole 10 Ground Fault 33 SCR Overtemp 11 Excess Starts 34 Motor PTC 12 Power Loss A 35 Open Bypass A 13 Power Loss B 36 Open Bypass B 14 Power Loss C 37 Open Bypass C 15 Hall ID 38 No Load A 16 NVS Error 39 No Load B 17 No Load 40 No Load C 18 Line Loss A 410 Line Imbalance 19 Line Loss B 420 Overvoltage 20 Line Loss C 43 Undervoltage 21 V24 Loss 45 Overload 22
30. Lug Wire Capacity and Tightening Torque SMC Lug Kit Wire Strip Conductor Max No Lugs Pole Tightening Torque Rating Cat No Length Range Line Side Load Side Wire Lug Lug Busbar 5 85A 18 20 mm 25 85mm 14 7 Nem 14 3 0 AWG 130 Ib in 108 135A 199 LF1 18 20 mm 16 120 mm 6 6 31 Nem 23 Nem Series A 6 250 275 Ib in 200 Ib in 201 251A 199 LF1 18 20 16 120 mm 6 6 31 Nem 23 Nem 6 250 275 Ib in 200 Ib in 317 480A 199 LG1 18 25 25 240 mm 6 6 42 Nem 45 Nem 4 500 375 Ib in 400 Ib in Control Power Wiring 3 5 Control Voltage The SMC Flex controller will accept a control power input of 100 240V AC 15 10 1 phase 50 60 Hz or 24V AC DC Refer to the product nameplate to verify the control power input voltage Connect control power to the controller at terminals 11 and 12 The control power requirement for the control module is 75 VA For controllers rated 5 480 A control power is also required for the heatsink fans as defined in Table 3 C Depending on the specific application additional control circuit transformer VA capacity may be required 3 6 Fan Power Control Wiring Table 3 B provides the control terminal wire capacity the tightening torque requirements and the wire strip length Each control terminal will accept a maximum of two wires Table 3 B Control
31. Parameter Mgt Parameter Mgt PTC Dual Ramp Option 2 Input Dual nable Ramp Overvoltage Parameter Mgt Starting Mode 2 Overvolt F Lvl Ramp Time 2 Overvolt F Dly Initial Torque 2 Overvolt A Lvl Phase Reversal Cur Limit Lvl 2 Overvolt A Dly Phase Reversal Kickstart Time 2 Kickstart Lvl 2 Parameter Mgt Preset SS Option 2 Input Preset SS Slow Speed Sel Slow Speed Dir Slow Speed Acc Slow Running Cur Parameter Mgt Option 2 Input Accu Stop Braking Current Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cu Stopping Current Parameter Mgt Parameter Mgt Parameter Mtg Unbalance Unbalance F Lvl Unbalance F Dly Unbalance A Lvl Unbalance A Dly Parameter Mgt Restart Starts Per Hour Restart Attempts Restart Dly Parameter Mgt Steps back one level For further information on parameters see Appendix B For further information on parameter management see page 4 7 Depending upon SMC option selected some parameters may not appear in product display 4 4 Programming Table 4 A Parameter Linear List seris a Sewer 8 Revue Wemtmus amp Ree Reese isk Pw 50 Oat gt
32. activated 1 An Allen Bradley programmable controller 2 An Allen Bradley programmable controller with a name that includes the letters PLC See Programmable Controller Port Power Factor Preset Speed Programmable Controller Protocol Remote I O RS 232 C RS 422 RS 485 Scrolling Serial Service Factor S F Silicon Controlled Rectifier SLC Controller Glossary lll On a communication link the logic circuitry or software at a station that determines its communication parameters for a particular communication channel A measurement of the time phase difference between the voltage and current in an AC circuit It is represented by the cosine of the angle of this phase difference Power factor is the ratio of Real Power kW to total kVA or the ratio of actual power W to apparent power volt amperes Preset speed refers to one or more fixed speeds at which the drive will operate A solid state system that has a user programmable memory for storage of instructions to implement specific functions such as I O control logic timing counting report generation communication arithmetic and data file manipulation A controller consists of a central processor input output interface and memory A controller is designed as an industrial control system A set of conventions governing the format and timing of data between communication devices I O connected to a processor across a serial link With a
33. after you have completed modifying the password 0 Preferences Change Password User Dspy lines After you have changed your password go to Parameter Management and Save to User Store Tocomplete the programming process re enter the Main Menu mode to log out This will eliminate unauthorized access to the programming system Note If you lose or forget the password contact your local Allen Bradley distributor 4 6 Programming Parameter Management Before you begin programming it s important to understand how the controller memory is e structured within the SMC Flex controller e used on power up and during normal operation Refer to Figure 4 3 and the explanations below Figure 4 3 Memory Block Diagram EEPROM lt gt RAM lt ROM Random Access Memory RAM This is the work area of the controller after it is powered up When you modify parameters in the Program mode the new values are stored in RAM When power is applied to the controller parameter values stored in the EEPROM are copied to RAM RAM is volatile and the values stored in this area are lost when the controller loses power Read only Memory ROM The SMC Flex controller comes with factory default parameter values These settings are stored in non volatile ROM and are displayed the first time you enter the Program mode Electrically Erasable Programmable Read only Memory EEPROM T
34. applicable and alarm contact closing Overvoltage Utilizing the overvoltage protection of the SMC Flex motor operation can be halted if a sudden increase in voltage is detected The SMC Flex controller provides an adjustable overvoltage trip setting from 0 199 of the programmed motor voltage Trip delay time can be adjusted from 0 99 seconds An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing Unbalance The SMC Flex is able to detect an unbalance in line voltages Motor operation can be halted if the unbalance is greater than the desired range The SMC Flex controller provides an adjustable unbalance setting from 0 25 of the line voltages Trip delay time can be adjusted from 0 99 seconds An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing Undervoltage overvoltage and voltage unbalance protection are disabled during braking operation 1 14 Product Overview Stall Protection and Jam Detection The SMC Flex controller provides both stall protection and jam detection for enhanced motor and system protection Stall protection is user adjust
35. level as a percentage of motor full load current and delay period Stall Allows the user to set the stall delay time Ground Fault amp Allows the user to enable the ground fault level in amps delay time and inhibit time A separate 825 CBCT is required Motor Allows the user to connect a PTC to the SMC and enable a fault when it becomes active Phase Reversal Determines the proper orientation of line connections to the SMC If Enabled and phases are out of sequence a fault will be indicated Restarts Allows the user to determine the maximum number of restarts per hour the unit can experience and delay time between consecutive starts The majority of parameters have a Fault and an Alarm setting Option Trip Class Service Factor Motor FLC Overload Reset Overload Alarm Level Underload Fault Level Underload Fault Delay Underload Alarm Level Underload Alarm Delay Undervoltage Fault Level Undervoltage Fault Delay Undervoltage Alarm Level Undervoltage Alarm Delay Overvoltage Fault Level Overvoltage Fault Delay Overvoltage Alarm Level Overvoltage Alarm Delay Unbalance Fault Level Unbalance Fault Delay Unbalance Alarm Level Unbalance Alarm Delay Jam Fault Level Jam Fault Delay Jam Alarm Level Jam Alarm Delay Stall Delay Ground Fault Enable Ground Fault Level Ground Fault Delay Ground Fault Inhibit Time Ground Fault Alarm Enable Ground Fault Alarm Level Ground Fault Alarm Delay PTC En
36. most drives to transfer data to and from the controller without using an Explicit Message The SMC Flex supports 16 bit DataLinks therefore the device can be configured to return up to four additional pieces of information without the need for an explicit message 8 10 Communications Rules for Using DataLinks e Each set of DataLink parameters in an SMC Flex be used by only one adapter If more than one adapter is connected multiple adapters must not try to use the same DataLink e Parameter settings in the SMC determine the data passed through the DataLink mechanism e When you use a DataLink to change a value the value is not written to the Non Volatile Storage NVS The value is stored in volatile memory and lost when the drive loses power Parameters 88 103 are used to configure the DataLinks For additional information regarding DataLinks refer to the user manual for the communication interface being used Note Node addressing of the DPI communication card can be programmed via software or a hand held DPI HIM The on board HIM cannot be used to address the communication card Updating Firmware The latest version of firmware and instructions for the SMC Flex can be obtained from www ab com Overview Fault Display Chapter 9 Diagnostics This chapter describes the fault diagnostics of the SMC Flex controller Further this section describes the conditions that cause various faults to occur Protect
37. should be set to N O Note Refer to Chapter 3 for typical power circuits Wiring 3 23 Figure 3 22 Typical Wiring Diagram for Applications Requiring an Isolation Contactor Control Power Option Stop FRESE EIS SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass 23 24 25 26 27 28 29 30 31 32 33 34 PEEP L ud ug ug PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Soft Stop Pump Stop or Brake Aux 2 should be set to N O 9 Note Refer to Chapter 3 for typical power circuits Refer to the controller nameplate to verify the rating of the control power input voltage 3 24 Wiring Figure 3 23 Typical Wiring Diagram for Hand Off Auto DPI Control Soft Stop Braking and Pump Control Only L1 1 T1 2 3 Phase L2 3 T2 4 Input Power L3 5 T3 6 Branch Protection SMC Flex Controller Control Power 100 240 VAC X00 H X00 21 22 19 20 1 Normal Up to Speed Bypass SMC Flex Control Terminals 23 24 KWH PTC Input 25 26 WH TACH Input 27 28 KH Ground Fault 29 30 31 32 33 34
38. the required current to operate the motor at the slow speed setting 0 450 of full load current Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 400 of full load current All braking stopping current settings in the range of 1 100 will provide 100 braking current to the motor Programming 4 15 Basic Set Up The Basic Set Up programming group provides a limited parameter set allowing quick start up with minimal adjustment If the user is planning to implement some of the advanced features e g Dual Ramp or Preset Slow Speed then the Setup programming group should be selected It provides all the Basic Set Up parameter set plus the advanced set Parameter Option SMC Option Standard Displays the type of controller This is factory set and not adjustable Motor Connection Line or Delta Displays the motor type to which the device is being connected Line Voltage Displays the system line voltage to which the unit is connected Starting Mode Soft Start Current Allows the user to program the SMC Flex controller for the type of starting that best fits the application Limit Full Voltage Linear Speed Ramp Time 0 30 s This sets the time period during which the controller will ramp the output voltage Initial Torque 0 90 of locked The initial reduced voltage output level for the voltage ramp is established and adjusted with th
39. 0 B 2 Parameter Information Table B 1 Parameter List Continued Grou Parameter Parameter Units Min Default User P Description Number Max Settings Settings Dual Ramp Kickstart Time 2 30 SEC 0 0 2 0 0 0 Dual Ramp Kickstart Level2 31 LRT 0 90 0 Basic Set Up Stop Mode 32 Disable Disable Soft Stop Linear Speed SMB Accu Stop Basic Set Up Stop Time 33 SEC 0 120 0 Basic Set Up Accu Stop Braking Current 35 FLC 0 400 0 Preset SS Accu Stop Slow Speed Sel 39 SS Low SS High SS High Preset SS Accu Stop Slow Speed Dir 40 SS FWD SS FWD SS REV Preset SS Accu Stop Slow Accel Cur 41 FLC 0 450 0 Preset SS Accu Stop Slow Running Cur 42 FLC 0 450 0 Accu Stop Stopping Current 43 FLC 0 400 0 Basic Set Up Overload Overload Class 44 Disable Disable Class 10 Class 15 Class 20 Class 30 Basic Set Up Overload Service Factor 45 0 01 1 99 1 15 Basic Set Up Overload Motor FLC 46 A 1 0 1000 0 1 0 Basic Set Up Overload Overload Reset 47 Manual Manual Auto Overload Overload A Lvl 50 MTU 0 100 0 Underload Underload F Lvl 51 FLC 0 99 0 Underload Underload F Dly 52 SEC 0 99 0 Underload Underload A Lvl 53 FLC 0 99 0 Underload Underload A Dly 54 SEC 0 99 0 Undervoltage Undervolt F Lvl 55 9oV 0 99 0 Undervoltage Undervolt F Dly 56 SEC 0 99 0 Undervoltage Undervolt A
40. 200 500V 71595 10 Rated Insulation Voltage N A 500V Rated Impulse Voltage N A 6000V Dielectric Withstand 2200V AC 2500V Repetitive Peak Inverse Voltage Rating 200 480V AC 200 415V 1400V 1400V 200 500V 1600V 200 600V AC 1600V Operating Frequency 50 60 Hz 50 60 Hz Utilization Category MG 1 AC 53B 3 0 50 1750 Protection Against Electrical Shock N A IPOO open device Optional IP20 DV DT Protection RC Snubber Network Transient Protection Metal Oxide Varistors 220 Joules Specifications A 3 Short Circuit Protection SCPD Performance SCPD List Max Max Available Circuit Fault Breaker A Line Device Operational Current 10 kA 35 Rating A 10 kA 150 10 kA 300 10 kA 300 10 kA 400 30 kA 300 30 kA 400 30 kA 600 700 800 1000 1200 Delta Device Operational Current 35 Rating A 150 300 300 400 500 700 1000 1200 1600 1600 1600 Control Circuit Rated Operational Voltage 100 240V AC 100 240V 24V AC 24V DC 24V 24V DC Rated Insulation Voltage N A 240V Rated Impulse Voltage N A 3000V Dielectric Withstand 1600V AC 2000V Operating Frequency 50 60 Hz 50 60 Hz Protection Against Electric Shock N A IP20 Power Requirements Control Module 75 VA Heatsink Fan s A 50 VA Vibration Operational 1G Non Operational 256 Fordevices rated 5 480 A heatsink fans can be powered by either 110 120
41. AC AC Contactor Ambient Temperature American Wire Gauge AWG Block Transfer BTR BTW Buffer Contactor Reversing COP Cursor Cycle Glossary Alternating current An alternating current AC contactor is designed for the specific purpose of establishing or interrupting an AC power circuit Ambient temperature is the temperature of air water or a surrounding medium where equipment is operated or stored A standard system used for designing the size of electrical conductors Gauge numbers have an inverse relationship to size larger numbers have a smaller cross sectional area However a single strand conductor has a larger cross sectional area than a multi strand conductor of the same gauge so that they have the same current carrying specification Block Transfer is the method used by a PLC to transfer data that does not require continuous updates To perform this function the module provides a status word to the PLC during normal discrete transfer scan This status word occupies the first module group in the PLC I O image table for the designated rack The status word is then used by the PLC program to control the BTW and BTR functions of the PLC A PLC Block Transfer Read instruction A PLC Block Transfer Write instruction 1 Insoftware terms a register or group of registers used for temporary storage of data to compensate for transmission rate differences between the transmitter and receiving devic
42. L Listed File No E96956 CSA Certified Class No 3211 06 A 6 Specifications Approximate Dimensions and Open Type Controllers Shipping Weights Dimensions are in millimeters inches Dimensions are not intended for manufacturing purposes Controller Rating A Weight 5 85 5 7 kg 12 6 Ib 108 251 304 kg 67 Ib 317 480 45 8 kg 101 Ib Enclosed Type Line Connected Controllers Factory installed options may affect enclosure size requirements Exact dimensions can be obtained after order entry Consult your local Allen Bradley distributor H gt IP65 Type 4 12 Controller Rating A or Rating p Height A Width C Depth Non Combination Controller 5 610 24 406 16 229 9 25 610 24 406 16 229 9 43 610 24 406 16 229 9 60 610 24 406 16 229 9 85 610 24 406 16 229 9 108 762 30 610 24 305 12 135 762 30 610 24 305 12 201 965 38 762 30 356 14 251 965 38 762 30 356 14 317 1295 51 914 36 356 14 361 1295 51 914 36 356 14 480 1295 51 914 36 356 14 Specifications A 7 IP65 Type 4 12 Controller Rating A ONE Rang p Height A Width C Depth Combination Controllers with Fusible D
43. Lvl 57 0 99 0 Undervoltage Undervolt A Dly 58 SEC 0 99 0 Overvoltage Overvolt F Lvl 59 0 199 0 Overvoltage Overvolt F Dly 60 SEC 0 99 0 Overvoltage Overvolt A Lvl 61 0 199 0 Overvoltage Overvolt A Dly 62 SEC 0 99 0 Unbalance Unbalance F Lvl 63 0 25 0 Unbalance Unbalance F Dly 64 SEC 0 99 0 Unbalance Unbalance A Lvl 65 0 25 0 Unbalance Unbalance A Dly 66 SEC 0 99 0 Jam Jam F Lvl 67 FLC 0 1000 0 Jam Jam F Dly 68 SEC 0 99 0 Jam Jam A Lvl 69 FLC 0 1000 0 Jam Jam A Dly 70 SEC 0 99 0 Parameter Information B 3 Table B 1 Parameter List Continued Group Parameter Parameter Units Min Default User Description Number Max Settings Settings Stall Stall Delay 71 SEC 0 0 10 0 0 Ground Fault Gnd Fit Enable 72 Disable Disable Enable Ground Fault Gnd Fit Level 73 A 1 0 5 0 2 5 Ground Fault Gnd Fit Delay 74 SEC 0 1 250 0 0 5 Ground Fault Gnd Fit Inh Time 75 SEC 2 25 10 Ground Fault Gnd Fit A Enable 76 Disable Disable Enable Ground Fault Gnd FIt A Lvl 77 A 1 0 5 0 2 0 Ground Fault Gnd Fit A Dly 78 SEC 0 250 10 PTC PTC Enable 79 Disable Disable Enable Phase Reversal Phase Reversal 80 Disable Disable Enable Restart Starts Per Hour 81 0 99 Restart Restart Attempts 82 0 5 Restart Restart Delay 83 SEC 0 60 Comm Masks Logic Mask 87 8 bit binary DataLinks Data In 1 88 DataLinks Dat
44. MC Option This parameter identifies the type of control present and is not user programmable 0 120s Standard Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 forward 1095 reverse High 1596 forward 20 reverse Slow Speed Direction This parameter programs the slow speed motor rotational direction Forward Reverse Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting 0 450 of full load current Option Pump Control Programming 4 13 Parameter Range Pump Control SMC Option This parameter identifies the type of control present and is not user programmable Pump Control Pump Stop Time Allows the user to set the time period for the pump stopping function 0 120s Starting Mode Allows the user to program the SMC Flex controller for the type of starting that best fits the application Pump Start Soft Start Current Limit Start Braking Control SMB Smart SMC Option Braking Control Motor Braking This parameter identifies the type of control present and is not user programmable Braking Current Allows the user to program the intensity of the braking current
45. Motor Braking 3 21 Preset Slow Speed 3 25 Slow Speed with Braking enne 3 27 Sequence of Operation essere 3 28 DOT QUOD sro eee eate eee bea a rs 3 28 Preset Slow Speed 3 29 Pump Control esses 3 30 SMB Smart Motor Braking Option 3 31 510 M 3 32 Slow Speed with Braking 3 33 Bulletin 150 SMC Flex Chapter 4 Programming Chapter 5 Motor Information Chapter 6 Metering Chapter 7 Optional HIM Operation aT 4 1 Keypad Description 4 1 Programming MENU eese 4 1 PASSWOMG ME 4 5 Parameter Management ccccccsssscscssssssssesssssesssessssssseseesers 4 6 Random Access Memory RAM 4 6 Read only Memory ROM 4 6 Electrically Erasable Programmable Read only Memory EEPROM 4 6 Using Parameter Management with DPI HIM 4 7 Parameter Modification essen 4 8 Soft ist eie RE RR eee eee 4 9 Current Limit Start 00 0 cccccsssecssssssscsss
46. V AC or 220 240V AC A 4 Specifications Environmental Steady State Heat Dissipation W Controller Rating A Auxiliary Contacts e 19 20 Normal Up to Speed External Bypass e 29 30 Fault Type of Control Circuit UL CSA NEMA IEC 95 95 106 122 155 167 176 200 218 225 245 290 e 31 32 Alarm e 33 34 Normal Electromagnetic relay Number of Contacts 1 Type of Contacts N O Type of Current AC Rated Operational Current 3A 120V AC 1 5 A 240V AC Conventional Thermal Current 5 Make Break VA 3600 360 Utilization Category AC 15 PTC Input Ratings Response Resistance 3400 150 Q Reset Resistance 1600 1000 Short Circuit Trip Resistance 250 100 Max Voltage at PTC Terminals 4 lt 7 5V Max Voltage at PTC Terminals Rptc open 30V Max No of Sensors 6 Max Cold Resistance of PTC Sensor Chain 1500 Q Response Time 800 ms Tach Input 0 5V DC 4 5V DC 100 Speed Operating Temperature Range 0 50 C 32 122 F open 0 40 C 32 104 F enclosed Storage and Transportation Temperature 20 75 C Range Altitude 2000 m 6560 ft Humidity 5 95 non condensing Pollution Degree 2 Specifications A 5 Mechanical Other Resistance to Vibration Resistance to Shock Construction Terminals EMC Emission Levels EMC Immunity Levels Overload Characteristics App
47. V Control Loss 46 Underload 23 System Faults 128 209 See Table 9 B for definition The fault and alarm auxiliary contacts are located at terminals 29 30 and 31 32 respectively These contacts can be programmed as either N O or N C Parameter setup can be found in the Parameter Motor Protection group when modifying parameters in the Program Mode 9 4 Diagnostics Fault Definitions Table 9 B shows the fault definitions for the SMC Flex Table 9 B Fault Definitions Fault Description Line Loss F1 F2 F3 The SMC Flex can determine if a line connection has been lost and will indicate this accordingly Shorted SCR Shorted SCRs will be detected and starting will be prohibited by the SMC Flex Open Gate Open gate indicates that an abnormal condition that causes faulty firing e g open SCR gate has been sensed during the start sequence The SMC Flex controller will attempt to start the motor a total of three times before the controller shuts down Power Pole PTC and SCR The power pole temperature in each phase is monitored If the temperature rises above the predetermined level the Overtemperature unit will fault to protect the power pole A reset can be performed once the temperature falls below this level Motor PTC A motor PTC can be connected to terminals 23 and 24 If the PTC parameter is enabled and the PTC trips the SMC Flex will trip and indicate a Motor PTC fault Open Bypass Power pole bypass c
48. Wiring and Tightening Torque Wire Size Torque Wire Strip Length 0 75 2 5 mm 18 14 AWG 9 6 Nem 5 Ib in 5 6 8 6 mm 0 22 0 34 in Controllers rated 5 480 A have heatsink fan s Refer to Table 3 C for the control power VA requirements of the heatsink fans Fan Terminations See Figure 3 2 for fan power connection locations The fan jumpers have been factory installed for 110 120 VAC input Refer to Figure 3 5 for 220 240 VAC fan wiring Figure 3 5 5 480 A Fan Terminations Factory Set Optional 110 120 VAC 220 240 VAC A A 1 1 To To 2 M Supply 2 Supply Jumpers r Jumper 3 A 3 4 4 Y Y Table 3 C Heatsink Fan Control Power SMC Rating Heatsink Fan VA 5 85A 15 108 480A 50 Wiring 3 7 Control Terminal Designations Terminal Number 11 12 13 14 15 16 17 18 19 20 21 22 Description Control Power Input Control Power Common Controller Enable Input Control Module Ground Option Input 2 Option Input 1 Start Input Stop Input N O Aux Contact 1 Normal Up to Speed External Bypass N O Aux Contact 1 Normal Up to Speed External Bypass Not Used Not Used As shown in Figure 3 6 the SMC Flex controller contains 24 control terminals on the front of the controller Figure 3 6 SMC Flex Controller Control Termina
49. a In A2 89 DataLinks Data In B1 90 DataLinks Data In B2 91 DataLinks Data In C1 92 DataLinks Data In C2 93 DataLinks Data In D1 94 DataLinks Data In D2 95 DataLinks Data Out 1 96 DataLinks Data Out A2 97 DataLinks Data Out B1 98 DataLinks Data Out B2 99 DataLinks Data Out C1 100 DataLinks Data Out C2 101 DataLinks Data Out D1 102 DataLinks Data Out D2 103 Motor Data Motor ID 104 0 65535 0 Motor Data CT Ratio 105 1 1500 Motor Data MV Ratio 106 1 10000 Basic Set Up Aux1 Config 107 Normal Normal Up To Speed External Bypass Basic Set Up Fault Contact 108 NO NO NC Basic Set Up Alarm Contact 109 NO NO NC B 4 Parameter Information Table B 1 Parameter List Continued Grou Parameter Parameter Units Min Default User P Description Number Max Settings Settings Basic Set Up Aux2 Config 110 NO NO NC Language Language 111 English English French Spanish German Portuguese Mandarin All Parameter Mgmt 115 Ready Ready User Recall User Store Factory Default Basic Set Up Backspin Timer 116 SEC 0 999 0 Description Control Modules Standard Renewal Parts SWCRaing Input Control Voltage All 120 240V AC Pump Control All Braking Control 5 85 A 108 251 A 317 480A Appendix C Part No 41391 454 01 S1FX 41391 454 01 B1FX 41391 454 01 D1AX 41391 454 01 D1BX 41391 454 01 D1CX Standard
50. able Phase Reversal Restarts Per Hour Restart Attempts Restart Delay Q The delay time must be set to a value greater than zero when Undervoltage Overvoltage and Unbalance are enabled For Jam and Underload detection to function the Motor FLC must be programmed in the Motor Protection group See Chapter 5 for instructions See details in Ground Fault on page 1 15 See details in Thermistor PTC Protection on page 1 16 Example Settings Programming 4 17 Undervoltage With Line Voltage programmed for 480V and the Undervoltage level programmed for 80 the trip value is 384V Overvoltage o With Line Voltage programmed for 240V and the Overvoltage level programmed for 115 the trip value is 276V Jam With Motor FLC programmed for 150 A and the Jam level programmed for 400 the trip value is 600 A Underload With Motor FLC programmed for 90 A and the Underload level programmed for 60 the trip value is 54 A average value of the three phase to phase voltages is utilized Q largest value of the three phase currents is utilized self protect Overview Motor Data Entry Motor Information Chapter 5 The Basic Set Up and Overload programming group allows the user to set parameters indicating to the controller the motor that is connected It is important to correctly input the data to achieve the best performance from your controller over
51. able from 0 0 10 0 seconds in addition to the ramp time programmed Figure 1 15 Stall Protection 600 Percent Full Load lt Programmed Start Time Stall Time seconds e An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing e Jam detection allows the user to determine the jam level up to 1000 of the motor s FLC rating and the delay time up to 99 0 seconds for application flexibility Figure 1 16 Jam Detection Percent User Programmed Trip Level Current Pa 100 4 r I Ji E i i 1 i i i 1 fi lt Running Jam Time seconds detection is disabled during slow speed and braking operation Q will self protect in a jam condition Product Overview 1 15 Ground Fault In isolated or high impedance grounded systems core balanced current sensors are typically used to detect low level ground faults caused by insulation breakdowns or entry of foreign objects Detection of such ground faults can be used to interrupt the system to prevent further damage or to alert the appropriate personnel to perform timely maintenance The SMC Flex s ground fault detection capabilities consist of instal
52. ace Regardless of the type of interface being used the information below can be used to configure the rest of the system Communications 8 7 Default Input Output Configuration Variable Input Output Configuration The default configuration for I O is 4 bytes in and 4 bytes out TX 4 bytes RX 4 bytes and is arranged according to the following table Table 8 E Consumed Data Control Word 0 Logic Status Logic Command Word 1 Feedback Reference Thefeedback word is always Current in Phase A The reference word is not used with the SMC Flex however the space must be reseverd The SMC Flex supports 16 bit DataLinks Therefore the device can be configured to return additional information The I O message size depends on how many DataLinks are enabled The following table summarizes the I O data sizes Table 8 F Rx Tx Logic Status Reference DataLinks Size Size Command FeedBack 16 bit 16 bit A B D 4 4 X X 8 8 X X X 12 12 X X X X 16 16 X X X X X 20 20 X X X X X X To configure DataLinks refer to Configuring DataLinks on page 8 9 8 8 Communications SMC Flex Bit Identification Table 8 0 Logic Status Word Bit Status Description 15 14 13 12 11 10 9 8 7 Enabled 1 Control Power Applied 0 No Control Power Running 1 Power App
53. aking Figure 3 20 through Figure 3 23 show the different wiring for the Soft Stop Pump Control and SMB Smart Motor Braking options Figure 3 20 Typical Wiring Diagram lt 3 Control Power 9 l Stop Start Option Stop 0 s 11 12 13 14 15 16 17 18 19 20 21 22 SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass 23 24 25 26 27 28 29 30 31 32 33 34 PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Soft Stop Pump Stop or Brake Refer to the controller nameplate to verify the rating of the control power input voltage Note Refer to Chapter 3 for typical power circuits 3 22 Wiring Figure 3 21 Typical Retrofit Wiring Diagram r Control Power O Option Stop PTSTSTSTSTSTeTe Te T Te Te SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass 23 24 25 26 27 28 29 30 31 32 33 34 eu Lae uH PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Overload protection should be disabled in the SMC Flex controller Refer to the controller nameplate to verify the rating of the control power input voltage Soft Stop Pump Stop or Brake Aux 2
54. applied to the motor 0 400 of full load current Accu Stop SMC Option This parameter identifies the type of control present and is not user programmable Braking Control Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 High 15 Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting 0 450 of full load current Braking Current Allows the user to program the intensity of the braking current applied to the motor 0 400 of full load current Stopping Current Allows the user to program the intensity of the braking current applied to the motor from slow speed operation 0 400 of full load current 4 14 Programming Option Slow Speed with Braking Parameter SMC Option This parameter identifies the type of control present and is not user programmable Range Braking Control Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 High 15 Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program
55. ces motor cooling efficiency Consult motor manufacturer for motor limitations Smart Motor Braking option Check duty cycle Consult motor manufacturer for motor limitations Motor short circuit e Winding fault Identify fault and correct Check for shorted SCR replace if necessary Ensure power terminals are secure 10 6 Troubleshooting Power Module Check If a power module needs to be checked use the applicable procedure that follows PATIENTION To avoid shock hazard disconnect main power shock hazard disconnect main power before working on the controller motor or control devices such as Start Stop push buttons viis iid sure that wires are properly marked and programmed parameter values are recorded Shorted SCR Test 1 Using an ohmmeter measure the resistance between the line and load terminals of each phase on the controller L1 T1 L2 T2 amp L3 T3 The resistance should be greater than 10 000 ohms Appendix A Specifications Functional Design Specifications Standard Features Installation Power Wiring Standard squirrel cage induction motor or a Wye Delta six lead motor Control Wiring 2 and 3 wire control for a wide variety of applications Setup Keypad Front keypad and backlit LCD display Software Parameter values can be downloaded to the SMC Flex Controller with DriveTools programming software and the Cat No 20 COMM DPI communica
56. conds Approximate Trip Time seconds Approximate Trip Time seconds 10 0 10 0 10 0 01 10 10 10 1 2 3 4 5678910 1 2 3 4 5678910 1 2 4 5678910 1 2 4 5 6 78910 Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC Approximate trip time for 3 phase balanced Approximate trip time for 3 phase balanced condition from cold start condition from hot start Figure 1 14 Restart Trip Curves after Auto Reset 100000 1000 1 iy Ww V 100 Seconds 59 lass 10 gt Class15 TOR TESSSES Class 20 Class 30 10 1 5 Auto Reset Times Class 10 90s Class 15 135s Class 20 180s Class 30 270s 0 100 1000 Percent Full Load Current Setting Product Overview 1 13 Undervoltage Utilizing the undervoltage protection of the SMC Flex motor operation can be halted if a sudden drop in voltage is detected The SMC Flex controller provides an adjustable undervoltage trip setting from 0 99 of the programmed motor voltage Trip delay time can be adjusted from 0 99 seconds An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD HIM Communication if
57. d to prevent inadvertent contact with terminals Disconnect the main power before servicing the motor controller or associated wiring The following table provides the maximum heat dissipation at rated current for the controllers For currents lower than rated value heat dissipation will be reduced Table 2 A Maximum Heat Dissipation SMC Rating 5A 25A 43A 60A 85A 108A 135A 201A 251A 317A 361A 480 A Max Watts 95 95 106 122 155 167 176 200 218 225 245 290 Enclosures The open style design of the SMC Flex controller requires that it be installed in an enclosure The internal temperature of the enclosure must be kept within the range of 0 50 C Installation 2 3 Enclosures For Type 12 IP54 enclosures the following guidelines are recommended to limit the maximum controller ambient temperature There should be a clearance of at least 15 cm 6 in above and below the controller This area allows air to flow through the heatsink Table 2 B Minimum Enclosure Size Controller IP65 Type 4 12 Rating A B Height A Width C Depth Non Combination Controller mm in 610 24 25 406 16 229 9 43 406 16 229 9 60 406 16 229 9 85 406 16 229 9 108 610 24 305 12 135 762 30 356 14 201 762 30 356 14 251 914 36 356 14 317 914 36 356 14 361 1016 40 457 18 1778 70 20 406 16
58. e 2 Inhardware terms an isolating circuit used to avoid the reaction of one circuit with another A method of reversing motor rotation by the use of two separate contactors one of which produces rotation in one direction and the other produces rotation in the opposite direction The contactors are electrically and mechanically interlocked so that both cannot be energized at the same time This instruction copies data from one location into another It uses no status bits If you need an enable bit program a parallel output using a storage address The intensified or blinking element in a video display A means for indication where data entry or editing occurs 1 sequence of operations that is repeated regularly 2 The time it takes for one sequence of operations to occur Glossary Il DH 485 Link Disable Duty Cycle Enable Fault G File Gate Jogging Jumper LCD Locked Rotor Torque Mode Normally Closed Contacts Normally Open Contacts PLC Controller Data Highway 485 link An Allen Bradley token passing baseband link for a local area network based on the RS 485 standard To inhibit logic from being activated The relationship between the operating and rest times or repeatable operation at different loads To allow an action or acceptance of data by applying an appropriate signal to the appropriate input Any malfunction that interferes with normal system operation G File con
59. e lead e Check gate lead connections to the control module PTC Power Pole 10 amp 11 e Controller ventilation blocked e Check for proper ventilation e Controller duty cycle exceeded e Check application duty cycle e Fan failure e Replace fan e Ambient temperature limit exceeded e Wait for controller to cool or provide external cooling SCR Overtemp e Failed thermistor e Replace power module e Failed control module e Replace control module Motor PTC 12 e Motor ventilation blocked e Check for proper ventilation e Motor duty cycle exceeded e Check application duty cycle e Wait for motor to cool or provide external cooling e PTC open or shorted e Check resistance of PTC Troubleshooting 10 3 Table 10 A SMC Fault Display Explanation Continued Display Fault Code Possible Causes Possible Solutions Open Bypass 13 14 amp 15 e Control voltage is low Check control voltage power supply e Inoperable power module bypass Replace power module Check control module TB2 TB4 and TB5 TB7 for Secureness Check Aux 1 configuration is not set to External Bypass No Load 16 17 18 amp Loss of load side power wiring Check all load side power connections and motor 40 windings Line Unbalance 19 e Supply unbalance is greater than the Check power system and correct if necessary user programmed value Extend the delay time to match the application e The delay time is too short for the requirem
60. e voltage ramp down time is user adjustable from 0 120 seconds and is adjusted independently from the starting time The load will stop when the output voltage drops to a point where the load torque is greater than the developed motor torque Figure 1 8 Soft Stop Percent Voltage Selectable Kickstart 100 p pU Coast to rest Soft Stop Initial L Torque Soft Stop Start _ Run Time seconds viis HIN Soft Stop is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements 1 8 Product Overview Control Options Modes of Operation Pump Control The SMC Flex controller offers the control options described below Important The options listed in this section are mutually exclusive and must be specified when ordering An existing controller may be upgraded to another control option by replacing the control module Consult your local Allen Bradley distributor Pump Control Option This option reduces surges during the starting and stopping of a centrifugal pump by smoothly accelerating and decelerating the motor The microprocessor analyzes the motor variables and generates commands that control the motor and reduce the possibility of surges occurring in the system The starting time is programmable from 0 30 seconds and the stopping time is programmable from 0 120 seconds Figure 1 9 Pump Contro
61. ed depending on the frictional and inertial characteristics of the connected load Note Depending on the application the Braking options SMB Motor Braking Accu Stop and Slow Speed may cause some vibration or noise during the stopping cycle This may be minimized by lowering the braking current adjustment If this is a concern in your application please consult the factory before implementing these options 10 2 Troubleshooting The following flowchart is provided to aid in quick troubleshooting Figure 10 1 Troubleshooting Flowchart YES a N Fault Displayed N pA NO Define Nature of Trouble Motor rotates sei tena but does not Motor stops while Miscellaneous motor accelerate to full running situations speed See See See See i See Table 10 A Table 10 B J Table 10 C Table 10 D Table 10 E Ne samt No ou Me ou DA S Wi Table 10 A SMC Fault Display Explanation Display Fault Code Possible Causes Possible Solutions Line Loss 1 2 3 e Missing supply phase e Check for open line i e blown fuse with phase e Motor not connected properly e Check for open load lead indication e Consult the factory Shorted SCR 4 5 amp 6 e Shorted Power Module e Check for shorted SCR replace power module if necessary Open Gate 7 8 amp 9 e Open gate circuitry e Perform resistance check replace power module if with phase necessary indication e Loose gat
62. ed and will provide Parameter 1 Current in Phase A automatically as the feedback word A complete listing of the SMC Flex parameters is located in Appendix B The parameter values stored and produced by the SMC Flex through communication are unscaled numbers When reading or writing values from a PLC image table it is important to apply the proper scaling factor which is based on the number of decimal places Read Example Parameter 11 Power Factor The stored value is 85 Since this value has two decimal places the value should be divided by 100 The correctly read value is 0 85 Write Example Parameter 46 Motor FLC The value which is to be written to the SMC is 75 A Since this value has one decimal place the value should be multiplied by 10 The correctly written value is 750 Some parameters have text descriptions when viewed from a HIM or through a communication software program such as RSNetworx When receiving or sending information from a PLC each text description has a numerical equivalent Table 8 I has an example of Parameter 44 Overload Class and the appropriate relationship between the text descriptor and the equivalent value This relationship is identical for other similar parameters located in Appendix B Table 8 1 Text Descriptor Numerical Equivalent Disabled 0 Class 10 1 Class 15 2 Class 20 3 Class 30 4 DataLinks are supported in the SMC Flex A DataLink is a mechanism used by
63. ed to the DeviceNet cable near the SMC Flex control module The recommended cores are TDK ZCAT2023 0930H and TDK ZCAT2035 0930 or equivalent All cores specified are the split type cores and can be added to existing connections Chapter 3 Wiring Terminal Locations The SMC Flex controller wiring terminal locations are shown in Figure 3 2 Make wiring connections as indicated in the typical connection diagrams Incoming three phase power connections are made to terminals L1 1 L2 3 and L3 5 Load connections to Line motors are made to T1 2 T2 4 and T3 6 while load connections to inside the Delta motors are made to T1 2 T2 4 T3 6 T4 8 T5 10 and T6 12 Figure 3 1 Wiring Terminal Locations 5 85 A Table 3 A Wiring Terminal Locations 1 Incoming Line Termination 2 Line Motor Connections 3 Delta Motor Connections 4 Control Terminations 5 Fan Terminations IP20 protective covers on Delta termination must be removed when connecting in a Delta configuration 3 2 Wiring Power Structure Figure 3 2 Wiring Terminal Locations 108 480 A Table 3 A Wiring Terminal Locations 1 Incoming Line Termination 2 Line Motor Connections 3 Delta Motor Connections 4 Control Terminations 5 Fan Terminations The SMC Flex product has an integrated mechanical run contactor on each phase of the motor to minimi
64. educed output voltage before switching to full voltage Option Current Limit 0 30s Current Limit Level This parameter provides adjustability for the reduced output voltage level provided to the motor 50 600 full load current Kickstart Time A boost of current is provided to the motor for the programmed time period Kickstart Level Adjusts the amount of current applied to the motor during the kickstart time 0 0 2 05 0 90 locked rotor torque If the controller senses that the motor has reached full speed before completing the current limit start it will automatically switch to providing full voltage to the motor 4 10 Programming Dual Ramp Start The SMC Flex controller provides the user with the ability to select between two Start settings The parameters below are available in the Set Up programming mode To obtain Dual Ramp control Ramp 1 is located in the Basic Set Up and Ramp 2 is located in the Option 2 Input Dual Ramp Parameter Set Up The user must select the Set Up programming mode to obtain access to the Dual Ramp parameters Option Basic Set Up Starting Mode Set Up as stated in previous pages Option 2 Input Dual Ramp This allows the user the option to choose between two Soft Start profiles defined by 1 Start Mode Ramp Time Initial Torque and 2 Start Mode 2 Ramp Time 2 Initial Torque 2 When this feature is turned on the ramp time initial torq
65. ents application Overvoltage 20 e Supply voltage is greater than user Check power system and correct if necessary programmed value Correct the user programmed value Undervoltage 21 e Supply voltage is less than user Check power system and correct if necessary programmed value Correct the user programmed value e The delay time is too short for the Extend the delay time to match the application application requirements Overload 22 e Motor overloaded Check motor overload condition e Overload parameters are not matched Check programmed values for overload class and to the motor motor FLC Underload 23 e Broken motor shaft Repair or replace motor e Broken belts toolbits etc Check machine e Pump cavitation Check pump system Jam 24 e Motor current has exceeded the user Correct source of jam programmed jam level Check programmed time value Stall 25 e Motor has not reached full speed by Correct source of stall the end of the programmed ramp time Phase Reversal 26 e Incoming supply voltage is not in the Check power wiring expected ABC sequence Coms Loss 27 28 amp 29 e Communication disconnection at the Check for a communication cable disconnection to serial port the SMC Flex controller Network 30 31 amp 32 e DPI network loss Reconnect for each DPI connected device Ground Fault 33 e Ground fault current level has Check power system and motor correct if exceeded programmed value necessary Check programmed ground fault levels to match application r
66. equirements Excess Starts Hr 34 e Number of starts in a one hour period Wait an appropriate amount of time to restart has exceeded the value programmed Turn off the Starts Hr feature Power Loss 35 36 e Missing supply phase as indicated Check for open line i e blown line fuse with phase amp 37 indication Hall ID 38 e Incorrect power module has been Check power module and replace installed NVS Error 39 e Data entry error Check user data and perform a User Store function Replace control module Line Loss 41 42 43 Line distortion Check supply voltage for capability to start stop High impedance connection motor Check for loose connections on line side or motor side of power wires Prestart fault indication Table 10 B Motor Will Not Start No Output Voltage to the Motor Display Fault displayed Possible Cause See fault description Possible Solutions See Table 10 A addressing fault conditions Display is blank Control voltage is absent Failed control module Check control wiring and correct if necessary Replace control module Cycle control power Stopped e Pilot devices Check wiring 0 0 Amps e SMC Enable input is Check wiring open at terminal 13 e Input terminals are not Check wiring wired correctly e Start Stop control has Follow the instructions on not been enabled for page 8 4 8 5 to enable the human interface control capability module e Control voltage Check control v
67. figuration is based on the devices that you have on the RIO link G File configuration consists of setting logical device starting addresses and the logical device image size of each physical device adapter with which the scanner communicates The control element of an SCR silicon controlled rectifier commonly referred to as a thyristor When a small positive voltage is applied to the gate momentarily the SCR will conduct current when the anode is positive with respect to the cathode of the SCR Current conduction will continue even after the gate signal is removed Jogging is a means of accomplishing momentary motor movement by repetitive closure of a circuit using a single push button or contact element A short conductor with which you connect two points Liquid crystal display which is a reflective visual readout device commonly used in digital watches and laptop computers The minimum torque that a motor will develop at rest for all angular positions of the rotor with rated voltage applied at rated frequency A selected method of operation Example run test or program A set of contacts on a relay or switch that are closed when the relay is de energized or the switch is de activated They are open when the relay is energized or the switch is activated A set of contacts on a relay or switch that are open when the relay is de energized or the switch is de activated They are closed when the relay is energized or the switch is
68. gure 3 12 Typical Wiring Diagram for Retrofit Applications 3 13 Figure 3 13 Typical Wiring Diagram for Isolation Applications CC 3 14 Figure 3 14 Typical Wiring Diagram for Shunt Trip Applications sese 3 15 Figure 3 15 Typical Wiring Diagram for Single Speed Reversing 3 16 Figure 3 16 Typical Wiring Diagram for Two speed Applications 5 t ine ete eese 3 17 Figure 3 17 Typical Wiring Diagram for SMC Off Bypass a 3 18 Figure 3 18 Typical Wiring Diagram for Hand Off Auto DPI COTILO eq oce ec 3 19 Figure 3 19 Typical Wiring Diagram for Hand Off Auto DPI 3 20 Figure 3 20 Typical Wiring Diagram 3 21 Figure 3 21 Typical Retrofit Wiring Diagram 3 22 Figure 3 22 Typical Wiring Diagram for Applications Requiring an Isolation 1 3 23 Figure 3 23 Typical Wiring Diagram for Hand Off Auto DPI Control Soft Stop Braking and Pump Control Only 3 24 Figure 3 24 Typical Wiring Diagram for the Preset Slow Speed UR 3 25 Figure 3 25 Typical Slow Speed Wiring Diagram for Hand Off Auto DPI 1 1 3 26 Figure 3 26 Typical Wiring Diagram for the Slow Speed with eatis de
69. he SMC Flex controller provides a non volatile area for storing user modified parameter values in the EEPROM Programming 4 7 Using Parameter Management with DPI HIM Memory Storage and Parameter Management perform the same function of saving programmed settings Description Saving to EEPROM To ensure that the newly modified parameters are not lost if control power is removed from the controller store the values into EEPROM Action Display Memory Storage Save EEPROM Recall EEPROM Recalling from EEPROM Parameters stored in EEPROM can be manually brought to RAM by directing the controller to recall the values stored in its EEPROM Memory Storage Recall EEPROM Reset to Defaults Recalling Defaults After parameter values have been modified and saved to EEPROM factory default settings can still be re initialized Memory Storage Reset to Defaults Save EEPROM 4 8 Programming Parameter Modification All parameters are modified using the same method The basic steps to performing parameter modification are described below Notes 1 Parameter values modified while the motor is operating are not valid until the next time that operation occurs 2 If the password is set parameters cannot be adjusted without logging in 3 Use the Sel key to highlight a single digit
70. hich the SMC Flex will trip It is adjustable from 1 0 5 0 A Important The ground fault inhibit timer starts after the maximum phase of load current transitions from 0 A to 30 of the device s minimum FLA Setting or the GF Current is greater than or equal to 0 5 A The SMC Flex does not begin monitoring for a ground fault condition until the Gnd Flt Inh Time expires Ground Fault Alarm The SMC Flex will indicate a Ground Fault Alarm if e No warning currently exists e Ground fault alarm is enabled e GF Inhibit Time has expired e GF Current is equal to or greater than the Gnd Fit A Lvl Parameter 77 Gnd Fit A Lvl allows the installer to define the ground fault current at which the SMC Flex will indicate a warning It is adjustable from 1 0 5 0 A Parameter 78 Gnd Fit A Dly allows the installer to define the time period a ground fault alarm condition must be present before a trip occurs It is adjustable from 0 1 25 seconds Thermistor PTC Protection The SMC Flex provides terminals 23 and 24 for the connection of positive temperature coefficient PTC thermistor sensors PTC sensors are commonly embedded in motor stator windings to monitor the motor winding temperature When the motor winding temperature reaches the PTC sensor s temperature rating the PTC sensor s resistance transitions from a low to high value Since PTC sensors react to actual temperature enhanced motor protection can be provided to address such cond
71. igh settings in the forward direction Reverse can also be programmed and offers 10 of base speed low and 20 of base speed high settings Figure 1 6 Preset Slow Speed 100 Motor Speed Forward imis d 15 High 4 7 Low Time seconds Start _ Run 10 Low XN a ri 20 High Reverse viuis iil Slow speed running is not intended for continuous operation due to reduced motor cooling 1 6 Product Overview Linear Speed Acceleration The SMC Flex has the ability to control the motor speed during starting and stopping maneuvers A tach input 0 5V DC is required to perform this start mode The start time is selectable from 0 30 seconds and determines the time the motor will ramp from 0 speed to full speed Kickstart is available with this option Figure 1 7 Linear Speed Acceleration Percent Speed 100 a Start Run Stop Time seconds Kickstart is also available with Linear Speed Acceleration vais iB Linear Stop is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements The Linear Stop does not need to be set up even if the linear start has been programmed The Linear Stop can not brake the motor load and reduce the stopping time Product Overview 1 7 Soft Stop This option can be used in applications that require an extended coast to rest Th
72. igure 3 18 Typical Wiring Diagram for Hand Off Auto DPI Control with no Stopping Control Li 1 T1 2 3 Phase 2 3 T2 4 Input Power L35 qp Branch SMC Flex Controller Protection LJ Q 12 13 T 11 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 81 32 33 34 AY Ground s P p Fault Contact Contact orma Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage 3 20 Wiring 3 Phase Input Power Figure 3 19 Typical Wiring Diagram for Hand Off Auto PLC Control with Stopping Control L1 1 T2 4 LL L2 3 rr L3 5 3 6 Mul Branch Protection LoJ I EE D SMC Flex Controller SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass BIG Ee Ts Ts TTs T Fault Alarm gt Contact Contact orma V Input Input Ground Fault Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage Wiring 3 21 Soft Stop Pump Control and SMB Smart Motor Br
73. ing Wire in an industrial control application can be divided into three groups power control and signal The following recommendations for physical separation between these groups is provided to reduce the coupling effect Different wire groups should cross at 90 inside an enclosure e Minimum spacing between different wire groups in the same tray should be 16 cm 6 in e Wire runs outside an enclosure should be run in conduit or have shielding armor with equivalent attenuation e Different wire groups should be run in separate conduits Minimum spacing between conduits containing different wire groups should be 8 cm 3 in e For additional guidelines please refer to Wiring and Ground guidelines publication DRIVES INO001 A EN P Additional Requirements e If linear acceleration is used a separate conduit or wire way should be used for the tachometer leads e Wire earth ground to control terminal 14 e Use shielded wire for PTC Tachometer and ground fault input e Terminate shielded wires to terminal 14 Ground fault CT must be inside or within m of metal enclosure To meet product susceptibility requirements ferrite cores need to be added to the communication lines When using an external HIM or DPI interface a core should be added to the HIM cable near the SMC Flex control module The recommended core is Fair Rite no 0431167281 or equivalent When using a DeviceNet circuit two cores need to be add
74. ion Programming Many of the protective features available with the SMC Flex controller can be enabled and adjusted through the programming parameters provided For further details on programming refer to the Motor Protection section in Chapter 4 Programming The SMC Flex controller comes equipped with a built in three line 16 character LCD The LCD displays the unit has faulted on the first line the fault number on the second line and the fault code on the third line Figure 9 1 Fault Display Faulted Fault 1 Line Loss A Note The fault display will remain active as long as control power is applied If control power is cycled the fault will be cleared the controller will re initialize and the display will show a status of Stopped Note You can hit Esc to get to another programming diagnostic list but the SMC Flex will still be in a faulted state Important Resetting a fault will not correct the cause of the fault condition Corrective action must be taken before resetting the fault 9 2 Clear Fault Fault Buffer Diagnostics You can clear a fault using any of several methods e Program the SMC Flex controller for a Clear Fault which can be found in Main Menu Diagnostics Faults e Ifa human interface module is connected to the controller press the Stop button Note stop signal from HIM will always stop the motor and clear the fault regardless of Logic Mask e Cycle control power to the SMC
75. is parameter rotor torque Current Limit Level The current limit level that is applied for the Ramp Time selected 50 600 FLC Kickstart Time 0 0 2 0 S A boost current is provided to the motor for the programmed time period Kickstart Level 0 90 of locked Adjusts the amount of current applied to the motor during kickstart rotor torque Option 2 Input Disable Preset SS Allows the user to select a Dual Ramp or Preset Slow Speed SS Dual Ramp Stop Mode Disable Soft Stop Allows the user to program the SMC Flex controller for the type of stopping that best fits the application Linear Speed Stop Time 0 0 120s This sets the time period which the controller will ramp the voltage during a stopping maneuver Aux1 Config Normal Up to N O contact is provided as standard with the SMC Flex controller This contact is located at terminals 19 and 20 Aux speed External Contacts 1 allows the user to configure the operation of the contacts Bypass Fault Contact N O N C A fault auxiliary contact is provided between terminals 29 and 30 Fault Contact allows the user to program the operation of the contact for a fault condition Alarm Contact N O N C An alarm contact is provided between terminals 31 and 32 Alarm contact allows the user to program the operation of the contact for an Alarm condition Aux2 Config N O N C This parameter provides the user with the ability to program the Normal
76. is product is tested to meet Council Directive 73 23 EEC Low Voltage per EN TEC 60947 4 2 This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection Notes Bulletin 150 SMC Flex Table of Contents Chapter 1 Other Related Documents 2 1 1 Product Overview 6566 1 1 1 2 Modes of Operation Standard 1 2 DOM LAME e sth 1 2 Selectable Kickstart 2 2 2 1 3 Current Limit Start esses 1 3 Dual Ramp Start ssssssseseeeeenennnnnnnnnes 1 4 Full Voltage Start essent 1 4 Preset Slow Speed 1 5 Linear Speed Acceleration 1 6 QUOD 1 7 Control e ers 1 8 Modes of Operation Pump 1 8 Pump Control Option 1 8 Modes of Operation Braking 1 1 9 SMB Smart Motor Braking Option 1 9 5 O
77. isconnect 5 30 A J 610 24 406 16 229 9 25 30 A J 610 24 406 16 229 9 43 60 A J 610 24 406 16 229 9 60 100 A J 610 24 406 16 229 9 85 100 A J 610 24 406 16 229 9 108 200 A J 965 38 762 30 356 14 135 200 A J 965 38 762 30 356 14 201 400 A J 965 38 762 30 356 14 251 400 A J 965 38 762 30 356 14 317 600 A J 1524 60 965 38 356 14 361 600 A J 1524 60 965 38 356 14 480 600 A J 1524 60 965 38 356 14 480 800 A J 2286 90 508 20 508 20 Combination Controllers with Circuit Breaker 5 15A 610 24 406 16 229 9 25 30A 610 24 406 16 229 9 43 80A 610 24 406 16 229 9 60 100A 610 24 406 16 229 9 85 125A 610 24 406 16 229 9 108 175 A 175 A Plug 965 38 762 30 356 14 135 225 N 225 A Plug 965 38 762 30 356 14 201 300 A 300 A Plug 965 38 762 30 356 14 251 400 A 400 A Plug 965 38 762 30 356 14 317 600 A 600 A Plug 1295 51 914 36 356 14 361 600 A 600 A Plug 1295 51 914 36 356 14 480 800 A 800 A Plug 1295 51 914 36 356 14 Usethis row for 460V 58 and 575V 59 this row for 460V 59 and 575V 60 and 61 Enclosed Type Delta Connected Controllers Controller IP65 Type 4 12 Rating A B Height A Width Depth Non Combination Controller 610 24 Notes Specifications Appendix B Parameter Information Table B 1 Parameter List
78. itions as obstructed cooling and high ambient temperatures Product Overview 1 17 The following table defines the SMC Flex PTC thermistor input and response ratings Table 1 4 Input Ratings Response resistance 3400 Q 1500 Reset resistance 1600 Q 100 Q Short circuit Trip Resistance 250 100 Maximum Voltage at PTC Terminals 4kQ lt T 5N Maximum Voltage at PTC Terminals open 30V Maximum Number of Sensors 6 Maximum Cold Resistance of PTC Sensor Chain 1500 Q Response Time 800 ms The following figure illustrates the required PTC sensor characteristics per IEC 34 11 2 Figure 1 18 PTC Sensor Characteristics per IEC 34 11 2 4000 1330 y 550 250 a 100 20 10 20 C 0 C PTC Trip TNF 20K TNF 15K TNF 5K TNF 5K TNF The SMC Flex will trip with a PTC indication if e other fault currently exists e protection is enabled e The resistance across terminals 23 and 24 is either greater than the relay s response resistance or less than the short circuit trip resistance Excessive Starts Hour The SMC Flex controller allows the user to program the allowed number of starts per hour up to 99 This helps eliminate motor stress caused by repeated starting over a short time period 1 18 Product Overview Overtemperature The SMC Flex controller monitors the tempe
79. ke you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage 1055 Attention statements help you to e identify a hazard e avoid a hazard e recognize the consequences IMPORTANT Identifies information that is critical for successful application and understanding of the product Trademark List Accu Stop Allen Bradley Remote 1 0 RSNetworx PLC PowerFlex SLC SMC SMC 2 SMC Flex SMC PLUS SMC Dialog Plus SMB and STC are trademarks of Rockwell Automation ControlNet is a trademark of ControlNet International Ltd DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association ODVA Ethernet is a registered trademark of Digital Equipment Corporation Intel and Xerox Corporation Modbus is a trademark or registered trademark of Schneider Automation Inc Profibus is a registered trademark of Profibus International European Communities EC If this product has the CE mark it is approved for installation within the Directive Compliance European Union and EEA regions It has been designed and tested to meet the following directives EMC Directive This product is tested to meet the Council Directive 89 336 EC Electromagnetic Compatibility EMC per EN IEC 60947 4 2 This product is intended for use in an industrial environment Low Voltage Directive Th
80. l Phase reversal is indicated when the incoming power to the SMC Flex controller is in any sequence other than ABC This pre start protective feature can be disabled Coms Loss The SMC Flex controller disables control through the DPI communication port as the factory default To enable control the Logic Mask found in the Communication programming group must be set to 4 If a Bulletin 20 HIM LCD Human interface module is disconnected from the SMC Flex controller when control is enabled a Comm Fault will occur Network Network faults are faults generated on the network external to the SMC Flex and are annunciated on the LCD display Ground Fault Ground faults are based on feedback from the user supplied 825 CT detecting ground fault currents Ground fault parameters of level and time delay must be programmed for proper operation Excess Starts Hour Excess starts hour is displayed when the number of starts in a one hour period exceeds the value programmed Power Loss Power loss indicates that an input power phase is not present The controller s LCD display will identify the missing phase If all three phases are absent when a start command is issued the LCD will display Starting without motor rotation Line Loss F41 F42 F43 During expected SCR gate periods the power pole voltage and currents are monitored If the SCR conduction is discontinuous a fault is indicated Phase loss ove
81. l Option 100 Motor Speed Pump Start Run Pump Stop Time seconds Kickstart is also available with Pump Control Pump stopping is not intended to be used as an emergency stop Refer to the applicable standard for emergency stop requirements viuis iN Pump stopping may cause motor heating depending on the mechanical dynamics of the pumping system Therefore select the lowest stopping time setting that will satisfactorily stop the pump Product Overview 1 9 Modes of Operation SMB Smart Motor Braking Option Braking Control This option can be used in applications that require reduced stopping times The SMC Flex controller incorporates a microprocessor based system that applies braking current to a motor without any additional equipment This option offers a user adjustable braking current setting from 0 to 400 of the motor s full load current rating Further it provides automatic shut off at zero speed detection Figure 1 10 SMB Smart Motor Braking Option 100 Motor Speed Note Smart Motor Braking Start Brake Automatic Zero Speed Time seconds Shut off All braking current settings in the range of 1 100 will provide 100 braking current to the motor Waseem SMB Smart Motor Braking is not intended to be used as an emergency stop Refer to applicable standards for emergency stop requirements
82. lied to Motor 0 Power not Applied to Motor Phasing 1 ABC Phasing 0 CBA Phasing Phasing 1 3 phase is valid Active 0 No valid 3 phase detected Starting 1 Performing a Start Maneuver Accel 0 Not Performing a Start Maneuver Stopping 1 Performing a Stop Maneuver Decel 0 Not Performing a Stop Maneuver Alarm 1 Alarm Present 0 No Alarm Present X Fault 1 Fault Condition Exists 0 No Fault Condition X At Speed 1 Full Voltage Applied 0 Not Full Voltage Applied X Start 1 Start Isolation Contactor Enabled Isolation 0 Start Isolation Contactor Disabled X Bypass 1 Bypass Contactor Enabled 0 Bypass Contactor Disabled X Ready 1 Ready 0 Not Ready Bits 12 15 Not Used Table 8 H Logic Command Word Control Bit Status Description 15 14 13 12 11 10 9 8 7 Stop 1 Stop Inhibit 0 No Action Start 1 Start 0 No Action Option 1 1 Stop Maneuver Inhibit Input 0 No Action Clear 1 Clear Faults Faults 0 No Action Option 2 1 Perform Option 2 function Input 0 No Action Bits 5 15 Not Used Reference Feedback Parameter Information Scale Factors for PLC Communication Display Text Unit Equivalents Configuring DataLinks Communications 8 9 The SMC Flex does not offer the analog Reference feature The analog Feedback feature is support
83. ling a Cat No 825 CBCT core balance current transformer for 1 5A core balanced ground fault protection with the option of enabling Ground Fault Trip Ground Fault Alarm or both Figure 1 17 ben on n TI 2 3 Phose Cr L3 5 73 6 Input SMC F lex Power Controller w E A BLACK WHITE SHIELD 11 112 13 14415 175118 SMC Flex Control Terminals 3 SHIELD 23 24 25 26 27 28 29 3031 32 33 34 BLACK WHITE Customer supplied Q No 825 CBCT Ground Fault Trip The SMC Flex will trip with a ground fault indication if e No other fault currently exists e Ground fault protection is enabled e GF Inhibit Time has expired e Current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay 1 16 Product Overview Parameter 75 Gnd Fit Inh Time allows the installer to inhibit a ground fault trip from occurring during the motor starting sequence and is adjustable from 0 250 seconds Parameter 74 Gnd Fit Delay allows the installer to define the time period a ground fault condition must be present before a trip occurs It is adjustable from 0 1 25 seconds Parameter 73 Gnd Fit Level allows the installer to define the ground fault current at w
84. lled position stopping During stopping braking torque is applied to the motor until it reaches preset slow speed 7 or 15 of rated speed and holds the motor at this speed until a stop command is given Braking torque is then applied until the motor reaches zero speed Braking current is programmable from 0 450 of full load current Slow Speed with Braking Used on applications that require slow speed in the forward direction for positioning or alignment and also require braking control to stop A 2 Specifications Wiring Diagram Electrical Ratings Figure A 1 Wiring Diagram Loan 3Phase t 123 T24 Input Power 135 T36 9 Controller mE EE Branch Protection 90 Opioniput i Opionipui2 7 18 19 20 21 22 Aux 1 23 24 25 26 27 28 ine PTC Ground Input Fault Customer supplied Power Circuit Rated Operation Voltage Normal Up to Speed Extemal Bypass E Intemal Auxillary 29 30 31 32 3B 4 Coni TETIT Fault Aux 2 Contact Contact Normal UL CSA NEMA IEC 200 480V AC 200 415V 200 600V AC
85. load protection it is critical that the data be entered as it appears on the motor nameplate In the Program mode enter the correct values into the Overload group Parameter Option Display Overload Class Disable 10 FG P The factory default setting disables 15 20 30 Overload Class overload protection To enable it enter the desired trip class in this parameter Service Factor oo 0 01 1 99 PAS Enter the value from the motor s Service Factor RE nameplate Motor FLC 000 1 0 1000 A Fg 46 Enter the value from the motor s Motor ETT DE Amos nameplate Overload Reset o Manual Auto PEAT Allows the user to select either a manual Overload Reset or auto reset after an overload fault Motor Connection Line Delta FaH PERS Enter the type of motor being connected ei Connection to the SMC Flex Line Delta Line Voltage 22 1 10 000V Pada Enter the system voltage in this Line Voltage i EET vot parameter This must be done to ensure optimum motor performance and correct operation of undervoltage and overvoltage protection Refer to the SMC Flex controller nameplate for maximum ratings Exceeding these could result in damage to the controller Found in Overload programming group Only one location needs to be programmed Found in Basic Set Up programming group Chapter 6
86. ls XI X Ej Terminal Number 23 24 25 26 27 28 29 30 31 32 33 34 Description PTC Input PTC Input Tach Input Tach Input Ground Fault Transformer Input Ground Fault Transformer Input Fault Contact N 0 N C Fault Contact N 0 N C Alarm Contact N O N C Alarm Contact N O N C Aux Contact 2 Normal 0 Aux Contact 2 Normal N 0 N C RCSnubbers are required on loads connected to auxiliary Donotconnect 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 relay once the motor reaches full speed The SMC FLEX overload functionality diagnostics and metering are disabled when the external bypass is activated Proper sizing of the contactor and overload is required 3 8 Wiring Standard Controller Wiring Figure 3 7 through Figure 3 18 show typical wiring for the SMC Flex Diagrams controller Figure 3 7 Typical Wiring Diagram for Standard Controller 3 Phase Input Power Branch Protection SMC Flex Controller PIETER ICICI SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass ee eee 83 PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Refer to the controller name
87. mmence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button is not active for Preset Slow Speed Slow Speed cannot be operated via the HIM 7 2 Optional HIM Operation Option Pump Control Action Operation Pump Control Braking Control The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button when pressed will initiate a pump stop maneuver Smart Motor Braking The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button when pressed will initiate a brake stop Accu Stop The green start button when pressed will commence motor acceleration to full speed The red stop button when pressed will provide a coast stop and or reset a fault With a stopped status the jog button when pressed will initiate slow speed motor operation From an at speed condition the jog button when pressed will initiate braking to slow speed operation The controller will maintain slow speed operation as long as the jog button is pressed Slow Speed with Braking The green start button when pressed will commence motor accele
88. n installing or inspecting the protective module make sure that the controller has been disconnected from the power source The protective module should be inspected periodically for damage or discoloration Replace if necessary Thermal motor overload protection is provided as standard with the SMC Flex controller If the overload trip class is less than the acceleration time of the motor nuisance tripping may occur viuis HB Overload protection should be properly coordinated with the motor Two applications require special consideration two speed motors and multi motor protection Two speed Motors The SMC Flex controller has overload protection available for single speed motors When the SMC Flex controller is applied to a two speed motor the Overload Class parameter must be programmed to OFF and separate overload relays must be provided for each speed Multi motor Protection If the SMC Flex controller is controlling more than one motor individual overload protection is required for each motor 2 10 Installation Electromagnetic Compatibility EMC This product has been designed for Class A equipment Use of the product in domestic environments may cause radio interference in which case the installer may need to employ additional mitigation methods The following guidelines are provided for EMC installation compliance Enclosure Install the product in a grounded metal enclosure Wir
89. nabled 44 Two HIMs on ports 2 and 3 and the DPI communication card on port 5 is enabled The Logic Mask parameter Parameter 87 allows the user to configure whether a communication device HIM or network connection can perform control commands such as starting Each communication port can be enabled or disabled as required When a given device is enabled through the logic mask that device is allowed to execute control commands In addition disconnecting any device with the logic mask enabled will result in a communication fault unless the communication fault is disabled When a given device is disabled through the logic mask that device cannot execute control commands but can still be used for monitoring A device that is disabled through the logic mask can be disconnected without causing a fault I d hi YN Stop commands override all start commands and can be initiated from the hardwired inputs or any port regardless of the logic mask The loss of communication fault will follow the functionality as defined in the DPI specification There will be separate faults for each device Since three DPI ports are supported there will be three faults that can be generated DPI provides a separate network fault for each port This fault can be generated directly by the peripheral and is separate from the Communications Loss fault which is actually generated by the SMC Flex itself The SMC is can be used with all LCD applicable DPI interf
90. ncelling effect Also mount the coils on insulated supports away from metal parts so they will not act as induction heaters If an isolation contactor is used put capacitors in front of contactor Note For further instructions consult the PFC capacitor vendor Figure 2 1 Typical Wiring Diagram for Power Factor Correction Capacitors un me 3 Phase us Input Power L3 5 T3 6 KO ll an an a cc Branch KO SMC Flex Protection Controller Paes Customer Supplied Overload protection is included as a PONE Factor standard feature of the SMC Flex controller Correction Capacitors Figure 2 5 Typical Wiring Diagram for Power Factor Correction Capacitors and Contactor T1 2 3 Phase L2 3 T2 4 Input Power L3 5 T3 6 Branch SMC Flex Protection Controller Customer Supplied Overload protection is included as a FoweriFactor standard feature of the SMC Flex controller Correction Capacitors Energize 1 2 second before start command to SMC Protective Modules Motor Overload Protection Installation 2 9 Protective modules containing metal oxide varistors MOVs can be installed on controllers rated 5 480 A to protect the power components from electrical transients The protective modules clip voltage transients generated on the lines to prevent such surges from damaging the SCRs Wada ila Whe
91. ng Accu Stop and Slow Speed with Braking control options 2 The elapsed time and kWH values are automatically saved to memory every 12 hours 3 Motor thermal capacity usage is determined by the built in electronic thermal overload An overload fault occurs when this value reaches 100 A serial interface port DPI is provided as standard which allows connection to the Bulletin 20 HIM LCD interface modules Figure 1 19 DPI Location DPI NN Caida E Two peripheral devices can be connected to the DPI The maximum output current through the DPI is 280 mA 1 20 Product Overview Programming Port 5 DPI Communications Port 2 Ports 2 and 3 when two HIMs are connected with a splitter Status Indication Setup is easy with the built in keypad and three line sixteen character backlit LCD Parameters are organized in a three level menu structure using a text format for straightforward programming Figure 1 20 Built in Keypad and LCD Four programmable hard contact outputs are provided as standard e The Auxiliary 1 Contact is N O programmable for Normal Up to speed External Bypass fault Contact is for fault indication and is programmable for N OJN C alarm Contact is for alarm indication and is programmable for N O N C The Auxiliary 2 Contact is for normal indication and is programmable for N O N C Figure 1 21 Control Terminals ERS Ts TTsTeTe Te A
92. nput Power Branch Protection SMC Flex Controller Dac ESE Ts Te Te SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass Le ae 92 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 voltage Fault Contact should be set to N O 3 16 Wiring Figure 3 15 Typical Wiring Diagram for Single Speed Reversing Applications F SF A 6 1 1 Lut 1 2 3 Phase 12 3 T2 4 Input Power 13 5 T3 6 D pa a ae Pe Branch R SMC Flex Protection Controller e R A AH SMC Flex Aux 1 Control Terminals Normal Up to Speed Bypass 23 a a5 2 27 28 29 30 31 32 33 34 a eee dee 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 No braking manuever allowed in wiring diagram Notes 1 Minimum transition time for reversing direction is 1 2 second 2 Phase Reversal protection must be disabled in reversing applications Wiring 3 17
93. ntroller offers a full range of starting modes as 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 Speed e Linear Speed Acceleration with Selectable Kickstart requires Tach feedback e Soft Stop Other features that offer further user benefit include e Expanded protective features Metering e Communication capability Innovative starting and stopping options provide enhanced performance e Pump Control e Braking Control e Smart Motor Braking SMB ccu Stop M e Slow Speed with Braking These modes features and options are further described in this chapter Latest revision 1 2 Product Overview Operation Modes of Operation Standard The SMC Flex controller can operate three phase squirrel cage motors rated 1 480 A or wye delta motors rated 1 8 831 A 200 480V AC or 200 600V AC 50 60 Hz Depending upon the catalog number ordered the controller will accept a control power input of either 100 240V AC or 24V AC DC If the control power input option is 100 240V AC the controller s microprocessor will self adjust to the input control voltage Note that the motor FLA must fall within the range of the SMC Flex as specified in the selection guide for proper operation Soft Start This mode has the most general application The motor is given an initial torque set
94. oltage e Failed control module Replace control module Starting e Twoor three power Check power system phases are missing Table 10 C Motor Rotates but does not accelerate to full speed Display Possible Cause Possible Solutions Fault displayed e See fault description See Table 10 A addressing fault conditions Starting e Mechanical problems Check for binding or Inadequate Current Limit setting Failed control module Table 10 D Motor Stops While Running Display Fault displayed Possible Cause See fault description external loading and correct Check motor Adjust the Current Limit Level to a higher setting Replace control module Possible Solutions See Table 10 A addressing fault conditions Display is blank Control voltage is absent Failed control module Check control wiring and correct if necessary Replace control module Stopped e Pilot devices Check control wiring and 0 0 Amps correct if necessary e Failed control module Replace control module Starting e Twoor three power Check power system phases are missing Failed control module Replace control module Table 10 E Miscellaneous Situations Situation Motor current and voltage fluctuates with steady load Possible Cause e Motor e Erratic Load Troubleshooting 10 5 Possible Solutions Verify type of motor as a standard squirrel cage induction motor Check load conditions Erratic o
95. oncondensing e Do not store equipment where it could be exposed to a corrosive atmosphere e Do not store equipment in a construction area 2 2 Installation General Precautions Heat Dissipation In addition to the precautions listed throughout this manual the following statements which are general to the system must be read and understood id Gem The controller contains ESD electrostatic A ATTENTION A ATTENTION Ab ATTENTION A discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing the assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures refer to applicable ESD protection handbooks An incorrectly applied or installed controller can damage components or reduce product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system Only personnel familiar with the controller and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to do this may result in personal injury and or equipment damage Hazardous voltages that can cause shock burn or death are present on L1 L2 L3 T1 T2 T3 T4 T5 and T6 Power terminal covers can be installe
96. ontacts are monitored for proper operation In the event that a contact closure is not sensed the SMC Flex will indicate an Open Bypass fault No Load The SMC Flex can determine if a load connection has been lost and No Load fault will be indicated Line Unbalance Voltage unbalance is detected by monitoring the three phase supply voltages The formula used to calculate the percentage voltage unbalance is as follows V 100 Va Va Vu Percent voltage unbalance V4 Maximum voltage deviation from the average voltage V4 Average voltage The controller will shut down when the calculated voltage unbalance reaches the user programmed trip percentages Overvoltage and Undervoltage Protection Overvoltage and undervoltage protection are user defined as a percentage of the programmed line voltage The SMC Flex controller continuously monitors the three supply phases The calculated average is then compared to the programmed trip level Underload Underload protection is available for undercurrent monitoring The controller will shut down when the motor current drops below the trip level This trip level a percentage of the motor s full load current rating can be programmed Overload Protection Overload protection is enabled in the Motor Protection group by programming the e Overload class Overload reset Motor FLC Service factor Refer to Chapter 5 for more information on Motor Protection Phase Reversa
97. ontroller interfacing in this diagram refers to hard wiring between the PLC s output contacts and the SMC Flex controller s control terminals 2 The OFF state leakage current for a solid state device must be less than 6 mA Notes 1 Wiring 3 11 Figure 3 10 Typical Wiring Diagram for Dual Ramp Applications 3 Phase Input Power Branch Protection SMC Flex Controller Jm CEES SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass amp Te Ts T PTC TACH Ground Input Input Fault Aux 2 Normal Fault Alarm Contact Contact Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage Note The Dual Ramp feature is available only with the standard control version 3 12 Wiring Figure 3 11 Typical Wiring Diagram for Start Stop Control via DPI Communications Note Use this wiring diagram when start stop will come from either a Bulletin 20 HIM LCD interface module or a Bulletin 20 COMM communication module connected to the SMC Flex Note Logic mask must be properly configured see Chapter 8 3 Phase T2 4 L3 5 13 6 E Input Power D Branch Protection SMC Flex Controller SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass m PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Customer supplied Q Refer to the con
98. ontroller with a name that includes the letters SLC See Programmable Controller Glossary IV Status Surge Protection Toggle Transient UL The condition at a particular time of any numerous entities within a system These conditions may be represented by values in a status line The process of absorbing and clipping voltage transients on an incoming AC line or control circuit MOVs Metal Oxide Varistors and specially designed R C networks are usually used to accomplish this To switch alternately between two possible selections A momentary deviation in an electrical or mechanical system Underwriters Laboratories a third party safety certification agency www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions 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 SA NV Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Ame
99. peration e Loose Shut off all power to controller and connections check for loose connections Accelerates too fast Starting time Increase starting time e initial torque Lower initial torque setting e Current limit Decrease current limit setting setting e Kickstart Lower kickstart time or turn off Accelerates too e Starting time Decrease starting time slow e Initial torque Increase initial torque setting e Current limit Increase current limit setting setting e Kickstart Increase kickstart time or turn off Fan does not e Wiring Check wiring and correct if operate necessary Failed fan s Replace fan module Motor stops too e Time setting Verify the programmed stopping quickly with time and correct if necessary Soft Stop option Motor stops too e Stopping time Verify the programmed stopping slowly with setting time and correct if necessary Soft Stop option e Misapplication The Soft Stop option is intended to extend the stopping time for loads that stop suddenly when power is removed from the motor Fluid surges with pumps still occur with the Soft Stop option Misapplication Soft Stop ramps voltage down over a set period of time In the case of pumps the voltage may drop too rapidly to prevent surges A closed loop system such as Pump Control would be more appropriately suited Refer to Publication 150 911 Motor overheats e Duty cycle Preset Slow Speed and Accu Stop options Extended operation at slow speeds redu
100. plate to verify the rating of the control power input voltage Wiring 3 9 Figure 3 8 Typical Wiring Diagram for Two Wire Control with No Stopping Control No DPI 2 3 Phase um we Input Power us m SMC Flex Controller Branch Protection Two Wire TISDSTSTSIS TS Te Te SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass PPP PP PPP Te Ts Ts PTC TACH Ground Fault Alarm Input Input Fault Contact Contact Aux 2 Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage Notes 1 Programmable controller interfacing in this diagram refers to hard wiring between the PLC s output contacts and the SMC Flex controller s control terminals 2 OFF state leakage current for a solid state device must be less than 6 mA 3 10 Wiring Figure 3 9 Typical Wiring Diagram for Two Wire Control with Stopping Control No DPI E 3 Phase ra Input Power SMC Flex Controller Branch Protection Two Wire Device of TT TS TST8 Te Te SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass PPP eT Ts s s Ts PTC TACH Ground Fault Alarm Input Input Fault Contact Contact Aux 2 Normal Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage Programmable c
101. ption seeseseeeeeenrnnnn nnn 1 10 Slow Speed with Braking Option 1 10 Protection and Diagnostics seeeeennnnnne 1 11 0 n 1 11 Winder lad eti e 1 11 Urdervoltage 3 niit e iced inis 1 13 Overvoltage 1 13 EIE 1 13 Stall Protection and Jam Detection 1 14 Ground Fault e cete timeri 1 15 Thermistor PTC Protection 1 16 Excessive Starts Hour essere 1 17 OvertemperatUre 1 18 Open Gate 1 18 NICE 1 18 ring 1 19 Communication eeeeseeeeeeeeennnnn nnns 1 19 Programing 1 20 Status Indicatioli i 2 rentre erinnere rire 1 20 Bulletin 150 SMC Flex Chapter 2 Installation Chapter 3 Wiring RECEIVING te 2 1 Uripackifig dite i 2 1 lune 2 1 iji E 2 1 General Precautions 2 2 Heat Dissipation 2 2 EfIClOSU BS esce aident tania
102. ption maneuver for example Pump Stop Wars iB The Bulletin 20 HIM interface module s stop PERETTI The Bulletin 20 HIM interface module s stop push button is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements viuis IBN The external HIM has a similar programming operation to the built in programmer but note that differences do exist All other controls available with the various human interface modules are non functional with the SMC Flex controller Communications Port 5 DPI Communications Port 2 Ports 2 and 3 when two HIMs are connected with a splitter Connecting the Human Interface Module to the Controller Figure 8 1 shows the connection of the SMC Flex controller to a human interface module Table 8 C provides a description of each port See Figure 3 11 on page 3 12 for the control wiring diagram that enables start stop control from a human interface module Figure 8 1 SMC Flex Controller with Human Interface Module Table8 C Description of Ports Port Description 1 Unused not available for use 2 First 20 HIM connected to SMC Flex 3 Second 20 HIM connected to SMC Flex 5 DPI Communication Board port HIM Control Enable To enable motor control from a connected human interface module follow the procedure below with the connected human interface module s programming keys The Bulletin 20 HIM LCD human inte
103. r HEH KW F Gi P 8 Kilowatt Hours iH KWH 9 Elapsed Time Hour 10 Meter Reset No F Gig P 11 Power Factor HHH 12 Mtr Therm Usage MTU Overview Human Interface Module Chapter Optional HIM Operation The SMC Flex controller offers a variety of unique control options that provide enhanced motor starting and stopping capabilities See chapter 1 for brief descriptions of each option Note Only one option can reside in a controller The control buttons available with the Bulletin 20 HIM LCD Human interface modules are compatible with the SMC Flex controller s control options The following table details the functionality of each button with regards to each option Notes 1 The logic mask port must be enabled prior to initiating control commands to the SMC Flex controller Refer to HIM Control Enable on page 8 4 for instructions 2 The control terminals must be wired according to Figure 3 11 on page 3 12 or Figure 3 18 on page 3 19 Option Action Operation Standard Soft Stop The green start button when pressed will Current Limit Ge commence motor acceleration to full speed Full Voltage Linear Speed The red stop button when pressed will provide a coast stop and or reset a fault The jog button when pressed will initiate the Jog programmed maneuver Preset Slow The green start button when pressed will Speed co
104. ration to full speed The red stop button when pressed will The jog button will initiate a brake stop Slow Speed cannot be operated via the HIM Oo provide a coast stop and or reset a fault ATTENTION The Bulletin 20 HIM LCD Human interface module s stop push button is not intended to be used as an emergency stop Refer to applicable standards for emergency stop requirements Overview Communication Ports Human Interface Module Chapter 8 Communications The SMC Flex provides advanced communications capabilities that allow it to be started and stopped from multiple sources as well as provide diagnostic information through the use of communication interfaces The SMC Flex uses the DPI method of communication therefore all standard DPI communication interfaces used by other devices i e PowerFlex Drives can be used in the SMC Flex Standard DPI communications cards are available for various protocols including DeviceNet ControlNet Remote I O ModBus and Profibus DP Other modules may be available in the future For specific programming examples configuration or programming information refer to the user manual for the communication interface being used A list of available interfaces is located below Table 8 A Protocol Type Cat No User Manual DeviceNet 20 COMM D 20COMM UM0020 EN P ControlNet 20 COMM C 20COMM UM0030 EN P Remote 1 0 20 COMM R 20COMM UM0040 EN P
105. rature of the SCRs and Bypass by using internal thermistors When the power poles maximum rated temperature is reached the unit will shut down and restart is inhibited An overtemperature condition can indicate inadequate ventilation high ambient temperature overloading or excessive cycling After the temperature is reduced to allowable levels the fault can be cleared Open Gate An open gate fault indicates that improper SCR firing typically caused by an open SCR gate has been detected on one of the power poles Before the controller shuts down it will attempt to start the motor a total of three times Line Faults The SMC Flex controller continually monitors line conditions for abnormal factors Pre start protection includes Line Fault with phase indication Line voltage loss Missing load connection Shorted SCR Running protection includes Line Fault no phase indication Line voltage loss Missing load connection Phase Reversal protection can be toggled either On or Off Phase Reversal protection is functional only at pre start Metering Communication Product Overview 1 19 Power monitoring parameters include e Three phase current e Three phase voltage e Power in kW e Power usage in e Power factor e Motor thermal capacity usage e Elapsed time Notes 1 Voltage measurement is not available during the braking operation of the SMB Smart Motor Braki
106. rface modules with control panels can start and stop the SMC FLEX controller However the factory default settings disable control commands other than Stop through the serial communication port To enable motor control from a connected human interface module or communication module you must take the following programming steps Communications 8 5 Series A 1 Disconnect the HIM and allow to power down 2 Reconnect the HIM On Initializing screen the bottom right cor ner of LCD shows Port X Note this port number 3 Go to Logic Mask found as follows Main Menu Parameter Communications Comm Mask Logic Mask 4 Set bOX equal to 1 where X is the port number noted in step 2 5 Goto Parameter Management and save as User Store Important The Logic Mask must be set to 0 prior to disconnecting a human interface module from the SMC FLEX controller If not the unit will fault on a Coms Loss If enabling control from the built in SMC Flex programmer the Logic Mask must be set as follows Table 8 D Logic Mask Requirements Mask Code Description 0 No external DPI devices are enabled 8 6 Communications Control Enable Loss of Communication and Network Faults SMC Flex Specific Information 4 Only one HIM on port 2 is enabled 12 Two HIMs are enabled on ports 2 and 3 32 Only the DPI communication cared on port 5 is enabled 36 One HIM on port 2 and the DPI communication card on port 5 in e
107. ricas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa Rockwell Automation Br hlstrafte 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 Publication 150 UMO008C EN P May 2004 PN 40055 218 01 3 Supersedes Publication 150 UM008B EN P January 2003 2004 Rockwell International Corporation Printed in the U S A
108. rol power input voltage Wiring 3 27 Slow Speed with Braking Figure 3 26 shows the wiring for the Slow Speed with Braking option Figure 3 26 Typical Wiring Diagram for the Slow Speed with Braking with an Isolation Contactor Control Power Q q 1 amp SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass PPP Pr er T WY 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 voltage Note Refer to Chapter 3 for typical power circuits 3 28 Wiring Sequence of Operation 100 Motor Speed Push Buttons Start Stop Soft Stop Auxiliary Contacts Normal Up to speed Closed Open Closed Open Closed Open Closed Open Closed Open Figure 3 27 through Figure 3 32 show the different operation sequences for the Soft Stop Preset Slow Speed Pump Control SMB Smart Motor Braking Accu Stop and Slow Speed with Braking options Figure 3 27 Soft Stop Sequence of Operation Coast to rest Soft Stop fx E Soft Stop Start Run Time seconds If Soft Stop Selected X If Coast to rest Selected vilis iil The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a pa
109. rovals Operational Non Operational Operational Non Operational Power Poles 5 85A 108 480 A 1 0 G Peak 0 15 mm 0 006 in displacement 2 5 G 0 38 mm 0 015 in displacement 5 5 G 25G Heatsink thyristor modular design Heatsink hockey puck thyristor modular design Control Modules Thermoset and Thermoplastic Moldings Metal Parts Power 5 85 A Terminals 108 251 A Plated Brass Copper or Painted Steel Cable size 2 5 85 mm 14 3 0 AWG Tightening torque 14 7 Nem 130 Ib in Wire strip length 18 20 mm 0 22 0 34 in Two M10 x 1 5 diameter holes per power pole 317 480 A Two M12 x 1 5 diameter holes per power pole Power Terminal Markings NEMA CENELEC EN50 012 Control Terminals M 3 screw clamp clamping yoke connection Conducted Radio Frequency Class A Emissions Radiated Emissions Class A Electrostatic Discharge 8 KV Air Discharge Radio Frequency Electromagnetic Field Fast Transient Surge Transient Current Range Trip Classes Trip Current Rating Number of Poles Open Type Controllers Per EN IEC 60947 4 2 Per EN IEC 60947 4 2 Per EN IEC 60947 4 2 Delta 5 1 7 9 25 8 6 43 43 14 8 75 60 20 8 104 85 29 4 147 108 94 187 135 117 234 201 174 348 251 218 435 317 275 549 361 313 625 480 415 831 10 15 20 and 30 117 of Motor FLC 3 CE Marked Per Low Voltage Directive 73 23 EEC 93 68 EEC U
110. rticular machine Wiring 3 29 Figure 3 28 Preset Slow Speed Sequence of Operation 100 a PER Coast to rest Motor Soft Stop Speed 4 7 or 1596 7 0N t Slow Speed be Start Run Coast Time seconds Push Buttons Start Closed Open I NE Closed Open oi Slow Speed Closed Open Auxiliary Contacts Normal Closed i Up to speed Closed 3 30 Wiring 100 Motor Speed Push Buttons Start Stop Pump Stop Auxiliary Contacts Normal Up to speed Closed Open Closed Open Closed Open Closed Open Closed Open Figure 3 29 Pump Control Sequence of Operation Coast to rest r Pump Start Run Pump Stop Time seconds If Pump Stop Selected A f Coast to rest Selected viis B The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine 100 Motor Speed Push Buttons Start Stop Smart Motor Braking Auxiliary Contacts Normal Up to speed Wiring 3 31 Figure 3 30 SMB Smart Motor Braking Sequence of Operation Smart Motor Braking
111. rvoltage and undervoltage protection are disabled during braking operation detection and underload protection are disabled during slow speed and braking operation Introduction Chapter 10 Troubleshooting For safety of maintenance personnel as well as others who might be exposed to electrical hazards associated with maintenance activities follow the local safety related work practices for example the NFPA 7OE Part II in the United States Maintenance personnel must be trained in the safety practices procedures and requirements that pertain to their respective job assignments ATTENTION A ATTENTION PIN Hazardous voltage is present in the motor circuit even when the SMC Flex controller is off To avoid shock hazard disconnect main power before working on the controller motor and control devices such as Start Stop push buttons Procedures that require parts of the equipment to be energized during troubleshooting testing etc must be performed by properly qualified personnel using appropriate local safety work practices and precautionary measures Disconnect the controller from the motor before measuring insulation resistance IR of the motor windings Voltages used for insulation resistance testing can cause SCR failure Do not make any measurements on the controller with an IR tester megger Note The time it takes for the motor to come up to speed may be more or less than the time programm
112. se the arrow keys to scroll through the digits Programming Menu Parameters are organized in a three level menu structure for straightforward programming Figure 4 1 details the programming menu structure and the three level hierarchy In order to change parameters the controller must be in the STOP mode and the control voltage must be present 4 2 Programming Figure 4 1 Menu Structure Hierarchy Power up and Status Display m T Select language being displayed OPERATION LEVEL Choose Mode A v MAIN MENU ce Q A v Device Memory Parameter Select lt gt Storage Preferences 4 Diagnostics Monitoring SMC FLEX Reset to Defaults Change Password Alarms Set Up Save to EEProm User Dspl Line Faults Motor Protection Recall EEProm User Dspl Time Device Revision Communications User Dspl Video Utility Reset User Display Linear Llst GROUP MENU Parameter menu continued in Figure 4 2 TheSMC Flex controller does not support EEPROM Link Process or Start up modes Steps back one level Programming 4 3 Figure 4 2 Parameter Menu Structure Parameter 9
113. ser Q The display will indicate that the second line is now active by highlighting the first character If the LCD display does not provide a highlighted cursor then the controller is in the Display mode Programming 4 9 Soft Start Current Limit Start The following parameters are specifically used to adjust the voltage ramp supplied to the motor Parameter Option Starting Mode Soft Start This must be programmed for Soft Start Ramp Time 0 30s This programs the time period that the controller will ramp the output voltage up to full voltage from the Initial Torque level programmed Initial Torque The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter 0 90 locked rotor torque Kickstart Time A boost of current is provided to the motor for the programmed time period Kickstart Level Adjusts the amount of current applied to the motor during the kickstart time 0 0 2 05 0 90 locked rotor torque If the controller senses that the motor has reached full speed before completing the Soft Start it will automatically switch to providing full voltage to the motor To apply a current limit start to the motor the following parameters are provided for user adjustment Parameter Starting Mode This must be programmed for Current Limit Ramp Time This programs the time period that the controller will hold the fixed r
114. serial link remote I O can be located long distances from the processor An standard that specifies electrical mechanical and functional characteristics for serial binary communication circuits in a point to point link An EIA standard that specifies electrical characteristics of balanced voltage digital interface circuits in a point to point link An EIA standard that specifies electrical characteristics of balanced voltage digital interface circuits in a multi point link The vertical movement of data on a display screen caused by the dropping of one line of displayed data for each new line added at the opposite end Pertaining to time sequential transmission of storage of or logic operations on data using the same facilities for successive parts When used on a motor nameplate a number which indicates how much above the nameplate rating a motor can be loaded without causing serious degradation i e a motor with 1 15 S F can produce 15 greater torque than one with 1 0 S F to adjust measured loads in an attempt to compensate for conditions which are difficult to measure or define A solid state switch sometimes referred to as a thyristor The SCR has an anode SCR cathode and control element called the gate The device provides controlled rectification since it can be turned on at will The SCR can rapidly switch large currents at high voltages They are small in size and low in weight An Allen Bradley programmable c
115. sessssessessesssseseessesessesatersers 4 9 Dual Ramp Start essere 4 10 Full Voltage Start i n iieri 4 11 Linear Speed cscceccsssscssesesssseseeseesessnseesesseeaesesseesessneneseeseeaess 4 11 Programming Parameters essere 4 12 Basic Set Up e tend 4 15 Motor Protection cccccssssssessssscsssscsssesssesssesesssseseesesaseeseess 4 16 Example Setlings 5 1 3 a endete 4 17 Undervoltage essen eren 4 17 OvervVoltage eee inerenti 4 17 WAIN 4 17 4 17 UTI 5 1 Motor Data Entry sess 5 1 VGIVIBW E N A dei satusesetsesdaatennace 6 1 Viewing Metering Data 6 1 VGIVIBW cs seas ettet ecards 7 1 Human Interface Module 7 1 Bulletin 150 SMC Flex Chapter 8 Communications Chapter 9 Diagnostics Chapter 10 Troubleshooting UTRUM 8 1 Communication Ports essen nnns 8 1 Human Interface Module 8 1 Keypad Description eese 8 2 Connecting the Human Interface Module to the Controller 8 3 HIM Control Enable eene 8 4 Control Enable
116. ter 12 Motor Thermal Usage an Overload Fault will occur when this value reaches 100 The programming parameters below provide application flexibility and easy setup Parameter Range Overload Class Off 10 15 20 30 Overload Reset Manual Auto Motor FLC 1 0 1000 A Service Factor 0 01 1 99 Notes 1 The factory default setting for Overload Class which is Off disables overload protection An overload trip class and the motor s full load current rating must be programmed to enable overload protection 2 Automatic reset of an overload fault requires the start input to be cycled in a 2 wire control scheme The trip rating is 117 of the programmed FLC Figure 1 13 and Figure 1 14 provide the overload trip curves for the available trip classes Underload Utilizing the underload protection of the SMC Flex controller motor operation can be halted if a sudden drop in current is sensed The SMC Flex controller provides an adjustable underload trip setting from 0 99 of the programmed motor full load current rating Trip delay time can be adjusted from 0 99 seconds Underload protection is disabled during slow speed and braking operations 1 12 Product Overview Figure 1 13 Overload Trip Curves Class 10 Class 15 Class 20 Class 30 1000 0 10000 0 10000 0 10000 0 100 0 1000 0 1000 0 1000 0 e 100 0 100 0 100 0 Approximate Trip Time seconds Approximate Trip Time se
117. ting which is user adjustable from 0 90 of locked rotor torque From the initial torque level the output voltage to the motor is steplessly increased during the acceleration ramp time The acceleration ramp time is user adjustable from 0 30 seconds If the SMC Flex controller senses that the motor has reached the up to speed condition during the voltage ramp operation the internal bypass contactor will be pulled in Figure 1 1 Soft Start Percent Voltage 100 Initial Torque Start Run Time seconds _ Kickstart is also available with Soft Start Product Overview 1 3 Selectable Kickstart This feature provides a boost at startup to break away loads that require a pulse of high torque to get started This is intended to provide a pulse of current that is selectable from 0 90 of locked rotor torque Selectable kickstart is user adjustable from 0 0 2 0 seconds Figure 1 2 Selectable Kickstart Percent Voltage 100 p Initial Torque Coast to rest Selectable Kickstart Soft Stop Soft Stop Current Limit Run Start Time seconds Start This starting mode provides a true current limit start it is used when limiting maximum starting current is necessary The Current Limit level is user adjustable from 50 600 of the motor full load ampere rating and the current limit time is user adjustable from 0
118. tion module Communications One DPI provided for connection to optional human interface and communication modules Starting Modes e Start Current Limit Start Dual Ramp Full Voltage Linear Speed Acceleration Preset Slow Speed Soft Stop Protection and Diagnostics Power loss line fault voltage unbalance excessive starts hour phase reversal undervoltage overvoltage controller temp stall jam open gate overload underload communication fault Metering A V KW KWH elapsed time power factor motor thermal capacity usage Alarm Contact Status Indication Auxiliary Contacts Optional Features Pump Control Overload underload undervoltage overvoltage unbalance jam stall and ground fault Stopped starting stopping at speed alarm and fault Contact programmable as normal up to speed external bypass one programmable for fault one programmable for alarm and one programmable for N O N C normal Helps reduce fluid surges in centrifugal pumping systems during starting and stopping period Starting time is adjustable from 0 30 seconds Stopping time is adjustable from 0 120 seconds Braking Control SMB Smart Motor Braking Provides motor braking without additional equipment for applications that require the motor to Stop quickly Braking current is adjustable from 0 400 of the motor s full load current rating Accu Stop Provides contro
119. troller nameplate to verify the rating of the control power input voltage Wiring 3 13 Figure 3 12 Typical Wiring Diagram for Retrofit Applications 3 Phase Input Power Existing Motor SMC Flex qp Branch Starter O Controller Protection EEC CCCI SMC Flex Control Terminals Aux 1 Normal Up to Speed Bypass aT TT TeTeTTe s Tes WY WY 2 Ground Fault Alarm Aux 2 4 Input Input Fault Contact Contact Normal Customer supplied Overload protection should be disabled in the SMC Flex controller Refer to the controller nameplate to verify the rating of the control power input voltage Aux 2 should be set for 3 14 Wiring Figure 3 13 Typical Wiring Diagram for Isolation Applications DPI also 3 Phase o3 T2 4 1 136 3 6 Input Power L pami Isolation Branch Protection Contactor SMC Flex IC Controller rol Jm PTSTSTSTSTe Te TT Te Te Te SMC Flex Aux 1 Control Terminals Normal Up to Speed Bypass aTsTsT TeTeTaTe s TTs Te WHY 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 voltage 2 should be set for N O Wiring 3 15 Figure 3 14 Typical Wiring Diagram for Shunt Trip Applications 3 Phase I
120. tt ne Nasheed 3 27 Figure 3 27 Soft Stop Sequence of Operation 3 28 Figure 3 28 Preset Slow Speed Sequence of Operation 3 29 Figure 3 29 Pump Control Sequence of Operation 3 30 Figure 3 30 SMB Smart Motor Braking Sequence of Operation aa E 3 31 Figure 3 31 Accu Stop Sequence of Operation 3 32 Figure 3 32 Slow Speed with Braking Sequence of Operation 3 33 Chapter 4 Figure 4 1 Menu Structure Hierarchy 4 2 Programming Figure 4 2 Parameter Menu Structure 4 3 Figure 4 3 Memory Block Diagram 4 6 vii Bulletin 150 SMC Flex Chapter 8 Figure 8 1 SMC Flex Controller with Human Interface Module 8 4 Communications Chapter 9 Figure 9 1 Fault Display ccscscscsecsssssesesscsesesesescscsesesescseeeees 9 1 Diagnostics Chapter 10 Figure 10 1 Troubleshooting Flowchart 10 2 Troubleshooting Appendix A Figure A 1 Wiring A 2 viii Other Related Documents Description Chapter 1 Product Overview e Quick Start Publication 150 QS001_ EN P e Renewal Part Instructions 41053 277 01 5 85 A 41053 228 01 108 480 A e Selection Guide Publication 150 SG008_ EN P e Application Guide Publication 150 AT002_ EN P The SMC Flex co
121. ue combination is determined by a hard contact input to terminal 15 When this input signal is low ramp time initial torque are selected When this input is high ramp time 2 initial torque 2 are selected Once the Option 2 Input has been set to Dual Ramp you must ESC back to the Parameter File menu Re enter into the Set Up menu to show both Basic Set Up and Dual Ramp Basic Set Up Start Mode This selects the start mode for option 1 Basic Set Up Ramp Time This programs the time period during which the controller will ramp the output voltage up to full voltage for the first Start setup 0 30 s Basic Set Up Initial Torque This parameter establishes and adjusts the initial reduced output voltage level for the first Soft Start setup 0 90 locked rotor torque Dual Ramp Start Mode 2 This selects the start mode for option 2 Dual Ramp Ramp Time 2 This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Start setup 0 30 s Dual Ramp Initial Torque 2 The initial reduced output voltage level for the second Start setup is established and adjusted with this parameter The Dual Ramp feaure is available on the standard controller Q Kickstart can be programmed for both start modes 0 90 locked rotor torque Full Voltage Start Linear Speed Programming 4 11 The SMC Flex controller may be programmed to provide a f
122. ull voltage start output voltage to the motor reaches full voltage within 1 4 second with the following programming Parameter Option Starting Mode Full Voltage This must be programmed for Full Voltage The SMC Flex provides the user the ability to control the motor speed during starting and stopping maneuvers A tach input is required as specified in Linear Speed Acceleration on page 1 6 Parameter Option Starting Mode Linear Speed This must be programmed for Linear Speed Ramp Time 0 30s This programs the time period that the controller will ramp from 0 speed to full speed Kickstart Time 0 0 2 2s A boost of current is provided to the motor for the programmed time period Kickstart Level 0 90 locked rotor Adjusts the amount of current applied to the motor torque during the kickstart time 4 12 Programming Programming Parameters The following table provides the option specific parameters that are provided with each control option These parameters are in addition to those already discussed in the Basic Set Up and Metering groups Diagrams supporting the options described below are shown later in this chapter Option Standard Soft Stop Preset Slow Speed Parameter SMC Option This parameter identifies the type of control present and is not user programmable Range Standard Soft Stop Time Allows the user to set the time period for the soft stopping function S
123. ux 1 SMC Flex Normal Up to Speed External Bypass Control Terminals PPE EPP b wo ye PTC TACH Ground Fault Alarm Aux 2 Input Input Fault Contact Contact Normal Figure 1 22 Receiving Unpacking Inspecting Storing Chapter 2 Installation It is the user s responsibility to thoroughly inspect the equipment before accepting the shipment from the freight company Check the item s received against the purchase order If any items are damaged it is the responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill Should any concealed damage be found during unpacking it is again the responsibility of the user to notify the freight agent The shipping container must be left intact and the freight agent should be requested to make a visual inspection of the equipment Remove all packing material wedges or braces from within and around the controller After unpacking check the item s nameplate catalog number against the purchase order The controller should remain in its shipping container prior to installation If the equipment is not to be used for a period of time it must be stored according to the following instructions in order to maintain warranty coverage e Store in a clean dry location e Store within an ambient temperature range of 20 C to 75 C 4 F to 167 F e Store within a relative humidity range of 0 to 95 n
124. ze heat generation during run time These contacts are pulled in sequentially in the 108 480 A units In the 5 85 A units these contacts are pulled in all at once The SMC Flex product also has a CT built in on each phase of the motor to provide current readings Wiring 3 3 Power Wiring The SMC Flex can be connected to a Line controlled motor as shown in Figure 3 3 Current ratings for the motor must be in the range of 1 A 480 A Figure 3 3 Line Power Wiring diagram 11 3 L2 5 3 XU dd XU 12 T6 8 74 10 75 271 472 6 73 OOM o NC nm The SMC Flex can be connected to a Wye Delta motor in an inside the Delta wiring configuration as shown in Figure 3 4 Current ratings for the motor must be in the range of 1 8 831 A 3 4 Wiring Figure 3 4 Delta Power Wiring diagram 1 L 3 L2 5 L3 zu VA YA a VA gt lt En C C 12 T6 2 T1 8 T4 4 T2 10 T5 6 T3 j gt Le e X AC 3 M N N AAR A Power lugs are available as optional kits Each kit contains three lugs The number of terminal lugs required is listed in the table below Table 3 A also provides the lug wire capacity and the tightening torque requirements Weed iB Terminal covers are available which can make the product deadfront IP2X safe See Appendix D for the appropriate catalog numbers for ordering Table

SMC-Flex™ - Columbia Electric Supply Pasco

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SMC-Flex&trade; - Columbia Electric Supply Pasco

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SMC-Flex™ - Columbia Electric Supply Pasco